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1
Improving Gas Well Drilling and Completion with High Energy Lasers
Brian C. GahanGas Technology Institute
2
Drilling for Oil and Gas in the US
Oil and Gas Wells Drilled, 1985-2000Exploratory and Development
0
50
100
150
200
250
300
350
85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00
Tota
l Foo
tage
Dril
led
(Mill
ions
of F
eet)
0
10
20
30
40
50
60
70
80
Tot
al W
ells
Dril
led
Per Y
ear (
000)
Total Footage Drilled (Oil, Gas, &Dry Holes)Petroleum Total Wells Completed
3
Drilling for Oil and Gas in the US7000
0
20
40
60
80
100
120
140
1959 1964 1969 1974 1979 1984 1989 1994
Dol
lars
per
Foo
t
Average Cost per Foot
Average Depth per Well
Estimated Cost Per Foot and Average Depth Per Well of All Wells (Oil, Gas and Dry) Drilled Onshore in the U.S. from 1959 - 1999 (DeGolyer and MacNaughton, 2000)
6000
5000
3000
4000
Dep
th (f
t)
2000
1000
0
Year
4
Drilling for Oil and Gas in the US
! 1990 GRI Study on Drilling Costs
Major Categories % of Total TimeMaking Hole 48
Changing Bits 27And Steel Casing
Well & Formation Characteristics 25
Total Drilling Time 100% .
5
High-energy Laser Applications
Lasers could play a significant role
as a vertical boring &
perforating tool in gas well drilling
6
System Vision
! Laser on surface or within drilling tubing applies infrared energy to the working face of the borehole.
! The downhole assembly includes sensors that measure standard geophysical formation information, as well as imaging of the borehole wall, all in real time.
! Excavated material is circulated to the surface as solid particles
7
System Vision
! When desired, some or all of the excavated material is melted and forced into and against the wall rock.
! The ceramic thus formed can replace the steel casing currently used to line well bores to stabilize the well and to control abnormal pressures.
8
System Vision
! When the well bore reaches its target depth, the well is completed by using the same laser emergy to perforate through the ceramic casing.
! All this is done in one pass without removing the drill string from the hole.
9
Laser Product Development
LASER BASIC RESEARCH
Laser FELaser Drilling
Assist
Laser Perf
10
Off Ramp: Perforating Tool
! Proposal Submitted to Service Industry Partner
! Purpose– Complete or re-complete
existing well using laser energy
! Requirements– Durable, reliable laser
system– Energy delivery system– Purpose designed
downhole assembly
11
Preliminary Feasibility Study
! Laser Drilling Experiments – 11/97– Basic Research – 2 years
! Three High-Powered Military Lasers– Chemical Oxygen Iodine Laser (COIL)– Mid Infra-Red Advanced Chemical
Laser (MIRACL) – CO2 Laser
! Various Rock Types Studied– Sandstone, Limestone, Shale– Granite, Concrete, Salt
12
MIRACL – Simulated Perf Shot
A two-inch laser beam is sent to the side of a sandstone sample to simulate a horizontal drilling application.
13
MIRACL – Simulated Borehole Shot
After a four-second exposure to the beam, a hole is blasted through the sandstone sample, removing six pounds of material.
14
GRI-Funded Study Conclusions
! Previous Literature Overestimated SE! Existing Lasers Able to Penetrate All Rock! Laser/Rock Interactions Are a Function of
Rock and Laser (Spall, Melt or Vaporize)! Secondary Effects Reduce Destruction! Melt Sheaths Similar to Ceramic
Study Conclusions Indicate Additional Research is Warranted
15
Laser Drilling Team – Phase I
Gas Technology Institute
DOE NETL
Argonne National Laboratory
Colorado School of Mines
Parker Geoscience Consulting
Halliburton Energy Services
PDVSA-Intevep, S.A
16
Drilling With The Power Of Light! DOE Cooperative Agreement DE-FC26-00NT40917
– Original Proposed Tasks and Timeline
Quarter 3 4 1 2 3 4 1 2 3 4 1 2
Quarter 1 2 3 4 1 2 3 4 1 2 3 4Task 1. Project Structure and ManagementTask 2. Fundamental Research2.1 Laser cutting energy
assessment series2.2 Variable Pulse Laser Effects2.3 Drilling Under Insitu
Conditions2.4 Rock-Melt Lining Stability2.5 Gas Storage Stimulation2.6 Laser Induced Rock
Fracturing Model2.7 Laser Drilling Engineering
Issue IdentificationTask 3. System Design Integration3.1 Solids Control3.2 Pressure Control3.3 Bottom-hole Assembly3.4 High Energy Transmission3.5 Completion and Stimulation
Techniques for Gas Well Drilling
3.6 Completion and Stimulation Techniques for Gas Storage Wells
Task 4. Data Synthesis and InterpretationTask 5. Integration and ReportingTask 6. MilestonesTask 7.Technology Transfer
Year 3Year 2Year 1
TABLE 3: WORK TASK TIMELINES2001 2002 20032000
17
First Phase (FY-01) Objectives
! Accepted Phase 1 Task List1. Laser cutting energy assessment 2. Variable pulse laser effects (Nd:YAG)3. Lasing through liquids
Quarter 4 1 2 3
Quarter 1 2 3 41.0 Project Structure and
Management
1.1 Laser cutting energy assessment series
1.2 Variable Pulse Laser Effects
1.3 Conduct Lasing Through Liquids
1.4 Topical Report
Year 1
20012000TABLE 3: WORK TASK TIMELINES
18
Phase I Laser: 1.6 kW Nd:YAG
Laser Beam
Rock
Neodymium Yttrium Aluminum Garnet (Nd:YAG)
Coaxial Gas Purge
Focusing Optics
1.27 cm
7.6 cm
19
Conclusions: GTI/DOE Phase I
! SE for Shale 10x Less Than SS or LS! Pulsed Lasers Cut Faster & With Less
Energy Than Continuous Wave Lasers.! Fluid Saturated Rocks Cut Faster Than Dry
Rocks.! Possible Mechanisms Include:
! More Rapid Heat Transfer Away From the Cutting Face Suppressing Melting
! Steam Expansion of Water! Contributing to Spallation
20
Conclusions: GTI/DOE Phase I
! Optimal Laser Parameters Observed to Minimize SE for Each Rock Type
! Shorter Total Duration Pulses Reduce Secondary Effects from Heat Accumulation
! Rethink Laser Application Theory – Rate of Application: Blasting vs Chipping
! Unlimited Downhole Applications Possible due to Precision and Control (i.e., direction, power, etc.)
21
DOE-GTI/NGOTP-ANL Phase 2 In Progress
! Continuation of SE Investigations– Effects at In-Situ Conditions – Effects of Multiple Bursts and
Relaxation Time– Observations at Melt/Vapor Boundary
22
Supporting Slides Detailing Phase I Work
23
Laser Cutting Energy Assessment
! Measure specific energy (SE) – Limitation of variables
• SS, shale and LS samples• Minimize secondary effects
– Identify laser-rock interaction mechanisms (zones)• Spall, melt, vaporize
24
Just Enough Power
! Conducted Linear Tests– Constant Velocity Beam Application (dx)– Constant Velocity Focal Change (dz)
! Five Zones Defined in Linear Tests! Identified Zones Judged Desirable for
Rapid Material Removal– Boundary Parameters Determined for Spall into
Melt Conditions
25
Laser/Rock Interaction Zones
! Zone Called Thermal Spallation Judged Desirable for Rapid Material Removal
! Optimal Laser Parameters Were Determined to Minimize:– Melting – Specific Energy (SE) Values– Other Energy Absorbing Secondary Effects, and– Maximize Rock Removal
! Short Beam Pulses Provided “Chipping” Mechanism Comparable to Conventional Mechanical Methods
26
Zonal Differences
! SE differs greatly between zones! Shale shows clear SE change between
melt/no melt zones! Much analysis remains to understand
sensitivities of different variables
27
SE vs Measured Average Power (kW)
SH11A
SH10
SH11B2SH18A
SH12B2
SH8
SH11B1SH13A
SH15A1
SH15A2 SH12B1 SH2 SH6
R2 = 0.9095
0
1
2
3
4
5
6
0 0.2 0.4 0.6 0.8 1 1.2 1.4
Measured Average Power (kW)
Spec
ific
Ener
gy (k
J/cc
)
Zone 3 - Significant Melt
Zone 2 - No MeltMinimum SE
Spallation
28
Lithology Differences
! Differences between lithologies more pronounced when secondary effects minimized
! Shale has lowest SE by an order of magnitude.
! Sandstone and limestone remain similar, as in CW tests
29
All ND:YAG Tests
0
1
10
100
1000
10000
0 200 400 600 800 1000 1200 1400
Average Power W
Spec
ific
Ener
gy k
J/cc Sandstone Limestone Shale
30
SE Values: Wet vs. Dry Samples
0
5
10
15
20
25
30
35
0 0.5 1
Power (kW)
Spec
ific
Ener
gy (k
J/cc
)
Dry rock samples Dry rock samples Water-saturated samples
Dry
Wet
Atmospheric Conditions.