New Roller Cone Bit Technology For Geothermal Application Significantly Increases On-Bottom Drilling Hours

Abstract

Geothermal energy has been used for centuries to satisfy general heating requirements. The modern geothermal plant is powered by production wells drilled to a source rock to produce steam at the surface. Depending on the location and depth, source formation temperatures vary. In Tuscany, Italy the operator must penetrate very hard and abrasive sediments to access steam in the granite basement formation. Historically, this was accomplished with a tungsten carbide insert (TCI) roller cone bit (RC). Standard geothermal bits and components, including grease and elastomer seals, are adequate for temperatures up to 150°C (302°F). Beyond these temperatures, the bit’s internal components and lubricating material can degrade causing bearing failure limiting on-bottom drilling hours. In Tuscany, the bottom hole temperature is approximately 180°C (350°F) and in some instances it can exceed 280°C (536°F). The extreme heat reduces on-bottom drilling hours leading to multiple bit runs/trips that drive up development costs. The operator required new roller cone technology that would endure the downhole environment. To solve this challenge, a series of tests were conducted with temperature resistant elastomers and grease compounds in a controlled laboratory environment. The experiments resulted in a new line of roller cone bits equipped with an innovative bearing system that includes new proprietary composite elastomer seals with Kevlar® fabric and a proprietary high temperature grease formula. These innovations increased seal life, lubricity and load capacity at elevated temperatures for HT/HP applications. The new geothermal bit technology has been run in the Italian application with outstanding results. Compared to standard roller cone products, the high-temperature bits have greatly increased on-bottom drilling hours while reducing total bit consumption and costly tripping for bit change out. Since successful development of the geothermal project is tied to reducing drilling costs, the new bit technology has significantly improved project economics. The authors will discuss development of the high temperature seal and grease compounds for drilling the granite basement source rock. They will also outline changes to the TCI cutting structure, field application, dull grades and bit performance data.