High Temperature, High Pressure Devices for Zonal Isolation in Geothermal Wells
The U.S. Department of Energy is leading the development of alternative energy sources that will ensure the long-term energy independence of our nation. One key renewable resource being advanced is geothermal energy which offers an environmentally benign, reliable source of energy for the nation. To utilize this resource, water will be introduced into wells 3 to 10 km deep to create a geothermal reservoir. This approach is known as an Enhanced Geothermal System (EGS). The high temperatures and pressures at these depths have become a limiting factor in the development of this energy source. For example, reliable zonal isolation for high-temperature applications at high differential pressures is needed to conduct mini-fracs and other stress state diagnostics. Zonal isolation is essential for many EGS reservoir development activities. To date, the capability has not been sufficiently demonstrated to isolate sections of the wellbore to: 1) enable stimulation; and 2) seal off unwanted flow regions in unknown EGS completion schemes and high-temperature (>200°C) environments. In addition, packers and other zonal isolation tools are required to eliminate fluid loss, to help identify and mitigate short circuiting of flow from injectors to producers, and to target individual fractures or fracture networks for testing and validating reservoir models. General-purpose open-hole packers do not exist for geothermal environments, with the primary barrier being the poor stability of elastomeric seals at high temperature above 175°C. Experimental packer systems have been developed for geothermal environments but they currently only operate at low pressure, they are not retrievable, and they are not commercially available. The development of the high-temperature, high-pressure (HTHP) zonal isolation device would provide the geothermal community with the capability to conduct mini-fracs, eliminate fluid loss, to help identify and mitigate short circuiting of flow from injectors to producers, and to target individual fractures or fracture networks for testing and validating reservoir models. The goal of this program, therefore, was to develop and demonstrate reliable high-temperature high-pressure zonal isolation devices that are compatible with the high-temperature downhole environment anticipated for Enhanced Geothermal Systems. Over the course of this 3 year program, CTD designed and demonstrated a high temperature high pressure zonal isolation device. CTD has utilized its expertise in high-temperature materials, shape memory composites and foams, and deployment mechanisms for spacecraft and oil tools to develop a new class of HTHP zonal isolation devices for use in EGS. Specifically, the objective was to demonstrate the ability to isolate sections of an EGS wellbore to: 1) enable stimulation; and 2) seal off unwanted flow regions in unknown EGS completion schemes and high-temperature (>200°C) environments at temperatures upwards of 300°C. A concept for a high-temperature, high-pressure zonal isolation device was designed for use in creating circulation paths in environments where temperatures are in excess of 300°C and differential pressures of up to 10,000 psi are required to stimulate solid granite. This new zonal isolation device distributes the high-pressure differential through a significant length of high temperature, shape memory polymer composite material. The development of differential pressure is initiated by a thermally triggered actuation of a ‘structural seal’ that fills the cross section of the bore with the shape memory material. After this preliminary seal is made, differential pressure begins to build through the material as the seal forces the flow to pass through pores in the shape memory material. The shape memory material is compressed into place to react the force of the internal