Drilling is a major cost driver in geothermal projects, often making up 30–50% of total CAPEX. Specialized techniques are required to manage extreme conditions, making cost reduction vital. Kwantis’ study presented at the 17th OMC Med Energy Conference & Exhibition in Ravenna explores how real-time monitoring, data integration, and performance optimization can effectively cut costs. It highlights the role of advanced analytics and structured feedback in driving continuous improvement and long-term project success.
Smart Drilling: A Hybrid Data Approach
By combining high-frequency sensor data with low-frequency sources like Daily Drilling Reports (DDR), drill pipe specs, and bit details, this approach creates a unified dataset for enhanced analysis. A digital platform consolidates and interprets this data to detect key operations (e.g., drilling, tripping, reaming) and calculate accurate KPIs such as Rate of Penetration, connection time, and Non-Productive Time. This integrated method supports real-time decision-making and long-term planning, ultimately reducing drilling costs. The strategy is structured around three pillars:
- Future Well Planning – Using past data to refine equipment selection, sequence planning, and budget allocation.
- Operations Monitoring – Real-time insights help reduce NPT, prevent failures, and track KPI trends over time.
- Post-Well Analysis – Comparing actual vs. planned performance to identify inefficiencies and continuously improve future operations.
Planning Optimization
Drilling planning is improved by selecting the best-performing equipment, especially drill bits and refining time and cost estimates using historical data. Bit performance is analyzed based on ROP, bit type, and formation data to guide future choices. At the same time, detailed analysis of activity durations helps create more accurate schedules and budgets. This data-driven approach reduces inefficiencies, improves planning accuracy, and enhances overall project profitability.
Real-Time Monitoring
Real-time KPI tracking – such as ROP, connection time, and casing/tripping speeds – is essential for evaluating and improving drilling performance. Monitoring trends over time allows for quick adjustments, benchmarking against offset wells, and continuous improvement. Drill pipe management also benefits from real-time monitoring. By combining sensor data with pipe inventory, operators can assess fatigue and wear, enabling predictive maintenance and reducing downtime. While the system is still in early stages, initial results show promise in extending equipment life and improving operational efficiency.
Reducing Invisible Inefficiencies
Invisible Lost Time (ILT) refers to hidden inefficiencies – like slow ROP or extended connection times – that aren’t logged as NPT but still increase drilling costs. ILT is identified by comparing real-time data to performance benchmarks from offset wells. In this study, ILT was assessed across key KPIs such as ROP, tripping speed, casing runs, and circulating time. Results showed time savings in some areas, while others – like circulating – require further optimization.
To support continuous improvement, the Kwantis study integrates drilling data into Italy’s geothermal digital hub. This unified platform streams real-time drilling parameters alongside plant data, enabling deeper analysis, predictive maintenance, and improved cross-team collaboration. By reducing Invisible Lost Time (ILT) and enhancing data integration, geothermal projects can significantly lower costs and increase overall efficiency.
Integrated Data, Optimized Results
Reducing drilling costs in geothermal projects requires a strategic blend of real-time monitoring, data integration, and performance optimization. Digital tools help identify inefficiencies, track KPIs like ROP and tripping speed, and support predictive maintenance – cutting NPT and boosting efficiency.
Integrating drilling data into geothermal digital hubs enables better decision-making, more accurate planning, and improved economic outcomes by enhancing NPV and reducing CAPEX. This approach fosters continuous improvement, innovation, and long-term sustainability in geothermal operations.