One of the most striking measurements taken during DOE’s EGS Collab project at the 4850-foot depth location was the so-called ‘sewer cam’, which enabled direct visualization of the flow of water into the production well through fractures during the stimulation. The ability to see directly which fractures were flowing and (roughly) how much was a breakthrough in understanding the topology of the created fracture network. Achieving this kind of fracture flow imaging at FORGE would be more challenging because of the 225°C temperature, but equally or even more valuable if it could be achieved. In 2017, a joint project between Sandia and Stanford developed a downhole tool concept to measure the enthalpy of multiphase fluid entering a geothermal well from individual fractures (Gao et al., 2017). For the FORGE project, measuring enthalpy is of less interest because the fluid is expected to be single-phase liquid water. However, the foundation of the device was the measurement of chloride ion concentration, which could form the basis for a direct measurement of inflow from fractures. During the 2017 project, this novel chloride sensing system was implemented into a laboratory test instrument, and we confirmed the capability of the system to measure the ion concentration of fluid entering a model wellbore through a small entry port. The wellbore was a 6-inch diameter model well, and the port was approximately 0.08 inch (2mm) in diameter. The device could measure the chloride concentration accurately even when the well was flowing in a bubbly flow. Given its accuracy, the tool should be able to identify locations of water entering the wellbore even if the ion concentration differs only slightly from that of the water in the well. It is likely that different fractures may flow slightly different chloride concentrations, which would make it feasible to detect individual fractures as well as to estimate the volume of their flow. Ultimately, we could also recognize different fractures flowing back significantly different ion concentrations after fracturing in the FORGE wells. This could be realized by adding different ions in the fracturing fluids in different fractures created at different stages of stimulation (and modifying the tool to include different ion specificity). Sandia’s tool was shown during the study to have the capability to withstand the 225°C temperature, and the electrochemical sensing elements were tested in the laboratory to 225°C at 1500 psia for 24 hours. An early implementation of the fully integrated downhole electrochemical tool, including high-temperature electronics, robust housing, and wireline truck interface, had previously been constructed and tested successfully at Sandia; thus, hardware development tasks focused on advancing the technology readiness level (TRL) of this promising technology for FORGE deployment, rather than on developing a new scientific basis for its operation. The data collection electronics in this tool allowed for several other sensors (pressure, temperature, flow spinner) to be implemented in parallel as well. The research was a new collaboration between Stanford and Sandia to modify and refine the tool for FORGE deployment, to make the downhole measurements, and to characterize the evolving fractures.
Downhole logging tools are commonly used to characterize multi-thousand-foot geothermal wells. The elevated temperatures, pressures, and harsh chemical environments present significant challenges for the long-term operation of these tools, especially when real-time data transmission to the surface is required via data cable lines. Teflon-based single or multi-conductor cables with grease-filled cable heads are typically used for downhole tools. However, over extended periods of operation, the grease used to seal the conductors can slowly dissolve into the well fluid, creating electrical shorts and disabling data transmission. Additionally, when temperatures exceed 260 °C, Teflon can soften, potentially allowing parallel conductors to make contact and cause shorts. Between 2009 and 2015, Draka Cableteq USA, now part of the Prysmian Group, developed a multi-conductor/fiber cable and a four-conductor cable capable of operating above 300 °C. While a full study was conducted on the conductor/fiber cable, the evaluation of the four-conductor cable remained incomplete. With the increasing need for long-term high-temperature (HT) operation of logging tools, Sandia National Laboratories is now completing the evaluation of the four-conductor cable. The four-conductor cable has two major novel aspects. Firstly, its glass braid insulation can operate above 300 °C, eliminating the potential for shorts. Secondly, the insulated conductors are encased in metal tubing along the full length of the cable, creating a high-pressure seal between the cable and the tool. This metal tubing eliminates the need for a grease seal, a major limiting factor in the operation time of common cable lines. Sandia National Laboratories will conduct multiple tests to characterize the cable at temperatures above 300 °C and pressures up to 5,000 psi. This cable would enable tools to operate continuously at elevated temperatures, pressures, and in harsh fluids for extended periods, potentially lasting months.
Downhole logging tools are commonly used to characterize multi-thousand-foot geothermal wells. The elevated temperatures, pressures, and harsh chemical environments present significant challenges for the long-term operation of these tools, especially when real-time data transmission to the surface is required via data cable lines. Teflon-based single or multi-conductor cables with grease-filled cable heads are typically used for downhole tools. However, over extended periods of operation, the grease used to seal the conductors can slowly dissolve into the well fluid, creating electrical shorts and disabling data transmission. Additionally, when temperatures exceed 260 °C, Teflon can soften, potentially allowing parallel conductors to make contact and cause shorts. Between 2009 and 2015, Draka Cableteq USA, now part of the Prysmian Group, developed a multi-conductor/fiber cable and a four-conductor cable capable of operating above 300 °C. While a full study was conducted on the conductor/fiber cable, the evaluation of the four-conductor cable remained incomplete. With the increasing need for long-term high-temperature (HT) operation of logging tools, Sandia National Laboratories is now completing the evaluation of the four-conductor cable. The four-conductor cable has two major novel aspects. Firstly, its glass braid insulation can operate above 300 °C, eliminating the potential for shorts. Secondly, the insulated conductors are encased in metal tubing along the full length of the cable, creating a high-pressure seal between the cable and the tool. This metal tubing eliminates the need for a grease seal, a major limiting factor in the operation time of common cable lines. Sandia National Laboratories will conduct multiple tests to characterize the cable at temperatures above 300 °C and pressures up to 5,000 psi. This cable would enable tools to operate continuously at elevated temperatures, pressures, and in harsh fluids for extended periods, potentially lasting months.
Underground chemical explosive testing has been conducted at the Nevada National Security Site under the Physics Experiment 1 (PE1) to validate explosive computer modeling and, ultimately, improve the accuracy of subsurface explosive detection. This SAND Report describes the dynamic temperature and pressure measurements within the chamber induced by the chemical explosive for the first of three experiments, PE1-A. The report details the instrumentation used for the experiment, the emplacement of the hardware, and the measured results. Dynamic temperature measurements were accomplished with the use of optical spectrometers and dynamic pressure was measured with a series of high-rated pressure transducers. This report includes details of the design and results of four cavity sensor systems used to measure early-time temperature, early-time pressure, late-time temperature, and late time pressure. The outcomes of PE1-A were used to inform the design of the remaining PE1 series experiments, PE1-B and PE1-DL.
This paper presents the ongoing development of a chloride-based wireline tool designed to detect and quantify inflows from feed zones in geothermal wells. The tool aims to characterize stimulation events in EGS wells at Utah FORGE (Frontier Observatory for Research in Geothermal Energy) and other EGS sites. Successful development of the chloride tool would greatly improve production monitoring of the fractures and enable proactive prescription of additional stimulations over the life of the field, thus helping to improve EGS commercial feasibility. The recent developments of the chloride tool have focused on preparing for and conducting the field deployment at the Utah FORGE site. The field-scale tool assembly features a FORGE sensor package housing the Ion Selective Electrode (ISE), a pH electrode, and a reference electrode, as well as a Mitco PTS sensor package for secondary downhole measurements. A high-temperature logging tool has been developed and tested to capture and transmit data from the chemical sensors to the surface through a 7-conductor wireline cable. Alongside the development of the field-scale tool, flow experiments were carried out in the artificial well system at the Stanford Geothermal Lab. These experiments provided crucial insights into how the chemical tool responds to different variables, including the chloride concentration in the feed zone, its vertical positioning relative to the feed zone, and the presence of other chemical species in the feed zone fluid. The results highlight the tool's sensitivity to various parameters, underscoring the potential of using chloride concentration measurements as a method for inferring feed zone inflow rates in geothermal wells. The tool was successfully deployed at the Utah FORGE site using a wireline truck in the vertical well 58-32 and the directional production well 16B(78)-32.
Evaluation of high temperature (HT) microcontrollers for Geothermal applications. The goal was to evaluate the limited microcontrollers capable of operating above 200 degrees Celsius. The knowledge obtained from this research has been documented for contributing to future development of high temperature geothermal tools. Along with this research, a HT data link for communications was developed and evaluated, also for HT geothermal tools.
In high temperature (HT) environments often encountered in geothermal wells, data rate transfers for downhole instrumentation are relatively limited due to transmission line bandwidth and insertion loss and the processing speed of HT microcontrollers. In previous research, Sandia National Laboratory Geothermal Department obtained 3.8 Mbps data rates over 1524 m (5000 ft) for single conductor wireline cable with less than a 1x10-8 bit error rate utilizing low temperature NITM hardware (formerly National InstrumentsTM). Our protocol technique was a combination of orthogonal frequency-division multiplexing and quadrature amplitude modulation across the bandwidth of the single conductor wireline. This showed it is possible to obtain high data rates in low bandwidth wirelines. This paper focuses on commercial HT microcontrollers (µC), rather than low temperature NITM modules, to enable high-speed communication in an HT environment. As part of this effort, four devices were evaluated, and an optimal device (SM320F28335-HT) was selected for its high clock rates, floating-point unit, and on-board analog-to-digital converter. A printed circuit board was assembled with the HT µC, an HT resistor digital-to-analog converter, and an HT line driver. The board was tested at the microcontroller's rated maximum temperature (210°C) for a week while transmitting through a 1524 m (5000 ft) wireline. A final test was conducted to the point of failure at elevated temperatures. This paper will discuss communication methods, achieved data rates, and hardware selection. This effort contributes to the enhancement of HT instrumentation by enabling greater sensor counts and improving data accuracy and transfer rates.
Sandia National Laboratories has developed technology enabling novel downhole electrochemical assessment in extreme downhole environments. High-temperature high-pressure (HTHP) electrodes selectively sensitive to hydrogen (H+), chloride (Cl-), iodide (I-) and overall ionic strength (Reference Electrode+-) have been demonstrated in representative geothermal environments (225°C and 103 bar in surrogate geothermal brine). This 2-year program is a collaboration effort between Sandia and Thermochem, Inc. with the goal of taking the prototype sensors and developing them into a commercial product that is operable up to 300°C and 345 bar. The Sandia-developed prototype HTHP chemical sensor package creates a capability that has never been possible to date. This technology is desired by the geothermal industry to fill a gap in available downhole real-time measurements. Only limited sensors are available that operate at the extreme temperatures and pressures found in geothermal wells. For the purpose of this paper, high temperature is defined as temperatures exceeding 200°C and high pressure is defined as pressures exceeding 35 bar. Chemical sensors exceeding these parameters and sized appropriately for downhole applications do not exist. The current Thermochem two-phase downhole sampling tool (rated to 350 °C) will be re-configured to accept the sensors. A downhole tool with an integrated pH real-time sensor capable of operation at 300°C and 345 bar does not exist and as such, the developed technology will provide the geothermal industry with data that would otherwise not be possible such as vertical in-situ pH-profiling of geothermal wells. The pH measurement was chosen as the first chemical sensor focus since it is one of the fundamental measurements required to understand downhole chemistry, scaling and corrosion processes.
The latest high temperature (HT) microcontrollers and memory technology have been investigated for the purpose of enhancing downhole instrumentation capabilities at temperatures above 210°C. As part of the effort, five microcontrollers (Honeywell HT83C51, RelChip RC10001, Texas Instruments SM470R1B1M-HT, SM320F2812-HT, SM320F28335-HT) and one memory chip (RelChip RC2110836) have been evaluated to its rated temperature for a period of one month to determine life expectancy and performance. Pulse rate of the integrated circuit and internal memory scan were performed during testing by remotely located axillary components. This paper will describe challenges encountered in the operation and HT testing of these components. Long-term HT tests results show the variation in power consumption and packaging degradation. The work described in this paper improves downhole instrumentation by enabling greater sensor counts and improving data accuracy and transfer rates at temperatures between 210°C and 300°C.
Carbon sequestration is a growing field that requires subsurface monitoring for potential leakage of the sequestered fluids through the casing annulus. Sandia National Laboratories (SNL) is developing a smart collar system for downhole fluid monitoring during carbon sequestration. This technology is part of a collaboration between SNL, University of Texas at Austin (UT Austin) (project lead), California Institute of Technology (Caltech), and Research Triangle Institute (RTI) to obtain real-time monitoring of the movement of fluids in the subsurface through direct formation measurements. Caltech and RTI are developing millimeter-scale radio frequency identification (RFID) sensors that can sense carbon dioxide, pH, and methane. These sensors will be impervious to cement, and as such, can be mixed with cement and poured into the casing annulus. The sensors are powered and communicate via standard RFID protocol at 902-928 MHz. SNL is developing a smart collar system that wirelessly gathers RFID sensor data from the sensors embedded in the cement annulus and relays that data to the surface via a wired pipe that utilizes inductive coupling at the collar to transfer data through each segment of pipe. This system cannot transfer a direct current signal to power the smart collar, and therefore, both power and communications will be implemented using alternating current and electromagnetic signals at different frequencies. The complete system will be evaluated at UT Austin's Devine Test Site, which is a highly characterized and hydraulically fractured site. This is the second year of the three-year effort, and a review of SNL's progress on the design and implementation of the smart collar system is provided.
In high temperature (HT) environments often encountered in geothermal wells, data rate transfers for downhole instrumentation are relatively limited due to transmission line bandwidth and insertion loss and the processing speed of HT microcontrollers. In previous research, Sandia National Laboratory Geothermal Department obtained 3.8 Mbps data rates over 1524 m (5000 ft) for single conductor wireline cable with less than a 1x10-8 bit error rate utilizing low temperature NITM hardware (formerly National InstrumentsTM). Our protocol technique was a combination of orthogonal frequency-division multiplexing and quadrature amplitude modulation across the bandwidth of the single conductor wireline. This showed it is possible to obtain high data rates in low bandwidth wirelines. This paper focuses on commercial HT microcontrollers (µC), rather than low temperature NITM modules, to enable high-speed communication in an HT environment. As part of this effort, four devices were evaluated, and an optimal device (SM320F28335-HT) was selected for its high clock rates, floating-point unit, and on-board analog-to-digital converter. A printed circuit board was assembled with the HT µC, an HT resistor digital-to-analog converter, and an HT line driver. The board was tested at the microcontroller's rated maximum temperature (210°C) for a week while transmitting through a 1524 m (5000 ft) wireline. A final test was conducted to the point of failure at elevated temperatures. This paper will discuss communication methods, achieved data rates, and hardware selection. This effort contributes to the enhancement of HT instrumentation by enabling greater sensor counts and improving data accuracy and transfer rates.
