Publications

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Achieving robust and efficient drilling is a critical part of reducing the cost of geothermal energy exploration and extraction. Drilling performance is often evaluated using one or more of three key metrics: depth of cut (DOC), rate of penetration (ROP), and mechanical specific energy (MSE). All three of these quantities are related to each other. DOC refers to the depth a bit penetrates into rock during drilling. This is an important quantity for estimating bit behavior. ROP is the simply the DOC multiplied by the rotational rate, and represents how quickly the drill bit is advancing through the ground. ROP is often the parameter used for drilling control and optimization. Finally, MSE provides insight into drilling efficiency and rock type. MSE calculations rely on ROP, drilling force, and drilling torque. Surface-based sensors at the top of the drill are often used to measure all these quantities. However, top-hole measurements can deviate substantially from the behavior at the bit due to lag, vibrations, and friction. Therefore, relying only on top-hole information can lead to suboptimal drilling control. In this work, we describe recent progress towards estimating ROP, DOC, and MSE using down-hole sensing. We assume down-hole measurements of torque, weight-on-bit (WOB). Our hypothesis is that these measurements can provide more rapid and accurate measures of drilling performance. We show how a multi-layer perceptron (MLP) machine learning algorithm can provide rapid and accurate performance when evaluated on experimental data taken from Sandia’s Hard Rock Drilling Facility. In addition, we implement our algorithms on an embedded system intended to emulate a bottom-hole-assembly for sensing and estimation. Our experimental results show that DOC can be estimated accurately and in real-time. These estimates when combined with measurements for rotary speed, torque, and force can provide improved estimates for ROP and MSE. These results have the potential to enable better drilling assessment, improved control, and extended component lifetimes.

This report captures the results of development and testing of a integral downhole motor and percussive hammer used for drilling in near-surface hard rock formations. The work was funded through the DOE Office of Technology Transitions Technology Commercialization Fund. It was a collaboration between Sandia National Labs and The Charles Machine Works (aka Ditch Witch). In the collaboration, Sandia developed a pneumatic motor derived from an indexing tool used in other drilling applications, and Ditch Witch developed the bearing pack tied to the output shaft of the motor as well as the angled beacon housing used for directional control.

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Robust in situ power harvesting underlies all efforts to enable downhole autonomous sensors for real-time and long-term monitoring of CO₂ plume movement and permeance, wellbore health, and induced seismicity. This project evaluated the potential use of downhole thermopile arrays, known as thermoelectric generators (TEGs), as power sources to charge sensors for in situ real-time, long-term data capture and transmission. Real-time downhole monitoring will enable “Big Data” techniques and machine learning, using massive amounts of continuous data from embedded sensors, to quantify short- and long-term stability and safety of enhanced oil recovery and/or commercial-scale geologic CO₂ storage. This project evaluated possible placement of the TEGs at two different wellbore locations: on the outside of the casing; or on the production tubing. TEGs convert heat flux to electrical power, and in the borehole environment, would convert heat flux into or out of the borehole into power for downhole sensors. Such heat flux would be driven by pumping of cold or hot fluids into the borehole—for instance, injecting supercritical CO₂—creating a thermal pulse that could power the downhole sensors. Hence, wireless power generation could be accomplished with in situ TEG energy harvesting. This final report summarizes the project’s efforts that accomplished the creation of a fully operational thermopile field unit, including selection of materials, laboratory benchtop experiments and thermal-hydrologic modeling for design and optimization of the field-scale power generation test unit. Finally, the report describes the field unit that has been built and presents results of performance and survivability testing. The performance and survivability testing evaluated the following: 1) downhole power generation in response to a thermal gradient produced by pumping a heated fluid down a borehole and through the field unit; and 2) component survivability and operation at elevated temperature and pressure conditions representative of field conditions. The performance and survivability testing show that TEG arrays are viable for generating ample energy to power downhole sensors, although it is important to note that developing or connecting to sensors was beyond the scope of this project. This project’s accomplishments thus traversed from a low Technical Readiness Level (TRL) on fundamental concepts of the application and modeling to TRL-5 via testing of the fully integrated field unit for power generation in relevant environments. A fully issued United States Patent covers the wellbore power harvesting technology and applications developed by this project.

This paper presents the ongoing development of a wireline tool designed to detect and quantify inflows from feed zones in geothermal wells based on measurement of chloride. The tool aims to characterize stimulation events in Enhanced Geothermal Systems (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 development of the chloride tool involves an Ion Specific Electrodes (ISE) probe and a reference electrode, assembled through a labor-intensive process, and designed to withstand downhole conditions for field deployment. Through laboratory experiments and numerical simulations, the tool demonstrated efficacy in identifying changes in chloride concentration, indicating its utility in feed zone detection. However, the impact of impedance on voltage measurements and discrepancies between laboratory and simulation results presented opportunities for further refinement. Notably, simulation results consistently underestimated actual chloride concentration by 30-40%, suggesting the need for compensatory calibration. Comparisons between different simulation software indicated that ANSYS was more accurate in replicating key features observed in laboratory experiments. Moreover, a Machine Learning (ML) approach was used to improve feed zone location detection and inflow rate measurement, utilizing Random Forest and Light Gradient Boosting Machine (LGBM) models, which delivered high performance scores. Thus, the chloride tool's recent development and integration with machine learning approaches offer promising advancements in feed zone identification and quantification.

The DOE GeoVision study identified that Enhanced Geothermal Systems (EGS) resources have the potential to provide a significant contribution toward achieving the goal of converting the U.S. electricity system to 100% clean energy over the next few decades. To further the implementation of commercial EGS development, DOE's Geothermal Technologies Office (GTO) initiated the Wells of Opportunity (WOO) Amplify program, where unproductive wells in selected geothermal fields are to be stimulated using EGS technologies, resulting in increased power production from these resources. As part of the WOO-Amplify project, GTO assembled the Amplify Monitoring Team (AMT), whose role is to provide in-field and near-field seismic monitoring design, deployment and data analysis for stimulations under the WOO-Amplify initiative. This team, consisting of scientists and engineers from Lawrence Berkeley National Laboratory (LBNL), Sandia National Laboratories (SNL), and the US Geological Survey (USGS), is working with WOO-Amplify EGS Operators in Nevada to develop and deploy optimized seismic monitoring systems at four geothermal fields where WOO-Amplify well stimulations are planned: Don A. Campbell, Tungsten Mountain and Jersey Valley operated by Ormat Technologies, and Patua operated by Cyrq Patua Acquisition Company LLC. Using geologic and geophysical field data provided by the WOO-Amplify teams, the focus of the AMT is to develop advanced simulation and modeling techniques, design targeted seismic monitoring arrays, develop innovative and cost-effective methodologies for drilling seismic monitoring boreholes, deploy effective seismic instrumentation, and facilitate the use of microseismic data to monitor well stimulation and flow within the geothermal reservoir. Realtime seismic data from the four WOO-Amplify sites will be streamed to a publicly accessible Amplify Monitoring website. AMT's advanced simulations and template matching techniques applied during pre-stimulation phases can help improve understanding of potential seismic hazard and inform the Operator's Induced Seismicity Mitigation Protocol (ISMP). Over the next two years, AMT will be drilling, instrumenting, and recording seismic data at the WOO-Amplify field sites, telemetering the seismic waveform data to AMT's central processing system and providing the processed location data to the WOO Amplify Operator teams. These data and monitoring systems will be critical for effective monitoring of the effects of planned well stimulation and extended flow tests during the next stage of the WOO-Amplify project.

Geothermal energy has been underutilized in the U.S., primarily due to the high cost of drilling in the harsh environments encountered during the development of geothermal resources. Drilling depths can approach 5,000 m with temperatures reaching 170 C. In situ geothermal fluids are up to ten times more saline than seawater and highly corrosive, and hard rock formations often exceed 240 MPa compressive strength. This combination of extreme conditions pushes the limits of most conventional drilling equipment. Furthermore, enhanced geothermal systems are expected to reach depths of 10,000 m and temperatures more than 300 °C. To address these drilling challenges, Sandia developed a proof-of-concept tool called the auto indexer under an annual operating plan task funded by the Geothermal Technologies Program (GTP) of the U.S. Department of Energy Geothermal Technologies Office. The auto indexer is a relatively simple, elastomer-free motor that was shown previously to be compatible with pneumatic hammers in bench-top testing. Pneumatic hammers can improve penetration rates and potentially reduce drilling costs when deployed in appropriate conditions. The current effort, also funded by DOE GTP, increased the technology readiness level of the auto indexer, producing a scaled prototype for drilling larger diameter boreholes using pneumatic hammers. The results presented herein include design details, modeling and simulation results, and testing results, as well as background on percussive hammers and downhole rotation.

Drilling systems that use downhole rotation must react torque either through the drill-string or near the motor to achieve effective drilling performance. Problems with drill-string loading such as buckling, friction, and twist become more severe as hole diameter decreases. Therefore, for small holes, reacting torque downhole without interfering with the application of weight-on-bit, is preferred. In this paper, we present a novel mechanism that enables effective and controllable downhole weight on bit transmission and torque reaction. This scalable design achieves its unique performance through four key features: (1) mechanical advantage based on geometry, (2) direction dependent behavior using rolling and sliding contact, (3) modular scalability by combining modules in series, and (4) torque reaction and weight on bit that are proportional to applied axial force. As a result, simple mechanical devices can be used to react large torques while allowing controlled force to be transmitted to the drill bit. We outline our design, provide theoretical predictions of performance, and validate the results using full-scale testing. The experimental results include laboratory studies as well as limited field testing using a percussive hammer. These results demonstrate effective torque reaction, axial force transmission, favorable scaling with multiple modules, and predictable performance that is proportional to applied force.

Wellbore integrity is a significant problem in the U.S. and worldwide, which has serious adverse environmental and energy security consequences. Wells are constructed with a cement barrier designed to last about 50 years. Indirect measurements and models are commonly used to identify wellbore damage and leakage, often producing subjective and even erroneous results. The research presented herein focuses on new technologies to improve monitoring and detection of wellbore failures (leaks) by developing a multi-step machine learning approach to localize two types of thermal defects within a wellbore model, a prototype mechatronic system for automatically drilling small diameter holes of arbitrary depth to monitor the integrity of oil and gas wells in situ, and benchtop testing and analyses to support the development of an autonomous real-time diagnostic tool to enable sensor emplacement for monitoring wellbore integrity. Each technology was supported by experimental results. This research has provided tools to aid in the detection of wellbore leaks and significantly enhanced our understanding of the interaction between small-hole drilling and wellbore materials.

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One of the greatest barriers to geothermal energy expansion is the high cost of drilling during exploration, assessment, and monitoring. Microhole drilling technology—small-diameter 2–4 in. (~5.1–10.2 cm) boreholes—is one potential low-cost alternative for monitoring and evaluating bores. However, delivering high weight-on-bit (WOB), high torque rotational horsepower to a conventional drill bit does not scale down to the hole sizes needed to realize the cost savings. Coiled tube drilling technology is one solution, but these systems are limited by the torque resistance of the coil system, helical buckling in compression, and most of all, WOB management. The evaluation presented herein will: (i) evaluate the technical and economic feasibility of low WOB technologies (specifically, a percussive hammer and a laser-mechanical system), (ii) develop downhole rotational solutions for low WOB drilling, (iii) provide specifications for a low WOB microhole drilling system, (iv) implement WOB control for low WOB drilling, and (v) evaluate and test low WOB drilling technologies.

Depth of cut (DOC) refers to the depth a bit penetrates into the rock during drilling. This is an important quantity for estimating drilling performance. In general, DOC is determined by dividing the rate of penetration (ROP) by the rotational speed. Surface based sensors at the top of the drill string are used to determine both ROP and rotational speed. However, ROP measurements using top-hole sensors are noisy and often require taking a derivative. Filtering reduces the update rate, and both top-hole linear and angular velocity can be delayed relative to downhole behavior. In this work, we describe recent progress towards estimating ROP and DOC using down-hole sensing. We assume downhole measurements of torque, weight-on-bit (WOB), and rotational speed and anticipate that these measurements are physically realizable. Our hypothesis is that these measurements can provide more rapid and accurate measures of drilling performance. We examine a range of machine learning techniques for estimating ROP and DOC based on this local sensing paradigm. We show how machine learning can provide rapid and accurate performance when evaluated on experimental data taken from Sandia's Hard Rock Drilling Facility. These results have the potential to enable better drilling assessment, improved control, and extended component life-times.