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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Utah FORGE: 16B(78)-32 RFS DSS Strain Change Rate vs. Depth During 16A(78)-32 Stimulation

This dataset contains strain change rate versus depth data acquired using a Rayleigh frequency shift (RFS) distributed strain sensing (DSS) system during hydraulic stimulation of well 16A(78)-32 at the Utah FORGE site in April 2024. The data were collected from an optical fiber installed in the annulus of production well 16B(78)-32, approximately 300 feet from the injection well. The dataset includes tabulated strain data and an explanation of the methodology used to generate the frac log, which integrates strain change rate signals over selected time windows to identify fracture events.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

A recyclable self-healing composite with advanced sensing property

Polymer-based composites frequently encounter damage, often lurking beneath the surface and proving challenges to their early detection and repair. While material-based sensors show promise for encoding self-sensing properties within these composites, their in situ healing and reprocessability remain significant challenges. Therefore, the overarching goal of this study is the creation of a reprocessable polymeric composite encoded with self-healing attributes and the ability to autonomously sense damage. At the core of this innovation are vitrimers, a polymeric material characterized by a covalently adaptive dynamic network responsive to external factors such as heat. They combine thermoset-like resilience with thermoplastic-like flowability on demand under external stimuli. We nanoengineer a polyester-based vitrimeric polymer by incorporating piezoresistive carbon nanotubes (CNTs) as reinforcing elements that not only enhance its mechanical strength but also create a percolation network within the composite, thereby enabling piezoresistive self-sensing properties, all the while preserving the intrinsic self-healing capabilities offered by the vitrimeric matrix. The fabrication process of the composite involves a solvent-free in situ polymerization method that combines epoxy and anhydride-containing monomers with ~ 0.1 wt.% of CNTs. Once it was established that the introduction of CNTs into the polymeric matrix did not compromise the mechanical properties of the composite, their strain-sensing properties were characterized by applying cyclic loading while measuring their electrical resistance. Strikingly, CNT-enhanced vitrimer composite consistently retains its mechanical and sensing properties through repeated cycles of reshaping and reprocessing, underscoring its potential as a robust distributed strain sensor. This polyester-based vitrimeric composite is also easily recyclable without harsh chemical treatments. Preliminary findings from this study conclusively demonstrate that the bulk composite boasts both self-sensing capabilities and in situ detect healing properties, charting a promising course towards the development of a mechanically resilient multifunctional composite that seamlessly integrates selfsensing and healing capabilities.

Rohewal, Sargun Singh↗
DOE OSTI2024

Simulation Analysis of Mode Hopping Impacts on OFDR Sensing Performance

This article examines the impacts of mode hopping on the sensing performance of optical frequency domain reflectometry (OFDR) and explores the potential for developing economical OFDR interrogators employing low-cost distributed feedback (DFB) lasers. By conducting numerical simulations, this study reveals that mode hopping has minimal effects on distance sensing measurements in free space due to the limited duration of beat interference signal at the incorrect frequency within the coherence length. Additionally, the simulations indicate that mode hopping only slightly affects the distributed strain sensing of OFDR, resulting in an error range of less than ±1µε when 100µε is applied to the sensing fiber. These findings highlight the potential of using low-cost DFB lasers with a 1-nm wavelength sweep range and a 1-MHz linewidth as tunable laser sources in OFDR while maintaining reliable and accurate sensing performance.

Wang, Qirui (ORCID:0000000336532984)↗
DOE OSTI2021

HFTS-2 Completions Design and State-of-the-Art Diagnostics Results

Various completion schemes were tested as part of the Hydraulic Fracture Test Site-2 (HFTS-2) project. The wells were instrumented with permanent fiber optic (FO) cable, and unique near-wellbore and far-field region surveys were acquired to evaluate spatial and temporal hydraulic fracture characteristics. The state-of-the-art diagnostics included substantial monitoring of both the well stimulation and longer-term production performance. The objective was to evaluate and improve stimulation distribution effectiveness (SDE) for different completion designs based on the diagnostics results. A hydraulic fracturing (HF) profile (i.e., proppant/fluid allocation among clusters) was obtained using near-wellbore Distributed Acoustic Sensing (DAS) data acquired during stimulation. Statistical analysis provided a quantitative assessment of SDE for the different completion designs. A novel workflow was developed to assess time-lapse fracture property changes at the cluster and stage levels based on Distributed Strain Sensing (DSS) data acquired during the production phase. These time-lapse fracture property changes were compared with the HF profile. Based on the statistical analysis, Rate Per Cluster (RPC) during proppant slurry placement appears to be a primary completion design variable, rather than the typical Rate Per Perf (RPP). If RPC was not maintained at a certain level, the likelihood of uneven distribution increased dramatically. The stage configurations that created low RPC while maintaining high RPP did not show improved SDE. The strain change results based on DSS data during the production phase indicated near-wellbore fracture property changes (e.g., aperture changes during well shut-in and flow periods) and aligned well with near-wellbore DAS signals acquired during stimulation. More importantly, fracture property changes based on DSS data acquired during two tests over a 7-month period show high consistency and good alignment with the near-wellbore HF profile. This workflow quantitatively evaluates SDE for different completion designs using diagnostic results and could help optimize completion strategy for future development projects. Here, the analysis and interpretation of results demonstrate the technical feasibility of using permanent fiber optic cable for stimulation and production monitoring and indic

58 GEOSCIENCES↗
DOE OSTI2022

HFTS-2 (Final Report)

This report delves into the research program, identified tasks, various studies, observations, results, and conclusions under the Hydraulic Fracturing Test Site (HFTS-2) project. This test site is located in Loving County close to the Texas, New Mexico border. The program targeted the Wolfcamp formation in Delaware Basin. The aim of the project was to improve our understanding of hydraulic fracturing processes to not only optimize unconventional resource development in US Basins but to minimize environmental footprint as well. Various new diagnostic technologies were demonstrated at this site, including distributed acoustic microseismic, high resolution strain using Rayleigh frequency band (DSS-RFS), and in-fill proppant logging tool. Significant conclusions from this study include: 1) lateral and vertical fracture growth mapping as well as proppant transport behavior, 2) Use of DSS-RFS as a diagnostic tool to understand cluster level behavior, 3) Validation of proppant log, both at core scale as well as in-fill well implementation, and 4) New modeling tools to map far-field strain response using distributed strain sensing data. Specifically, far-field fracture distribution is influenced by linear fracture corridors defined by the stress-state as well as clustering behavior influenced by spatio-temporal effects. Depletion impacts on new stimulation was demonstrated and technically quantified. Significant vertical fracture height growth was observed. However, our understanding is limited by available gauge data availability. Numerical strain modeling techniques have been developed and demonstrated to help understand observed strain response behavior. Finally, proppant log has been further validated as a useful tool to map propped zones within the SRV. It has also shown very strong correlation with observed drawdown behavior at this test site. This report will detail many of these studies as well as technical results and conclusions from said studies. These include general subsurface characterization work, completion designs as implemented, studies looking at fracture geometry, high resolution microseismic study including source mechanisms, advanced DSS-RFS studies including drainage characterization, core characterization results, proppant analysis (core and in-fill child well), geochemistry, etc.

02 PETROLEUM↗
DOE OSTI2020

Static Strain Modelling, Calibration, and Measurements for High-Temperature Wireless SAW Resonator Operation

Static strain measurements are relevant for Integrated System Health Monitoring of civil structures, aircrafts, power plants and advanced manufacturing equipment, with implications for safety, process efficiency, and maintenance costs. Wireless strain sensing is highly desirable where the presence of wires poses significant safety concerns, increases maintenance, and thus overall costs, or where they are not feasible, such as in applications which contain moving parts. This paper presents wireless interrogation of surface acoustic wave resonators (SAWRs) fabricated on langasite (LGS) along Euler angles (0°, 138.5°, 32.9°) and aimed at the detection of static strain at hightemperature (HT, above 100°C). Both commercial HT strain gauges and finite element analysis (FEA Abaqus software) were used and compared for SAWR strain calibration from room temperature (RT) to HT. In addition, this work investigated a compromise between high temperature operation vs. sensitivity based on the thickness of ceramic adhesive used. For instance, a reduction in the adhesive thickness from about 150 μm to 135 μm, resulted in a 39% increase in sensitivity at RT. It was also observed that the sensitivity dropped up to 34% from RT to 200°C. Furthermore, wireless operation, calibration, and increase in sensitivity constitute important advances in the use of LGS SAW devices to monitor static stress in high-temperature harsh environments.

42 ENGINEERING↗
DOE OSTI2022

Temperature and Dynamic Strain Measurements Using a Single SAWR Sensor

Dynamic strain sensing is relevant in numerous applications involving structural health monitoring, condition-based maintenance, operation efficiency preservation, and work environment safety. These sensors are particularly critical for high-temperature (HT) harsh-environment (HE) industries such as aerospace, automotive, power plants, and advanced manufacturing. In HT/HE, sensor implementation and measurement present challenges such as maintaining sensor stability, accounting for temperature cross-sensitivity, providing HT attachment, and packaging of the sensors and system. Surface acoustic wave resonator (SAWR) sensors can address these needs and offer additional benefits such as compact size and wireless interrogation capability. The SAWR sensitivity to dynamic strain is temperature dependent, making it necessary to measure the sensor temperature in order to use the correct dynamic strain calibration curve. In this work, a method for determining the temperature, dynamic strain magnitude, and dynamic strain spectral components using a single SAWR sensor is presented. Here, the established technique for determining operational temperature and dynamic strain magnitude/spectral components using only one SAWR simplifies the sensor measurement system, thus being very attractive for HT /HE applications.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Phase Demodulation by Frequency Chirping in Coherence Microwave Photonic Interferometry

This paper presents a signal processing method to demodulate the optical interference phase of cascaded individual optical fiber intrinsic Fabry-Perot interferometric (IFPI) sensors in a coherent microwave-photonic interferometry (CMPI) distributed sensing system. The new method utilizes the chirp effect of electro-optic modulator (EOM) to create a quasi-quadrature optical interference phase shift between two adjacent pulses which correspond to two adjacent reflection points in the time domain. The phase shift can be controlled by adjusting the bias voltage that is applied to the EOM. The interference phase is calculated by elliptically fitting the phase shift. The interference phase change is proportional to the optical path difference (OPD) change of the interferometer, and the sign can be used to differentiate the increase or decrease of the OPD. The method is demonstrated for distributed strain sensing, showing good linearity, high resolution and large dynamic range.

42 ENGINEERING↗
DOE OSTI2022

Measuring nonlinearities of a cantilever beam using a low-cost efficient wireless intelligent sensor for strain (LEWIS-S)

In the context of experimental vibration data, strain gauges can obtain linear and nonlinear dynamic measurements. However, measuring strain can be disincentivizing and expensive due to the complexity of data acquisition systems, lack of portability, and high costs. This research introduces the use of a low-cost efficient wireless intelligent sensor for strain (LEWIS-S) that is based on a portable-sensor-design platform that streamlines strain sensing. Additionally, the softening behavior of a cantilever beam with geometric and inertial nonlinearities is characterized by the LEWIS-S based on high force level inputs. Two experiments were performed on a nonlinear cantilever beam with measurements obtained by the LEWIS-S sensor and an accelerometer. First, a sine sweep test was performed through the fundamental resonance of the system, then a ring-down test was performed from a large initial static deformation. Good agreement was revealed in quantities of interest such as frequency response functions, the continuous wavelet transforms, and softening behavior in the backbone curves.

42 ENGINEERING↗
DOE OSTI2020

Design of a Biomass Scale Cubical Triaxial Tester

The bioenergy industry is dependent on predictable and reliable feedstock handling equipment. High profile failures in the industry demonstrate the need for better modeling tools for feedstock handling, specifically tools which can model the bulk flow of biomass feedstock materials in handling equipment such as hoppers or screw conveyors. Measurement of bulk material flow characteristics is a critical component to inform modeling tools. Following examples in the soils and pharmaceuticals industries, a Cubical Triaxial Tester (CTT) was selected as a critical component to study relationships between applied stress on a bulk sample and the resulting strain on the bulk material. In cooperation with The Pennsylvania State University, Forest Concepts designed a CTT specifically to measure bulk biomass flowability characteristics. Several mechanical design constraints were identified to ensure proper scaling and repeatability. Major design constraints included sample chamber size versus particle length, volumetric strain sensing accuracy, independent axial pressure control, and sample chamber handling. This report explains how major design constraints were determined.

09 BIOMASS FUELS↗
DOE OSTI2020

Demonstration of Embedded Sensors in Ceramic Structures

The Transformational Challenge Reactor (TCR) program seeks to demonstrate an advanced 3D printed nuclear reactor core. A binder jet additive manufacturing process is used to fabricate the complex SiC ceramic components of the TCR core. After printing, the components are densified via chemical vapor infiltration (CVI). This process allows complex cavities to be created in which sensors can be placed at strategic locations. Inserting the sensors during the CVI process allows the sensors to be embedded within the component as it is infiltrated. The primary challenge for embedding the sensors is identifying the sensors and sensor sheath materials that can survive the temperatures (>1,000°C) and chemical exposure to H 2 and HCl during CVI. The embedded sensors that are being investigated for use during TCR operation include thermocouples, self-powered neutron detectors, and spatially distributed fiber-optic temperature sensors. This report describes the CVI materials compatibility tests and initial trials for embedding functional sensors. Mo is identified as the most suitable sensor sheath material based on its availability in small diameter tubing, relatively low neutron absorption cross section, and compatibility with H 2 , HCl, and the surrounding SiC matrix at the process temperatures. Amorphous SiO2 fiber-optic samples with Au and Cu metal coatings were successfully embedded in SiC along with bare fibers, although the metal coatings showed some evidence of localized melting during CVI. Initial experiments attempting to embed functional sensors showed that the sensors can be embedded in 3D printed SiC parts, but there are still challenges that must be overcome to ensure that the sensors and sensor sheaths do not fail during CVI. In particular, Nb-sheathed Mo-Nb thermocouples failed at temperatures far lower than expected despite thermodynamic calculations and materials compatibility tests that show the Nb sheath to be compatible with the CVI environment. One potential explanation for the large expansion of the Nb sheath could be related to hydride formation in the lower temperature region of the sheath. Future work will focus on Mo-sheathed thermocouples instead of Nb. The fiberoptic sensors tested during the instrumented experiment broke due to the lack of mechanical protection after their polymer-based coatings were vaporized. Future instrumented experiments will use metal-coated optical fibers for strain sensing to provide additional mechanical protection. However, custom coatings with higher melting points than commercially available Au and Cu might be required. Regardless, fiber-optic sensors are still candidates for spatially distributed temperature measurements since they can be inserted into an embedded metal sheath after CVI.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Abstract for CRADA between National Energy Technology Laboratory and Colonial Pipeline Company

The National Energy Technology Laboratory (NETL) and Colonial Pipeline Company (Participant) will collaborate in the field demonstration of optical fiber sensor systems developed at NETL on Participant’s fuel pipeline. The optical fiber sensor technologies are capable of distributed temperature and strain sensing, distributed acoustic sensing, and ultrasensitive acoustic sensing. Real-time monitoring of these parameters enables pipeline integrity monitoring, security monitoring, flow rate monitoring, etc. Successful demonstration on a real fuel pipeline at Participant’s facilities will validate the sensor technologies and installation methods at a real scale. This effort aligns with NETL’s mission in reliable and sustainable energy and reducing environmental effects due to pipeline failures.

42 ENGINEERING↗
DOE OSTI2023

Enhancing photonic systems using topology and non-Hermiticity

The broad goal of this project was to develop new analytical and numerical insights for how important photonic processes can be improved using recently discovered principles in topological and non-Hermitian physics. In particular, there are two recent discoveries that we aimed to harness to achieve this goal. First, it was discovered in condensed matter physics that crystalline symmetries can protect low-dimensional topologically protected states in lattices without the need for breaking time-reversal symmetry. These so-called ‘higher-order’ topological systems represent an important development for photonic systems, where it is very difficult to break time-reversal symmetry, and which had been previously thought necessary to realize topological phenomena. Second, the last decade has seen a significant amount of interest in phenomena which are unique to non-Hermitian systems, i.e., systems which do not conserve energy. For example, spatially patterned gain and loss can be used to realize exceptional points, which are degeneracies in a system’s spectrum where the system becomes defective, while the existence of radiative losses also enables a new route to confinement through bound states in the continuum. For such non-Hermitian phenomena, photonics again represents a critical platform, as photonic systems naturally lose light to their radiative environments, making them generally non-Hermitian, and it is also possible to incorporate additional gain or loss. Based on these broad principles, we pursued a range of projects to harness bound states in the continuum in a variety of different systems and architectures, develop real-space methods for classifying topological systems to yield better photonic design principles, and a novel Brillouin-based fiber laser for sensing strain.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2023

Multifunctional Fiber-Reinforced Polymer Composites for Damage Detection and Memory

Self-structural health monitoring (SHM) functionalities for fiber-reinforced polymer composites have become highly sought after to ensure the structural safety of newly advancing components in the automotive, civil, mechanical, and aerospace industries. This paper introduces a self-damage detection and memory (SDDM) hybrid composite material, where the structural carbon fiber tow is transformed into a piezoresistive sensor network, and the structural glass fiber operates as electrical insulation. In this study, SDDM specimens were fabricated, and tensile and impact tests were performed. The tensile tests of SDDM specimens find two distinct loading peaks: first where the carbon fiber fails, and second where the glass fiber fails. A linear correlation was observed between the carbon fiber resistance and composite strain up to a threshold, beyond which a sharp nonlinear increase in resistance occurred. The resistance then approached infinity, coinciding with the first loading peak and failure of the carbon fiber elements. This demonstrates the potential for a damage early warning threshold. Additionally, the effect of stitching the sensor tow in a zig-zag pattern over a large area was investigated using tailored fiber placement (TFP) of 1-loop, 3-loop, and 5-loop specimens. Tensile testing found that increasing the number of loops improved the sensor’s accuracy for strain sensing. Furthermore, impact tests were conducted, and as the impact energy progressively increased, the sensor resistance permanently increased. This illustrates a capability for self-memory of microdamage throughout the life cycle of the structure, potentially useful for predicting the remaining life of the composite.

Demo, Luke B. (ORCID:0000000208806522)↗
DOE OSTI2024

Experimental Investigation of Low-Frequency Distributed Acoustic Sensor Responses to Two Parallel Propagating Fractures

Low-frequency distributed acoustic sensing (LF-DAS) is a diagnostic tool for hydraulic fracture propagation with far-field monitoring using fiber optic sensors. LF-DAS senses strain rate variation caused by stress field change due to fracture propagation. Fiber optic sensors are installed in the monitoring wells in the vicinity of a fractured well. From the strain responses, fracture propagation can be evaluated. To understand subsurface conditions with multiple propagating fractures, a laboratory-scale hydraulic fracture experiment was performed simulating the LF-DAS response to fracture propagation with embedded distributed optical fiber strain sensors under these conditions. The experiment was performed using a transparent cube of epoxy with two parallel radial initial flaws centered in the cube. Fluid was injected into the sample to generate fractures along the initial flaws. The experiment used distributed high-definition fiber optic strain sensors with tight spatial resolutions. The sensors were embedded at two different locations on opposite sides of the initial flaws, serving as observation/monitoring locations. We also employed finite element modeling to numerically solve the linear elastic equations of equilibrium continuity and stress–strain relationships. The measured strains from the experiment were compared to simulation results from the finite element model. The experimentally derived strain and strain-rate waterfall plots from this study show the responses to both fractures propagating, while the fracture at the lower position took most of the fluid during the experiment. Interestingly, a fracture first began propagating from the upper flaw of the two flaws, but once the lower fracture was initiated, it grew much faster than the upper fracture. Both fibers were intercepted by the lower fracture, further verifying the strain signature as a fracture is approaching and intersecting an offset fiber.

Chemistry↗
DOE OSTI2024

Utah FORGE: Well 16A(78)-32 Hydraulic Fracturing Stage 8 Crosswell Strain FDI and Microseismic Presentations - April 2024

This is a pair of PowerPoint presentations from Neubrex Energy Services (US), LLC. The presentations review work done in April 2024 on crosswell strain fracture driven interactions (FDI) and microseismic event monitoring during hydraulic fracturing in stage 8 of Utah FORGE well 16A(78)-32. Well 16B(78)-32 was the monitoring well and was where the data for these presentations were collected.

15 GEOTHERMAL ENERGY↗