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At least 667 records · Page 37

Fluid-powered linear motor with rotary pistons and motion rectifier

A fluid-powered linear motor with rotary pistons is disclosed. An application is for a downhole motor but it could be used in other applications. Rotational pistons provide increased torque generation as the torque generated is proportional to motor length. Since downhole drills are long (generally up to a maximum length of 30 ft.), a high-torque motor can be produced using this method. A pressurized fluid is used to drive the piston assemblies to produce bit shaft power. This concept employs rotary pistons and a mechanical rectifier to convert the rotational reciprocation produced by a reciprocating rotational piston into continuous rotary motion.

42 ENGINEERING↗

Detection and quantification of proppant for optimized fracture treatment design in in-fill and new wells

A system and method for detecting and quantifying proppant for optimized fracture treatment design in in-fill and new wells. Proppant is isolated from drilling fluids and then analyzed to determine whether a formation within the well has been properly stimulated based on the analysis. Placement of an in-fill well may be based upon the determination of whether the well has been properly stimulated.

04 OIL SHALES AND TAR SANDS↗

Analysis of Hydraulic Fracturing on the 4100 Level at the Sanford Underground Research Facility

A series of hydrofractures were performed on the 4100 ft. level of the Sanford Underground Research Facility (SURF) to quantify the minimum principal stress and stress orientation. The motivation for this work was to determine the suitability of the site as a second testbed for the EGS Collab project and to inform the testbed design. EGS Collab is a meso-scale project where experiments are being performed to increase permeability in low-permeability rock and improve our understanding of appropriate techniques and models required for developing enhanced geothermal systems. In order to design the second testbed, a ~50 m vertical HQ (96 mm) pilot borehole was drilled in June, 2019, to perform a series of mini-frac tests to determine rock stress state. Utilizing an elastic model based on the ISIP (Instantaneous Shut In Pressure), testing indicates that the minimum principal stress is 20.4 MPa oriented NNE (24°) and plunges at an angle of approximately 28°.

Ingraham, Mathew↗

Slip Tendency Analysis of Fracture Networks to Determine Suitability of Candidate Testbeds for the EGS Collab Hydroshear Experiment

Experiment 2 of the EGS Collab project is aimed at testing stimulation by hydro-shearing of existing natural fractures, versus Experiment 1, which is focused on hydraulic fracturing a rock mass to enhance permeability. The main criterion for the testbed selection in Experiment 2 is the presence of an interconnected network of fractures, at least 10 meters in extent, and with orientations such that shear slip can be induced at injection pressures less than the minimum horizontal stress (Shmin). The feasibility analysis for this experiment requires a well-constrained stress state along with well-characterized fracture networks. The fracture systems at two candidate locations in the Sanford Underground Research Facility (SURF), the 4850 Level (number refers to depth below ground surface in feet) and the 4100 Level, have been characterized to different extents. The 4850 Level has a well-characterized Discrete Fracture Network (DFN) from borehole (drilled for an experimental test bed) and drift observations. In contrast, the 4100 level has a fracture network characterized only by observations from the drift wall, which provides little constraint on fracture extents. This paper will present assessments for the interpreted slip potential for the natural fractures at the two locations. Data uncertainties are addressed by performing a probabilistic analysis that takes into account the uncertainty in the stress state, uncertainty in the fracture properties, and preliminary borehole locations. There is strong evidence of shear stimulation of some natural fractures in Experiment 1 on the 4850 level. We use examples of natural fractures strongly linked to shear stimulation in Experiment 1 from multiple monitoring indicators to test the consistency of the stress model and guide the uncertainty interpretation. This analysis is intended to guide the site selection process for Experiment 2 by highlighting the fracture orientations that are likely to be shear-stimulated in a majority of modeled realizations.

40 EE - Geothermal Technologies Office (EE-4G)↗

A Preliminary Investigation on the Cost Reduction Potential of Optimizing Bore Fields for Commercial Ground Source Heat Pump Systems

The high initial cost of ground heat exchangers (GHE) is a primary hurdle preventing wider adoption of ground source heat pump (GSHP) systems. GHEs used for commercial GSHP systems commonly consist of vertical boreholes installed on a grid with equal spacing between boreholes. Significant thermal loads require a large number of boreholes to be present in the field. However, due to thermal interactions among boreholes, the ground formation in the center of a bore field can, over time, become thermally saturated when the thermal load is not balanced on an annual basis. The loss of effectiveness due to thermal saturation at the center boreholes in regularly spaced borehole fields suggests that larger spacing near the center of the bore field could be more optimal, and in return reduce initial costs. Through computer simulations using the latest development of a GHE modeling tool, this study evaluates the impacts of various unconventional designs of the borehole field on the performance and cost of the GHEs of a typical commercial GSHP system. The unconventional designs include irregular spacing among boreholes with decreased spacing around the perimeter and increased spacing in the interior of the field. The unconventional bore field design shortens the total drilling length by up to 42% while giving better heat transfer performance than a conventional bore field design. The significant total bore length reduction is due to improved heat transfer effectiveness of each borehole in the unconventional bore field.

Spitler, Jeffery↗

Deterministic Discrete Fracture Network (DFN) Model for the EGS Collab Project on the 4850 Level of the Sanford Underground Research Facility (SURF)

The EGS Collab is conducting hydraulic fracture stimulation and fluid circulation experiments in the Sanford Underground Research Facility (SURF) located in Lead, South Dakota. A total of eight ~60m-long subhorizontal boreholes were drilled from the 4850 Level (~1.5 km below the ground surface) into the crystalline rock of this former mine. Six of these holes are used for geophysical monitoring, one is used for hydraulic fracture stimulation, and the remaining hole was designed as a production borehole that receives water from the injection well via the induced and natural fracture system. The primary goal of creating the discrete fracture network model is to show that these modeling methods are critical for the development of enhanced geothermal systems (EGS). This includes the prediction of rock behavior during fracturing and during an extended period of water flow between the parallel injection and production boreholes. Understanding the results from the induced fracturing and flow is complicated by the presence of significant natural fractures that interact with the stimulation and/or flow pathways. The delineation and characterization of natural fractures is thus an important part of the project, and therefore a model of the Discrete Fracture Network (DFN) was developed on a deterministic basis. The DFN was populated using observations and interpretations integrated from drift (horizontal passageways that allow access in the underground) fracture mapping, analysis of core recovered from the eight boreholes, borehole televiewer logs and videos, and observations of flow between and within boreholes and in the drift. The natural fracture system is dominated by a pervasive northwest-trending, steeply dipping shear system that is identifiable in the drifts and the core. Hydraulic fracture stimulation, flow/tracer circulation tests, and geophysical monitoring revealed that the behavior of the injected water, and perhaps the growth of induced fractures, has been significantly influenced by the existing fractures identified in the DFN.

40 EE - Geothermal Technologies Office (EE-4G)↗

Infrastructure and Metocean Technology

<strong>Research Problem: </strong>Changes in the ocean environment (i.e., mudslides or burial from subsea currents, strong weather events or natural fluctuations) have been linked to <strong>billions of dollars of impacts</strong>. These events can have a significant effect on the <strong>success and longevity </strong>of offshore infrastructure, as well as affect <strong>safety and cost </strong>during exploration and production activities.<strong>Research Approach: (1) </strong>Determine current state of knowledge regarding hazardous metocean and bathymetric conditions, and data availability regarding these conditions and historic events. (2) EY19 -Evaluate if Ml/AI model can be developed to better identify current hazardous metocean and bathymetric conditions. (3) EY 20 + -develop, train, and test ML/AI model to identify current conditions and forecast changes and vulnerability that may impact offshore infrastructure and operations. <strong>Benefit: </strong>Improved characterization of seabed related hazards in the offshore environment will help to manage and minimize costs and risks during drilling and production operations, and help prevent catastrophic incidents.

Duran, Rodrigo↗

Geology and Hydrothermal Alteration of the Raft River Geothermal System, Idaho

The Raft River geothermal system is located in southern Idaho, near the Utah-Idaho state boarder in the Raft River Valley. The field, which is owned and operated by U.S. Geothermal, has been selected as an EGS demonstration site by the U. S. Department of Energy. This paper summarizes ongoing geologic and petrologic investigations being conducted in support of this project. The reservoir is developed in fractured Proterozoic schist and quartzite, and Archean quartz monzonite cut by younger diabase intrusions. The basement complex was deformed during the mid Tertiary and covered by approximately 5000 ft of late Tertiary sedimentary and volcanic deposits. Listric normal faults of Cenozoic age disrupt the Tertiary deposits but do not offset the basement rocks. RRG-9, the target well, was drilled southwest of the main well field to a measured depth (MD) of 6089 ft. The well is deviated to the west and cased to a depth of 2316 ft MD. It penetrated the Proterozoic reservoir rocks at a depth of 5286 ft MD and encountered a maximum temperature of 139 degrees C. Bottomhole temperatures in other deep wells range from 133 to 149 degrees C. X-ray diffraction and thin section analyses are being conducted on samples from 5 deep wells, RRG- 1, 2, 3, 7 and 9, to determine the characteristics of the rock types and hydrothermal alteration within the geothermal system. Thin section analyses of samples from RRG-9 document the presence of strong alteration and brecciation at the contact between the Tertiary and basement complex. The Tertiary rocks consist of ash-flow tuffs, lava flows, tuffaceous siltstone, greywacke, and sandstone. No core is available from RRG-9 but core was obtained from RRG-3C. The sample is a brecciated and altered siltstone from the base of the Tertiary sequence and is similar to rocks at the base of the Tertiary deposits in RRG-9. Here, the results of thermal and quasi-static mechanical property measurements that were conducted on the core sample are presented.

Jones, Clay↗

Proposed Potential Mitigation of Wastewater Disposal Through Treated Produced Water in Bakken Formation

The recent global expansion in the development of unconventional oil and gas assets has also resulted in a tremendous increase in the number of extended horizontal drilling and hydraulic fracturing projects in the Bakken. The United States is presently the largest global crude oil producer, and the Bakken Formation in North Dakota is one of the major contributors to this achievement. However, the wastewater produced from these increased oilfield activities are highly saline (∼170,000 to 350,000 ppm TDS) and no technology currently available can satisfactorily treat it. As a result, more than 90% of wastewater in the Bakken is disposed of by deep injection into disposal wells. However, there are growing environmental and operational concerns about the sustainability and impacts of this approach. Research has shown that cumulative wastewater injection in some areas could increase the chances of earthquakes in those areas. However, if this produced water is efficiently treated, it could be reused in hydraulic fracturing operations or to support coal mining and irrigation activities. All these applications would reduce the need for wastewater injection and reduce the demand for fresh water used in hydraulic fracturing operations across North Dakota. For this purpose, we propose an enhanced supercritical technology we call Supercritical Water Extraction – Enhance Targeted Recovery to handle the issue of high TDS of flowback and produced water in the Bakken.

04 OIL SHALES AND TAR SANDS↗

Inkjet-Based 3D Printing: From Quantum Dots to Steel Tools

Inkjet-based additive manufacturing (AM) technologies are highly versatile among manufacturing processes due to their ability to shape any material in powder or ink form. The two inkjet-based AM technologies are binder jetting and material jetting, and as each of their names suggest, the former uses inkjet to deposit binder into the actual build material and the latter uses inkjet to deposit the actual build material. With each of these technologies comes unique opportunities in the form of embedding functional components within the build, creating material gradients within parts by selectively layering feedstocks, shaping non-weldable materials, and creating low-cost tooling with conformal cooling channels. Dr. Amy Elliott at Oak Ridge National Laboratory has explored a variety of materials and approaches with inkjet-based manufacturing technologies, focusing on industry-relevant applications such as injection molding tooling and mining drills.

Elliott, Amy↗

Emerging Issues in the Development of Geologic Models for Gas Hydrate Numerical Simulation

The numerical simulation of gas hydrate reservoirs has evolved greatly in recent years. Scientific and industrial drilling programs have acquired detailed characterization data from gas hydrate systems in Alaska, Japan, India, Korea, China, and the Gulf of Mexico. These data provide invaluable calibration points that serve to ground-truth hydrate reservoir modeling efforts.

Boswell, Ray↗

Report on Mowry Shale Thermal Maturity Mapping in the Powder River Basin, Wyoming

The Enhanced Oil Recovery Institute (EORI) has completed a map of thermal maturity of the Mowry Shale in the Powder River Basin (PRB). Thermal maturity, the degree to which the total organic carbon in a formation has been transformed from kerogen to producible hydrocarbons due to heat and pressure, is an important measure for not just the quality of a source rock, but also helps for delineating areas more favorable for unconventional drilling. There is a dearth of published Mowry maturity maps available for the PRB and this publication endeavors to provide a detailed map based on a large, public data set covering the Wyoming portion of the PRB. Additional data, currently held confidential by operators in the basin, would be of benefit to future iterations of this map.

58 GEOSCIENCES↗

Additive Manufacturing Case Study

Geothermal technologies include an extremely wide range of products required for well construction, completion, production, intervention and surface energy conversion activities. Many of these products are geometrically complex, require multi-step and highly specialized fabrication processes, and are expensive due to the low production numbers typically associated with the geothermal market. These challenges along with the high temperature demands of the geothermal environment have also hindered the adoption of many tools routinely used in the oil & gas industry.Recent advancements in Additive Manufacturing (AM) materials of construction, build volumes and part quality have transitioned the technology from primarily cosmetic prototyping applications to the point where AM can be used to make production parts, even for the most demanding applications. These improved AM capabilities along with the inherent ability of AM to produce complex parts and, in some cases, geometries that cannot be manufactured using conventional casting, machining and joining fabrication approaches motivate an exploration of its potential to positively impact geothermal well construction and operations technologies.Sandia National Labs collaborated with Oak Ridge National Laboratory on a case study examining additive manufacturing opportunities for Geothermal applications. The study focused on designing components with improved performance characteristics that cannot be fabricated conventionally. A rotor for a downhole motor was chosen based on the potential for improving its rotational dynamics. Topology optimization was used as a design method to reduce the rotational inertia of the part while preserving sufficient rotational stiffness to transmit the torque required for the drilling application. The optimization resulted in a nearly 50% reduction in polar moment of inertia while maintaining other desired performance characteristics. The design developed using the topology optimization approach was fabricated using additive manufacturing and cannot be fabricated conventionally. This paper will discuss the design approach, performance improvements and manufacturing methods used to produce the part.

Polsky, Yarom↗

Analysis of Selected Publicly Available Geothermal Exploration Data Gaps

As part of a United States Department of Energy (DOE) supported retrospective analysis of DOE's Play Fairway Analysis (PFA) projects, the National Renewable Energy Laboratory (NREL) compiled and analyzed publicly available geothermal exploration datasets to identify and highlight data gaps in areas prospective for hosting geothermal resources. The analysis was intended to understand the existing geographic coverage of selected datasets commonly utilized both by the PFA projects and geothermal developers during resource assessments including geologic mapping, temperature gradient drilling, and aeromagnetic, gravimetric, and lidar surveys. Results indicate that broad areas of the western United States estimated to have geothermal potential lack sufficient geologic and geophysical coverage necessary for even regional resource exploration. The study directly informed the recent Geoscience Data Acquisition for Western Nevada, or GeoDAWN - which united DOE's Geothermal Technologies Office (GTO) with the U.S. Geological Survey (USGS) of the U.S. Department of the Interior to assist U.S. needs for energy and critical minerals. The study also has the potential to inform public investment in further data acquisition for characterization of the Earth both for geothermal and other natural resource assessments.

data↗

The EGS Collab Project: Status and Accomplishments

The EGS Collab project, supported by the US Department of Energy, is addressing challenges in implementing enhanced geothermal systems (EGS). This includes improving understanding of the stimulation of crystalline rock to create appropriate flow pathways, and the ability to effectively simulate both the stimulation and the flow and transport processes in the resulting fracture network. The project is performing intensively monitored rock stimulation and flow tests at the 10-m scale in an underground research laboratory. Data and observations from the field test are compared to simulations to understand processes and to build confidence in numerical modeling of the processes. In Experiment 1, we examined hydraulic fracturing an underground test bed at the Sanford Underground Research Facility (SURF) in Lead, South Dakota, at a depth of approximately 1.5 km. We drilled eight sub-horizontal boreholes in a well-characterized phyllite. Six of the boreholes were instrumented with many sensor types to allow careful monitoring of stimulation events and flow tests, and the other two boreholes were used for water injection and production. We performed a number of stimulations and flow tests in the testbed. Our monitoring systems allowed detailed observations and collection of numerous data sets of processes occurring during stimulation and during dynamic flow tests. Long-term ambient temperature and chilled water flow tests were performed in addition to many tracer tests to examine system behavior. Data were rapidly analyzed, allowing adaptive control of the tests. Numerical simulation was used to answer key experimental design questions, to forecast fracture propagation trajectories and extents, and to analyze and evaluate results. Many simulations were performed in near-real-time in conjunction with the field experiments, with more detailed process study simulations performed on a longer timeframe. Experiment 2 will examine hydraulic shearing in a test bed being built at the SURF at a depth of about 1.25 km in amphibolite under a different set of stress and fracture conditions than Experiment 1. Five sets of fracture orientations were considered in design, and three orientations seem to be consistently observed.

EGS Collab↗

Initial Field Testing in the Deep Subsurface for the Thermal Breakout Project for Measuring In Situ Stress

The current state-of-the-art technology for in situ stress measurements involves an integrated approach that combines borehole breakout observations, drilling-induced tensile fractures, and hydraulic fracturing tests (i.e., mini-fracs); however, this methodology has several limitations that often prevent successful in situ stress measurements. One major limitation is that breakouts do not appear in every borehole and are generally a natural occurrence that cannot easily be controlled. Because borehole breakouts are used to measure the maximum horizontal in situ stress magnitude, the absence of borehole breakouts presents a major data gap for in situ stress measurements. As a response to this data gap a new thermal breakout technology is being developed that will provide a method for thermally inducing borehole breakouts and obtaining consistent measurements of the maximum horizontal stress magnitude. This thermal breakout technology involves heating the borehole and increasing the thermoelastic compressive stress in the rock until a breakout develops, which is directly correlated to the maximum horizontal stress magnitude. An initial component of the thermal breakout project involves developing a prototype downhole tool and performing field testing in the deep subsurface. The primary objective of the initial tool development and field testing is to provide a physical proof of concept for the thermal breakout technology. Three thermal breakout field tests were performed at approximately 4850 feet deep in the Sanford Underground Research Facility. Each test was performed in a borehole that had been previously used for overcoring stress measurements. The third and final test successfully created two diametrically opposed breakouts after deploying the thermal breakout tool for approximately 3 hours of continuous heating. Post-analysis of the thermally induced breakouts confirmed that the thermal breakout orientation directly corresponds to the known in situ stress orientation and magnitude.

Voegeli, Sam↗

Modeling Validation of Mechanical and Thermal Borehole Breakouts From Polyaxial Laboratory Tests to Determine Maximum Horizontal in Situ Stress

To accurately assess rock behavior in the deep subsurface, it is necessary to measure the in situ stress directions and magnitudes. The current methods for measuring the in situ stress state in the deep subsurface primarily include hydraulic fracturing tests (i.e., the minimum horizontal stress) or occasionally observing existing compressive borehole breakouts (i.e., the maximum horizontal stress) that have occurred naturally from drilling. If there are no existing compressive breakouts in a borehole, the maximum horizontal in situ stress cannot be estimated with much confidence. In response to this data gap, a new thermal breakout technology is being developed that will provide a method for thermally inducing borehole breakouts and obtaining consistent measurements of the maximum horizontal stress magnitude. This thermal breakout technology involves heating the borehole and increasing the thermoelastic compressive stress in the rock until a breakout develops, which is directly correlated to the maximum horizontal stress magnitude. In support of developing the thermal breakout technology, polyaxial laboratory tests have been performed on small-scale boreholes within rock blocks where mechanically- and thermally-induced borehole breakouts have been created. Numerical models along with the principal of superposition were created and used to analyze the polyaxial laboratory tests to predict the maximum horizontal stress, given the same data that would be obtained in an actual subsurface borehole thermal breakout test. Multiple failure criteria were used to evaluate the best prediction of the breakout onset and maximum horizontal stress. The maximum horizontal stress predictions were compared to the actual maximum horizontal stress applied at breakout using acoustic events recorded from emission sensors in the polyaxial tests. The results showed consistent results that could be used to refine the modeling approach and failure criterion that are used to make the maximum horizontal stress predictions. This study provided insight and validation for the thermal breakout stress measurement concept.

Jones, Matt↗

Combined Structural Analysis of Core and Image Log of TGH 76-31 South East of Mt Baker, Washington State

Despite active volcanism, few geothermal energy resources have been developed in the Cascades Range. Temperature Gradient Hole 76-31 was drilled to ~440 m measured depth to probe for zones where fractures provide fluid conduits that transport deep volcanic heat to shallow depths that could support baseload, carbon neutral electrical generation. These zones were predicted by a Play Fairway assessment (PFA) of resource potential along a zone 11 km west-southwest of the summit of Mount Baker Volcano. Rock core, temperature logs, and an acoustic image log were obtained. By comparison to outcrops, the core has been initially interpreted as the Chilliwack group comprised of partially metamorphosed basaltic to andesitic volcanics. Core mapping reveals complex, steeply dipping networks of fractures and brecciation along slickensided strike slip faults; clay alteration is common in many of these structures. The majority of fractures are thoroughly healed by layers of chlorite and calcite; preservation of pyrite indicates anoxic conditions. The majority of fracture porosity resides in very dense fractures a few centimeters or less in length. The image log provides good insights into attitude of fractures that fully transect the core, but generally underestimates fracture density. The combination of complex, non-planar fracture zones containing many short fractures and healing promote misinterpretation of natural fracture attitude and density in the image log. The healing and anoxic minerals are consistent with the conductive temperature gradient measured in the well below a shallow isothermal zone, although, several fractures are open or only partially healed and resulted in fluid entries into the well. Here, the equilibrated measured temperature gradient of 64ºC/km and calculated heat flow of 145 mW/m2 is more than twice the regional average, indicating local influence of the Mt Baker magmatic system at the Little Park Creek TGH site.

Cascades↗