SEARCH · Engineering Papers

Results for “downhole”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 127 records · Page 7

All sources NASA NTRS DOE OSTI

DOE OSTI2024

Characterization of the Structural–Stratigraphic and Reservoir Controls on the Occurrence of Gas Hydrates in the Eileen Gas Hydrate Trend, Alaska North Slope

One of the most studied permafrost-associated gas hydrate accumulations in Arctic Alaska is the Eileen Gas Hydrate Trend. This study provides a detailed re-examination of the Eileen Gas Hydrate Trend with a focus on the gas hydrate accumulation in the western part of the Prudhoe Bay Unit. This integrated analysis of downhole well log data and published geophysical data has provided new insight on structural, stratigraphic, and reservoir controls on the occurrence of gas hydrates in the Eileen Gas Hydrate Trend. This study revealed the relatively complex nature of the gas hydrate occurrences in the Eileen Gas Hydrate Trend, with gas hydrates present in a series of coarsening upward, laterally pervasive, mostly fine-grained sand beds exhibiting high gas hydrate saturations. Most of the gas hydrate-bearing reservoirs in the Eileen Gas Hydrate Trend are laterally segmented into distinct northwest- to southeast-trending fault blocks, occur in a combination of structural–stratigraphic traps, and are only partially hydrate filled with distinct down-dip water contacts. These findings suggest that the traditional parts of a petroleum system (i.e., reservoir, gas source, gas migration, and geologic timing of the system formation) also control the occurrence of gas hydrates in the Eileen Gas Hydrate Trend.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2022

Effects of Charged Solute-Solvent Interaction on Reservoir Temperature during Subsurface CO2 Injection

A short-term side-effect of CO2 injection is a developing low-pH front that forms ahead of the bulk water injectant, due to differences in solute diffusivity. Observations of downhole well temperature show a reduction in aqueous-phase temperature with the arrival of a low-pH front, followed by a gradual rise in temperature upon the arrival of a high concentration of bicarbonate ion. In this work, we model aqueous-phase transient heat advection and diffusion, with the volumetric energy generation rate computed from solute-solvent interaction using the Helgeson–Kirkham–Flowers (HKF) model, which is based on the Born Solvation model, for computing specific molar heat capacity and the enthalpy of charged electrolytes. A computed injectant water temperature profile is shown to agree with the actual bottom hole sampled temperature acquired from sensors. The modeling of aqueous-phase temperature during subsurface injection simulation is important for the accurate modeling of mineral dissolution and precipitation because forward dissolution rates are governed by a temperature-dependent Arrhenius model.

58 GEOSCIENCES↗

DOE OSTI2024

Magnetic Field Sensing via Acoustic Sensing Fiber with Metglas® 2605SC Cladding Wires

Magnetic field sensing has the potential to become necessary as a critical tool for long-term subsurface geophysical monitoring. The success of distributed fiber optic sensing for geophysical characterization provides a template for the development of next generation downhole magnetic sensors. In this study, Sentek Instrument’s picoDAS is coupled with a multi-material single mode optical fiber with Metglas® 2605SC cladding wire inclusions for magnetic field detection. The response of acoustic sensing fibers with one and two Metglas® 2605SC cladding wires was evaluated upon exposure to lateral AC magnetic fields. An improved response was demonstrated for a sensing fiber with in-cladding wire following thermal magnetic annealing (~400 °C) under a constant static transverse magnetic field (~200 μT). A minimal detectable magnetic field of ~500 nT was confirmed for a sensing fiber with two 10 μm cladding wires. The successful demonstration of a magnetic field sensing fiber with Metglas® cladding wires fabricated via traditional draw processes sets the stage for distributed measurements and joint inversion as a compliment to distributed fiber optic acoustic sensors.

Dejneka, Zach (ORCID:0000000179415708)↗

DOE OSTI2025

Acoustic Sensing Fiber Coupled with Highly Magnetostrictive Ribbon for Small-Scale Magnetic-Field Detection

Fiber-optic sensing has shown promising development for use in detecting magnetic fields for downhole and biomedical applications. Coupling existing fiber-based strain sensors with highly magnetostrictive materials allows for a new method of magnetic characterization capable of distributed and high-sensitivity field measurements. This study investigates the strain response of the highly magnetostrictive alloys Metglas® 2605SC and Vitrovac® 7600 T70 using Fiber Bragg Grating (FBG) acoustic sensors and an applied AC magnetic field. Sentek Instrument’s picoDAS interrogated the distributed FBG sensors set atop a ribbon of magnetostrictive material, and the corresponding strain response transferred to the fiber was analyzed. Using the Vitrovac® ribbon, a minimal detectable field amplitude of 60 nT was achieved. Using Metglas®, an even better sensitivity was demonstrated, where detected field amplitudes as low as 3 nT were measured via the strain response imparted to the FBG sensor. Distributed FBG sensors are readily available commercially, easily integrated into existing interrogation systems, and require no bonding to the magnetostrictive material for field detection. The simple sensor configuration with nanotesla-level sensitivity lends itself as a promising means of magnetic characterization and demonstrates the potential of fiber-optic acoustic sensors for distributed measurements.

Dejneka, Zach (ORCID:0000000179415708)↗

DOE OSTI2024

Optimizing Deep Geothermal Drilling for Energy Sustainability in the Appalachian Basin

This study investigates the geological and geomechanical characteristics of the MIP 1S geothermal well in the Appalachian Basin to optimize drilling and address the wellbore stability issues encountered. Data from well logs, sidewall core analysis, and injection tests were used to derive elastic and rock strength properties, as well as stress and pore pressure profiles. A robust 1D-geomechanical model was developed and validated, correlating strongly with wellbore instability observations. This revealed significant wellbore breakout, widening the diameter from 12 ¼ inches to over 16 inches. Advanced technologies like Cerebro Force™ In-Bit Sensing were used to monitor drilling performance with high accuracy. This technology tracks critical metrics such as bit acceleration, vibration in the x, y, and z directions, Gyro RPM, stick-slip indicators, and bending on the bit. Cerebro Force™ readings identified hole drag caused by poor hole conditions, including friction between the drill string and wellbore walls and the presence of cuttings or debris. This led to higher torque and weight on bit (WOB) readings at the surface compared to downhole measurements, affecting drilling efficiency and wellbore stability. Optimal drilling parameters for future deep geothermal wells were determined based on these findings.

Environmental Sciences & Ecology↗

DOE OSTI2025

Proceedings of the UT-GOM2-2 Hydrate Pressure Coring Expedition

In the summer and fall of 2023, the University of Texas (UT) Deepwater Hydrate Coring Expedition (UT-GOM2-2) drilled, cored, made downhole measurements, and analyzed samples from the seafloor to the base of the gas hydrate stability zone at Site H, in the Walker Ridge Protracted Area Block 313 (Site H, WR313), in the Terrebonne Basin, deepwater Gulf of America (Gulf of Mexico).

03 NATURAL GAS↗

DOE OSTI2020

Study of Additive Manufacturing Application to Geothermal Technologies

Geothermal reservoir characterization, field construction, and reservoir operations are very technology intensive activities that contribute significantly to the cost of delivering electricity produced from geothermal resources. Many geothermal technologies, such as downhole tools and drilling equipment, have unusual material, design, and manufacturing considerations dictated by the harsh geothermal environment and extreme aspect ratios required for deployment in a borehole. An additional challenge that faces geothermal applications is the low tool production volume needed to support the industry. Whereas tens of thousands of Oil & Gas wells are drilled and completed in the U.S. annually, there are typically only tens of geothermal wells that are drilled and completed. If a tool typically used in Oil & Gas applications cannot be directly used for geothermal, then the cost associated with making the tool suitable for geothermal is often prohibitive. There is therefore a much smaller inventory of technologies available to geothermal as compared to Oil & Gas and the level of efficiency and sophistication associated with field practice suffers accordingly. A number of advanced manufacturing methods, such as additive manufacturing, have received increased R&D as well as commercial attention in recent years because of their ability to rapidly prototype complex parts. Additive manufacturing in particular provides an opportunity to increase the technology available to the geothermal industry by either reducing fabrication costs associated with complex components or enabling economic production of low volume parts where specialized tooling is often required. Additional potential benefits of additive manufacturing include increased design freedom to make higher performing parts that cannot be made conventionally, the ability to integrate components into assemblies without joining operations, and the ability to economically fabricate variations on design in cases, such as casting molds, where there are large up-front costs associated with tooling. We have recently completed a study that investigated technology needs, representative use cases, manufacturability, and a techno-economic framework for comparing conventional to additive manufacturing methods for geothermal applications. This paper will provide an overview of this recent effort, describe the different elements of the assessment, and summarize the key takeaways related to both the feasibility of using additive manufacturing for geothermal technology applications as well as the potential benefits and impacts.

Polsky, Yarom↗

DOE OSTI2021

Multi-barrier wellbore integrity inspection system with eccentricity correction

A downhole inspection system includes a neutron imaging device operable to generate data for detecting potential wellbore anomalies and an electromagnetic imaging device operable to generate data for detecting potential wellbore eccentricity. The neutron imaging device includes a neutron generator operable to emit neutrons, and a neutron detector fixed relative to the neutron generation unit and operable to detect backscattered neutrons from a surrounding environment. The electromagnetic imaging device includes at least one transmitter for generating electromagnetic pulse, and at least one receiver for detecting returning electromagnetic pulse. Correlation of the neutron imaging data with the electromagnetic imaging data provides additional data regarding the potential wellbore anomalies.

Kasten, Ansas Matthias↗

DOE OSTI2021

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↗

DOE OSTI2020

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↗

DOE OSTI2022

The weathered bedrock vadose zone: A hidden control on water availability in the western United States (Final Technical Report)

This report summarizes the research completed during the project entitled "The weathered bedrock vadose zone: A hidden control on water availability in the western United States" (Award: DE-SC0018039). The report covers work completed between 9/15/17 and 9/14/20. The objective of the exploratory project work was to evaluate the overarching hypothesis that the subsurface underlying actively eroding landscapes is systematically structured as a result of a balance between weathering and erosion and that this structure leads to dynamic moisture storage within weathered rock. To accomplish project objectives, we characterized hillslope weathering profile structure and conducted subsurface moisture monitoring across four study sites with comparable bedrock types but differing erosion rate and hydroclimate: The Angelo Coast Range Reserve (ACRR), Sagehorn-Russell Ranch (SRR), Antelope Valley Ranch (AVR), and the LBNL Watershed Function Scientific Focus Area (SFA). New characterization and monitoring infrastructure at the AVR and SFA sites was established through this project and enables long-term monitoring of hydrologic and carbon fluxes at the sites for comparison with long-term monitoring in other sites. Deep drilling, downhole logging, and characterization of chemistry and porosity of rock recovered from drilling reveals two weathering fronts across the sites. A shallower front is marked by the extent of pervasive fracturing and oxidation of pyrite and organic carbon. A deeper weathering front is marked by the appearance of open fractures and discoloration. At the AVR site, multiple ridge tops of different hillslope length were investigated to establish the relationship between the weathering front and topography. Drilling reveals that the fraction of the hillslope relief that is weathered scales with hillslope length, consistent with the theoretical framework that guided the project relating groundwater drainage with landscape evolution. With the establishment of new boreholes, we have documented significant water storage in weathered bedrock using low-field borehole nuclear magnetic resonance (NMR) across all four sites. In the upper 4 m of bedrock, the average water contents at ACRR, AVR, SRR, and SFA are approximately 25%, 16%, 25%, 23% respectively. At the ACRR site, where long-term monitoring via neutron probe surveys and time-domain transmission sensors are available, we have demonstrated that NMR reliably records moisture content and importantly, moisture content dynamics in weathered bedrock. Across all sites, our NMR monitoring has also revealed that a considerable fraction of the water storage occurs in fractures or pores that are significantly larger than the fine-grained bedrock matrix of the parent rock. To identify the proportion of water storage occurring in fractures and large pores, we analyzed the NMR signal by evaluating both the sum of echoes and an inversion of the NMR signal for a distribution of T2 relaxation times. Both methods reveal that at least 20% of the water storage occurs in fractures and larger pores across all sites. To constrain the interpretation of the in-situ field-scale NMR measurements, we compare the NMR response in the field to independent pore-structure information obtained via helium pycnometry. Results support the inference that dynamic seasonal water storage is dominantly restricted to the fracture network, which can reach 7% of the total volume. This dynamic range in water content is comparable to that of some soils, underscoring the need to understand how this region of the Earth System is structured, and functions as a hydrologic reservoir.

58 GEOSCIENCES↗

DOE OSTI2021

Field Data Analysis and Modeling of Drillstring Vibrations to Identify Inefficiency in Deep Geothermal Drilling

One challenge that hinders efficient drilling and causes downhole tool failures is severe drillstring vibrations. The objective of this paper is to identify the root cause of drillstring vibrations in deep geothermal wells and investigate their effect on drilling performance using data analytics and vibration modeling. A near-bit sub was utilized to collect vibration data, where the burst data was used to obtain the drillstring torsional natural frequency. The data showed that the highest lateral acceleration and stick-slip severities (SSS) occur at the higher mechanical specific energy (MSE) range, while the low vibration levels were encountered in the optimum range of the MSE curve. The elevated SSS levels consistently occur at the low to mid-range of applied RPM and the highest sonic velocity. Additionally, the lateral acceleration levels are higher at the low to mid-range of the applied RPM. The effect of drillstring vibration on drilling performance was recognized by the presented MSE analysis.

15 GEOTHERMAL ENERGY↗

DOE OSTI2021

Fixed Bit Rotary Drilling Failure Criteria Effect on Drilling Vibration

Polycrystalline diamond compact (PDC) bit use has been expanded to geothermal drilling applications due to their improved performance in drilling compared to roller cone bits. Multiple vibration models have been developed yet and there are limited use of field data to study the ability of numerical vibration model to predict recorded vibration in the field. The objective of this paper is to evaluate the capabilities of two different rock-bit interaction models with two different ROP formulations for predicting the actual behavior seen in the field. The first model (Model-I) considers the rock-bit interaction, incorporating the effect of subsurface formation characteristics. The second model (Model-II) is a PDC bit model that uses calculated threshold weight-on-cutter (WOCt) to study the interaction of the bit with the rock surface. The models, which couple the drill stem axial and torsional motions, are solved numerically using the fourth-order Runge-Kutta method and compared with recorded downhole drilling data from the Chocolate Mountain Aerial Gunnery Range (CMAGR) geothermal well located in California. An 8–½" PDC bit with 8 blades was modeled and vibration simulation was performed to investigate stick-slip vibrations at 1400 ft. depth. Simulation results using field data indicate that Model-II encounters a low range of stick-slip severity (SSV) as compared to Model-I, which is in the moderate range. Comparison with the field value for SSV shows Model-II is the best representative of the field case for this depth. The sensitivity analysis shows that results are sensitive to model constants making prediction of SSV from models uncertain.

15 GEOTHERMAL ENERGY↗

DOE OSTI2021

Systems and methods that use harmonic drives for converting reciprocating axial motion to continuous rotary motion, helical drives for converting reciprocating rotary motion to reciprocating axial motion and combinations thereof for converting reciprocating rotary motion to continuous rotary motion

A harmonic drive assembly and fluid-powered linear motors with both axial pistons are rotary piston arrangements incorporating the harmonic drive assembly are disclosed. The motors may be used in downhole drilling applications, but the drive assembly and/or motors may be used in other applications. The assembly, motors and methods use advanced harmonic drives, advanced helical drives, and combinations thereof with 1) motors with axial pistons and reciprocating linear rings to convert reciprocative axial motion to continuous rotary motion, and 2) motors with rotary pistons and reciprocating linear rings to rectify reciprocative rotary motion to continual rotary motion to improve performance over prior configurations.

Raymond, David W.↗

DOE OSTI2021

Systems, methods and tools for subterranean electrochemical characterization and enthalpy measurement in geothermal reservoirs

The present disclosure is directed to systems, methods and tools that measure ionic concentrations and downhole enthalpy of a flowing geothermal fluid in real-time at high-temperature and pressure. The systems, methods and tools include measuring the concentration of selected naturally occurring ions found in the liquid phase of the geothermal fluid throughout the wellbore using novel electrochemical sensor technologies. The change in liquid-phase ion concentration will be used to calculate the proportion of liquid to steam and allow for accurate enthalpy measurements. The techniques and technologies described here can be applied to any application of electrochemical sensing in extreme environments.

Cieslewski, Grzegorz↗

DOE OSTI2022

Optimizing Rate of Penetration and Tripping Decision-Making using Real-Time Bit Wear Monitoring While Drilling Geothermal Wells

Understanding bit wear while drilling is critical to minimizing non-productive time (NPT) and optimizing rate of penetration (ROP). Lengthening drilling runs with damaged bits does not only lower the ROP, but also elevates the risk of inducing severe bit damage, which could potentially lead to time-consuming fishing operations. When drillers believe the bit has worn off substantially, the bit is tripped out to be replaced. On geothermal wells, tripping can take up to 20% of the overall well construction time, and this is generally acknowledged as an opportunity for improvement. Ideally, a bit run should be terminated before the bit is damaged beyond repair. At the same time, premature bit pulls are to be avoided as well. This study aims to leverage bit and tooth wear metrics that can be obtained in real time to characterize bit condition in order to optimize ROP and determine the optimal time to pull the bit. Two metrics were explored in this study: a bit wear metric that incorporated depth-of-cut, and a tooth wear metric developed by Bourgoyne & Young characterizing the state of bit teeth dull. Both metrics were computed using recorded data from 12¼ inches roller cone insert bit runs in five geothermal wells targeting a granodiorite formation in the western United States. Together with the actual dull grades, determined after the bits were pulled to surface, the metric trends were interpreted to characterize the downhole bit condition and identify the point at which the bit should have optimally been tripped out. The insights from studying the actual dull grades and how they relate to the two metrics were used to establish a reliable bit pull criterion. The bit wear metric trend correctly showed a noticeable departure from baseline for bits experiencing major dulling behavior. Additionally, the tooth wear model predicted the cutter dull within two dull grades for most runs, with better performance in predicting the inner teeth dull. Moreover, the combination of the bit wear and tooth wear metrics was effective in revealing the cause of the bit performance impairment. Proactive tracking of these two metrics in real-time can facilitate geothermal drilling ROP optimization and better-informed tripping decision-making, thereby avoiding wasted time and cost.

Ashari, Rahmat↗

DOE OSTI2023

High temperature and high pressure AlGaN/GaN electronics

Disclosed herein are devices, systems and methods useful for downhole sensors and electronics suitable for harsh thermal and mechanical environment associated with high-temperature geothermal drilling and high-temperature/high-pressure oil and gas drilling.

Ginley, David Samuel↗

DOE OSTI2023

Data fusion enhanced multi-modality wellbore integrity inspection system

A downhole multi-modality inspection system includes a first imaging device operable to generate first imaging data and a second imaging device operable to generate second imaging data. The first imaging device includes a first source operable to emit energy of a first modality, and a first detector operable to detect returning energy induced by the emitted energy of the first modality. The second imaging device includes a second source operable to emit energy of a second modality, and a second detector operable to detect returning energy induced by the emitted energy of the second modality. The system further includes a processor configured to receive the first imaging data and the second imaging data, and integrate the first imaging data with the second imaging data into an enhanced data stream. The processor correlates the first imaging data and the second imaging data to provide enhanced data for detecting potential wellbore anomalies.

Kasten, Ansas Matthias↗