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Utah FORGE 2439: Well 16B(78)-32 Field-Test Data from Mini-Frac Tests
This submittal includes the field-test data collected during stress tests conducted in the Utah FORGE 16B(78)-32 wellbore to measure/characterize the stresses in the geothermal reservoir. The type of stress test performed is referred to as a mini-frac test or a micro-frac test. The test is a hydraulic fracture test that involves injecting a small volume of water into a short interval of the reservoir that is isolated by a straddle packer to create a fracture. The test provides information about the minimum and maximum horizontal stress at the test depths. A total of seven mini-frac tests were performed within the upper (vertical or nearly vertical) section of the 9-5/8-inch diameter uncased wellbore, between depths of 5,202 ft MD [5,202 ft TVD] and 5,980 ft MD [5966.18 ft TVD]. Two types of data were generated as part of the mini-frac tests. The first type of data is time-series data for each mini-frac test (e.g., injection-rate, test-interval pressure), and are contained in the "Mini-Frac Test Data.zip" file below. The second type is geophysical log data, attached below in the "Geophysical Logs.zip" file. Here, two types of image logs and acoustic logs were obtained before and after the mini-frac tests to examine each test depth for visual evidence of induced fracture(s) and to measure the azimuth (orientation) of any observed fractures. The attached Readme file includes the test depth information and contents of each data file included here. Analysis of the field-test data was conducted and is documented in the attached report below.
Field Test Report Neutron Scintillator Array Dry Storage Cask Scanner FY2024
During two weeks of Field Testing at the Idaho National Laboratory INTEC Cask Farm in July and August 2024, the LLNL Dry Storage Cask Scanner Array was lifted on top of an MC-10 dry storage fuel cask and operated to acquire neutron and gamma-ray data from the 24 fuel bundle positions. Neutron and gamma-ray data acquisition scans across the top of the cask of varying dwell times were performed July 15-18, 2024 and August 19-22, 2024 to evaluate the ability of the scanner data to reveal asymmetries in the fuel positions that reflect asymmetries in the MC-10 cask fuel bundle loading. The MC-10 cask 24 position fuel bundle loading at the INTEC Cask Farm is well documented, including the locations of six empty fuel bundle positions. This loading presents an opportunity to test the ability of the scanner system to detect diversion of spent fuel bundles as well as to validate the MC-10 cask MCNP modeling. The cask scanner array consists of six Stilbene crystal scintillator detectors and a linear actuator frame that moves the six detectors across the MC-10 dry storage cask to obtain data above each of the 24 fuel bundle positions. The detectors are connected to a pulse-shape discrimination data acquisition system capable of generating separate neutron and gamma-ray spectra for each detector and for each scan position. From the prior single detector Field Test in 2021 and iteration with MCNP modeling, the neutron and gamma-ray data were analyzed in multiple energy regions to identify an analysis method that would provide the strongest and most consistent signature of the asymmetric MC-10 cask fuel loading1 . From both the 2021 Field Test and the current Field Test results, the neutron capture gamma-ray count rate around 2.2 MeV provides the strongest signature of the asymmetric MC-10 cask fuel loading and has qualitative agreement with MCNP calculations. Counting all gamma-rays produces a similar signature. Neutrons emerging from the cask top are moderated and captured by the hydrogen in the polyethylene moderator and scintillator detector, producing a 2.2 MeV gamma ray which is seen in the scintillator gamma-ray spectrum. The count rate in the 2.2 MeV gamma-ray region is ~50 c/s, which is ~1000x higher than the ~0.05 n/s rate in the > 4MeV neutron region, and ~50x greater than the ~1 n/s rate in the neutrons > 500 keV region. Analysis of the 2.2 MeV neutron-capture Compton-scattered gamma-rays produces a statistically significant signature of the INTEC Cask Farm MC-10 asymmetric fuel loading. MCNP simulations indicate that the average neutron energy spectrum offers the potential to detect a large asymmetry from several missing bundles as well as individual missing fuel bundles. Testing this feature will require measurements on a cask with single missing elements.
Water-cooled Helmholtz coil for Ultra-low Magnetic Field Testing
Ultra-low magnetic field testing requires precise and finely calibrated instrumentation interacting with very marginal magnetic fields in highly controlled environments. We designed a large Helmholtz coil system for implementation around a 17.825-inch outer diameter Helium-3 Cryogenic fridge, to serve as both a field-zeroing device and to enable higher resolution on magnetic field sweeps during experiments. We present finite volume modeling and finite element analysis results which indicate the device could safely run at 20 [A] in perpetuity, producing a magnetic field of 65 [mT], without the surface facing the Cryogenic fridge exceeding 50°C. The overall system parts expense is $\$$4,882.76.
Field Testing of Self-Healing Metallic Coatings for Internal Corrosion Protection of Natural Gas Pipelines
Internal corrosion occurs in natural gas pipelines primarily due to the presence of water, carbon dioxide, and hydrogen sulfide. Internal corrosion can eventually result in leakage, cracks, and rupture of the pipeline. The objective of this work is to mitigate internal corrosion in steel pipelines transporting natural gas using cold spray coatings. The corrosion behavior of carbon steel coated with self-healing zinc chromium (ZnCr) and zinc niobium (ZnNb) cold spray coatings was investigated in a natural gas environment. For comparison purposes, hot-dip galvanized steel (HDGS) was tested under the same conditions as cold spray coatings. The field test was performed at the NW Natural gas storage facility in Mist, Oregon. The field test was conducted in a 6-inch diameter pipe transporting wet natural gas out of an underground storage well at 500 psi and 4.4 °C. The coupons were tested for 15 and 32 days under stagnant and flow conditions, respectively. Weight loss method was used to measure the corrosion rate of metallic coatings. Post-corrosion surface characterization was performed on the specimen using a scanning electron microscopy (SEM) equipped with energy dispersive X-ray spectroscopy (EDS). Crystalline phases were determined by X-ray diffraction (XRD). The field-test results confirmed that the metallic coatings provided corrosion protection of carbon steel exposed to wet natural gas under stagnant and flow conditions. The formation of the ZnCO 3 layer on top of ZnNb and ZnCr coatings led to passivation of the coatings which helps to reduce the self-corrosion. These layers form a barrier for diffusion of corrosive species to the surface.
Site Selection for Field Testing of a Marine Hydrokinetic Turbine Platform to Serve as a Floating Unmanned Mobile Recharging Station for Aerial Drones
Abstract Expanding applications of unmanned aerial vehicles (UAVs) in coastal areas suggests a need for stations along or close to the coast where the UAV batteries can be easily recharged. A small-scale low flow marine current turbine in support of a floating autonomous recharge station for small UAVs has been designed and assembled at Florida Atlantic University and is being prepared for field testing. Surveys of identified test sites in the Intracoastal Waterways and at open ocean locations are being conducted to determine their suitability in meeting resource, system design and permitting requirements. A sensor platform has been developed for measuring local currents at the identified sites in support of resource characterization. Two out of the eight sites surveyed in the Intracoastal Waterways are found to meet the field-testing requirements for current resource, water depth, and sea bottom conditions. Planned field testing will include parametric characterization studies of the performance of the current turbine for a range of turbine blade configurations, current speeds, turbine wheel submergence levels, and test site location (channeled flow vs open ocean flow).
Results from the First Field Test of a Ruggedized Continuous Holdup Monitor
A first field test of the inexpensive and ruggedized online holdup monitor under development at the US Department of Energy’s Oak Ridge National Laboratory (ORNL) was performed in September of 2023 with highly successful results. ORNL staff collaborated with personnel at the National Fuel Services (NFS) to place two battery-powered detector units at the facility, one on a fuel processing line and the other on a HEPA filter. Both units collected gamma-ray counts per second, temperature, humidity, and battery power data every 5 s seconds over the course of 19 days. Analyzed results from the measurements were discussed with NFS personnel after the units were removed. Vendor feedback on the units was overwhelmingly positive with an expressed desire to deploy finished units at the facility and an open invitation for testing future prototypes.
Long-Term field testing of the accuracy and HVAC energy savings potential of occupancy presence sensors in A Single-Family home
The energy-saving potential of occupancy-centric smart thermostats has been extensively explored in simulations but lacked field testing for energy savings quantification and sensor performance assessment in real buildings. This paper presents a long-term field study conducted in a single-family home in Texas, U.S. to evaluate the performance of occupancy-centric controls (OCC) of HVAC (heating, ventilation, and air-conditioning) system in terms of energy savings, sensor accuracy, and impact on electric peak demand. The test site was equipped with a commercial off-the-shelf (COTS) smart thermostat and multiple occupancy presence sensors for OCC implementation. Additionally, a sub-metering system was installed to monitor electricity consumption of various end-use equipment, including the HVAC system. A supplementary device was installed to track the ground-truth occupancy for the accuracy evaluation of the occupancy presence sensor. Scenarios of baseline and OCC controls were alternated weekly over the 20-month testing period. The results indicated an effective OCC execution, as evidenced by indoor temperature profiles. During the 2023 cooling season, OCC achieved total energy savings of 1,958 kWh, corresponding to a 17.6% energy savings ratio. Under certain conditions, daily HVAC energy savings reached as high as 17 kWh, with a savings ratio of 35%. Sensor performance showed an overall accuracy of 83.8%, a False Positive Rate (FPR) of 12.8%, and a False Negative Rate (FNR) of 47.4%. A key limitation was the sensor’s inability to detect stationary occupants during sleep, leading to a midnight FNR of nearly 100% and significantly compromising thermal comfort. Additionally, the implementation of OCC resulted in extended periods of high electricity demand on summer afternoons, affecting occupant’s thermal comfort and posing potential challenges to community-level grid operations if OCC were widely adopted. Furthermore, this study addresses a critical research gap by empirically investigating energy-saving potential and occupancy sensor performance in residential buildings. Through a comprehensive field-testing study, the research examines the interrelationship between sensor accuracy, energy savings, and thermal comfort, an area that has received limited attention in the current literature.
Scale up, Field Testing, and Optimization of Nontoxic, Durable, Economical Coatings for Control of Invasive mussels at Hydropower Facilities (Final Report for CRADA 527)
In this effort, Pacific Northwest National Laboratory (PNNL) demonstrated the technical maturation of a durable, economical, and nontoxic coating (Superhydrophobic Lubricant Infused Composite, SLIC) that prevents invasive mussels and other unwanted organisms from growing on hydropower and marine structures. The physical characteristics of SLIC were measured using a variety of industry standard methods, just as a commercially available paint would, to show that it can rival other antifouling paints on the market not just in antifouling efficacy, but in structural integrity. SLIC also underwent extensive field testing in diverse field sites across the US to demonstrate that it is effective in varying environments. Engagement with industrial partners showed there is continued interest and need for a cost-effective, durable antifouling coating such as SLIC.
GRC1.5 Project: Joint Industry Megawatt Scale Gearbox Field Tests (Final Report)
A new DOE/NREL industry collaboration called the Gearbox Reliability Collaborative (GRC) 1.5 will undertake field testing on current commercial multi-megawatt wind turbine gearboxes to collect loading data from installed turbines to thoroughly characterize gearbox input loads and responses during actual in-field conditions. A chief outcome is to provide operational loading data relative to the most common failure modes. This will provide a greater understanding of steady-state, transient, and fault response for both the input and output of the gearbox, thus facilitating improvements in the gearbox, power converter or turbine controller.
First field test of a novel optical gas analyser in the exhaust of Wendelstein 7-X
A novel optical gas analyser, designed for isotope-resolved exhaust composition measurement, was field-tested at Wendelstein 7-X (W7-X) to validate its laboratory-proven concept under operational fusion experiment conditions. The system, Optix, comprises a cold cathode remote plasma generator and a high-resolution Fabry–Perot spectrometer and was deployed in the exhaust line of W7-X during the OP2.3 campaign. The injection of 3 He and 4 He for minority ion-cyclotron heating provided a test case for helium isotope discrimination. Despite limitations due to background gas and low partial pressures of the target species, isotope-resolved spectral signatures were successfully observed, demonstrating the fundamental viability of the Optix approach. Additionally, the spectrometer was evaluated for plasma emission measurements from both core and edge sightlines. While helium line emission was detectable, interpretation was hindered by complex background signals, highlighting the benefits of controlled remote plasma generators for spectroscopy. This first deployment provides critical insight into pressure requirements, spectral resolution, and operational constraints, informing future applications of optical exhaust diagnostics in fusion devices.
Geomagnetically Induced Current Field Test on Large Grid-Connected Power Transformers: Analysis, Model Development, and Simulations
Geomagnetic-induced current (GIC) flow in power grids can cause undesirable effects such as transformer overheating, harmonics, higher reactive power demand, etc. Many simulation models have been developed to study these effects, but real-world verification on modern transformer designs is rare. Here, this paper presents the first long-duration GIC field test in the U.S. performed on high-voltage, grid-connected transformers featuring winding clamps and tie rods instead of conventional tie bars. Field measurements were taken to evaluate GIC effects. These measurements also aided in developing and validating thermal and electromagnetic transient (EMT) models of the transformers. During the test, significant current and voltage distortions were observed along with considerable transformer reactive power losses. Analysis of the field measurements showed that the transformers’ hottest spot was at the inner windings, and their k-factors were close to factory test and software default values. Thermal simulations indicated that the transformers would not violate their thermal limits even for a GIC waveform that peaks at about 200 A/phase. EMT simulations revealed that increased transformer loading may reduce GIC-induced reactive power demand and harmonics in certain scenarios. The study also highlighted potential inaccuracies in using the k-factor method to calculate transformer reactive power losses.
A Cultural Resource Survey of 110.55 Acres at the Coyote Test Field, Sandia National Laboratories, Kirtland Air Force Base, Bernalillo County, Albuquerque, New Mexico
This report presents the results of a Section 110 cultural resource survey of Sandia National Laboratories’ (Sandia) 9930 and 9939 Complexes, in the Coyote Test Field (CTF), located on lands permitted to the Department of Energy (DOE) by the Department of Defense (DOD), Kirtland Air Force Base (KAFB), Bernalillo County, Albuquerque, New Mexico. The Department of Energy, National Nuclear Security Administration Sandia Field Office (DOE/NNSA SFO) and National Technology and Engineering Solutions of Sandia, LLC, in accordance with Section 110 and Section 106 of the National Historic Preservation Act (NHPA) and its implementing regulations 36 C.F.R. Part 800, states that every federal agency must establish their own historic preservation program for the identification, evaluation, and protection of historic properties and to ensure that historic preservation is fully integrated into the ongoing programs of federal agencies. Sandia’s Cultural Resources Program (CRP) establishes areas of potential effects based upon projected Sandia mission needs. Some of these areas have no immediate undertakings planned but are in areas where undertakings can happen at a future date.
Field Testing of an Affordable Zero-Liquid-Discharge Arsenic-Removal Technology for a Small-Community Drinking Water System in Rural California
Arsenic contamination in groundwater threatens public health, particularly in small, low-income communities lacking affordable treatment solutions. This study investigated the field implementation of novel air cathode assisted iron electrocoagulation (ACAIE) technology for arsenic removal in Allensworth, California, where groundwater arsenic concentrations exceeded 250 µg/L. Over four months, a pilot-scale ACAIE system, operating at 600 L/h, consistently reduced arsenic levels to below the EPA’s maximum contaminant level of 10 µg/L. Laboratory experiments informed the optimization of charge dosage and flow rates, which were validated during field testing of the ACAIE 600 L/h system. The in-situ generation of hydrogen peroxide at the cathode speeded up the reaction kinetics, ensuring high arsenic removal efficiency while allowing high throughput, even with a compact reactor size. An economic analysis demonstrated a treatment cost of USD 0.02/L excluding labor, highlighting the system’s affordability compared to conventional methods. Adding labor costs increased the treatment cost to USD 0.09/L. The regeneration of air cathodes extended their operational life, addressing a key maintenance challenge, thus reducing the costs slightly. Intermittent challenges were encountered with filtration and secondary contaminant removal; these issues highlight opportunities for further operational improvements. Despite these challenges, ACAIE’s low operational complexity, scalability, and cost-effectiveness make it a promising solution for underserved small communities. These findings provide critical insights into deploying sustainable arsenic remediation technologies that are tailored to the needs of rural, low-resource communities.
Evaluation of NETL’s Self-Healing Metallic Coating for Internal Corrosion Protection of Natural Gas Pipelines: Field Test
Steel pipelines are a safe, reliable, and affordable way to transport natural gas. However, the presence of impurities (e.g., water, carbon dioxide, and hydrogen sulfide) in the natural gas can cause internal corrosion, which can lead to pipeline leaks and failure. This paper reports on field tests of an innovative self-healing, corrosion-resistant, metallic coating developed at the National Energy Technology Laboratory (NETL) for protecting the interior surfaces of pipelines.
Field Testing of a Mixed Potential IoT Sensor Platform for Methane Quantification
Emissions of CH 4 from natural gas infrastructure must urgently be addressed to mitigate its effect on global climate. With hundreds of thousands of miles of pipeline in the US used to transport natural gas, current methods of surveying for leaks are inadequate. Mixed potential sensors are a low cost, field deployable technology for remote and continuous monitoring of natural gas infrastructure. We demonstrate for the first time a field trial of a mixed potential sensor device coupled with machine learning and internet-of-things platform at Colorado State University’s Methane Emissions Technology Evaluation Center (METEC). Emissions were detected from a simulated buried underground pipeline source. Sensor data was acquired and transmitted from the field test site to a remote cloud server. Quantification of concentration as a function of vertical distance is consistent with previously reported transport modelling efforts and experimental surveys of methane emissions by more sophisticated CH 4 analyzers.
Field Test and Thermal Performance Comparison of a Novel Underground Thermal Battery with a Single U-tube Borehole Heat Exchanger for Geothermal Heat Pump Application
Geothermal Heat Pumps (GHP) are a proven technology to electrify and decarbonize space heating and cooling by utilizing the thermally consistent underground as a heat sink or source. However, the high drilling costs of conventional borehole heat exchangers (BHEs) associated with GHP systems and subsurface heterogeneity have been two major challenges to their widespread adoption. In this paper, we present results from a field-scale pilot of an Underground Thermal Battery (UTB) as a potential alternative to a conventional BHE. To benchmark the UTB performance, a side-by-side field test was conducted to compare the UTB with a conventional BHE installed at the same site. The UTB was installed in a 7.01-meter-deep borehole having a diameter of 0.9 meter, whereas the conventional BHE (with single U-tube loop) is in a borehole with 36.6-meter depth and 0.15-meter diameter. Both are integrated into a GHP system to meet the thermal energy demands of office space at the Illinois Energy Farm on the University of Illinois Urbana-Champaign campus. The system’s performance is compared in terms of heat transfer rate, outlet temperatures, and contributions to the overall thermal power of the GHP system under varying thermal demands and in different heat pump operation modes: heating only, cooling only, and hybrid (alternative, diurnal heating and cooling). Results to date indicate that the UTB delivers a more consistent response under during a time period of varying thermal demands. Its operational performance is better during short-term with higher thermal demands, while the conventional BHE performs better under continuous, long-term thermal demands.
Field Test Best Practices
This report can be used as a resource for advice on every stage of field research in residential buildings. It can be used as a reference document to find descriptions of specific types of common measurements and tricks of the trade, or as a primer on home field research providing a basic education on the subject. The report begins with descriptions of field experiment design and discusses advantages and disadvantages of different types of data acquisition systems. The bulk of the paper describes the common measurements needed in residential field work, the hardware options for making the measurements, and field notes on with tips, tricks, and cautions.