Publications

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Enhanced Geothermal Systems (EGS) require the stimulation of the drilled well, likely through hydraulic fracturing. Whether fracturing of the rock occurs by shear destabilization of natural fractures or by extensional failure of weaker zones, control of the fracture process will be required to create the flow paths necessary for effective heat mining. As such, microseismic monitoring provides one method for real-time mapping of the fractures created during the hydraulic fracturing process. This monitoring is necessary to help assess stimulation effectiveness and provide the information necessary to properly create the reservoir. In addition, reservoir monitoring of the microseismic activity can provide information on reservoir performance and evolution over time. To our knowledge, no seismic tool exists that will operate above 125 C for the long monitoring durations that may be necessary. Replacing failed tools is costly and introduces potential errors such as depth variance, etc. Sandia has designed a high temperature seismic tool for long-term deployment in geothermal applications. It is capable of detecting microseismic events and operating continuously at temperatures up to 240 C. This project includes the design and fabrication of two High Temperature (HT) seismic tools that will have the capability to operate in both temporary and long-term monitoring modes. To ensure the developed tool meets industry requirements for high sampling rates (>2ksps) and high resolution (24-bit Analog-to-Digital Converter) two electronic designs will be implemented. One electronic design will utilize newly developed 200 C electronic components. The other design will use qualified Silicon-on-Insulator (SOI) devices and will have a continuous operating temperature of 240 C.

The envisioned benefits of Diagnostics-While-Drilling (DWD) are based on the principle that high-speed, real-time information from the downhole environment will promote better control of the drilling process. Although in practice a DWD system could provide information related to any aspect of exploration and production of subsurface resources, the current DWD system provides data on drilling dynamics. This particular set of new tools provided by DWD will allow quicker detection of problems, reduce drilling flat-time and facilitate more efficient drilling (drilling optimization) with the overarching result of decreased drilling costs. In addition to providing the driller with an improved, real-time picture of the drilling conditions downhole, data generated from DWD systems provides researchers with valuable, high fidelity data sets necessary for developing and validating enhanced understanding of the drilling process. Toward this end, the availability of DWD creates a synergy with other Sandia Geothermal programs, such as the hard-rock bit program, where the introduction of alternative rock-reduction technologies are contingent on the reduction or elimination of damaging dynamic effects. More detailed descriptions of the rationale for the program and early development efforts are described in more detail by others [SAND2003-2069 and SAND2000-0239]. A first-generation low-temperature (LT) DWD system was fielded in a series of proof-of-concept tests (POC) to validate functionality. Using the LT system, DWD was subsequently used to support a single-laboratory/multiple-partner CRADA (Cooperative Research and Development Agreement) entitled Advanced Drag Bits for Hard-Rock Drilling. The drag-bit CRADA was established between Sandia and four bit companies, and involved testing of a PDC bit from each company [Wise, et al., 2003, 2004] in the same lithologic interval at the Gas Technology Institute (GTI) test facility near Catoosa, OK. In addition, the LT DWD system has been fielded in cost-sharing efforts with an industrial partner to support the development of new generation hard-rock drag bits. Following the demonstrated success of the POC DWD system, efforts were initiated in FY05 to design, fabricate and test a high-temperature (HT) capable version of the DWD system. The design temperature for the HT DWD system was 225 C. Programmatic requirements dictated that a HT DWD tool be developed during FY05 and that a working system be demonstrated before the end of FY05. During initial design discussions regarding a high-temperature system it was decided that, to the extent possible, the HT DWD system would maintain functionality similar to the low temperature system, that is, the HT DWD system would also be designed to provide the driller with real-time information on bit and bottom-hole-assembly (BHA) dynamics while drilling. Additionally, because of time and fiscal constraints associated with the HT system development, the design of the HT DWD tool would follow that of the LT tool. The downhole electronics package would be contained in a concentrically located pressure barrel and the use of externally applied strain gages with thru-tool connectors would also be used in the new design. Also, in order to maximize the potential wells available for the HT DWD system and to allow better comparison with the low-temperature design, the diameter of the tool was maintained at 7-inches. This report discusses the efforts associated with the development of a DWD system capable of sustained operation at 225 C. This report documents work performed in the second phase of the Diagnostics-While-Drilling (DWD) project in which a high-temperature (HT) version of the phase 1 low-temperature (LT) proof-of-concept (POC) DWD tool was built and tested. Descriptions of the design, fabrication and field testing of the HT tool are provided. Background on prior phases of the project can be found in SAND2003-2069 and SAND2000-0239.

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This overview is intended to provide the reader with insight into basic reliability issues often confronted when designing long-term geothermal well monitoring equipment. No single system is looked at. General examples of the long-term reliability of other industries are presented. Examples of reliability issues involving electronic components and sensors along with fiber optic sensors and cables are given. This paper will aid in building systems where a long operating life is required. However, as no introductory paper can cover all reliability issues, basic assembly practices and testing concepts are presented.

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This report focuses on Sandia National Laboratories' effort to create high-temperature logging tools for geothermal applications without the need for heat shielding. One of the mechanisms for failure in conventional downhole tools is temperature. They can only survive a limited number of hours in high temperature environments. For the first time since the evolution of integrated circuits, components are now commercially available that are qualified to 225 C with many continuing to work up to 300 C. These components are primarily based on Silicon-On-Insulator (SOI) technology. Sandia has developed and tested a simple data logger based on this technology that operates up to 300 C with a few limiting components operating to only 250 C without thermal protection. An actual well log to 240 C without shielding is discussed. The first prototype high-temperature tool measures pressure and temperature using a wire-line for power and communication. The tool is based around the HT83C51 microcontroller. A brief discussion of the background and status of the High Temperature Instrumentation program at Sandia, objectives, data logger development, and future project plans are given.