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Enhanced Geothermal Systems EGS Research & Development MagiQ and Sandia National Laboratory developed a high-temperature wellbore deployment system, which comprises a housing package equipped with a latching arm that mechanically clamps the tool system to the borehole wall. The middle section is the arm that swings out and clamps to the wellbore. MagiQ Technologies Inc. The ability to accurately locate and characterize the release of seismic energy, generated from micro earthquakes (MEQ) is of paramount importance to the development and monitoring of EGS. An innovative small business, MagiQ Technologies Inc. has developed a seismic sensor that does just that, all while operating at temperatures up to 300°C. In 2013, MagiQ successfully completed a Small Business Innovative Research Phase II award. This project culminated in the third-party testing and evaluation of their optical-based seismic sensor at Sandia National Laboratory’s (SNL) Ground-Based Monitoring Research and Evaluation Center. MagiQ’s sensor offers a number of important technical advantages: the sensor package does not contain electronic components that are failure-prone at high temperatures and it can be scaled to hundreds of sensors deployed on a single optical fiber. Preliminary results show sub-Hz to multi-kilohertz (kHz) frequency response, with sensitivity less than 10 nano-gravity/Hertz 1/2 (up to 1 kHz), sampling rates up to 10 MHz, with a dynamic range of 80 decibels. The success of this technology development was made possible by a strong private- public partnership between MagiQ and SNL. In a separate effort, SNL Geothermal Research Division developed a high- temperature wellbore deployment system, which comprises a housing package equipped with a latching arm that mechanically clamps the tool system to the borehole wall. MagiQ integrated their sensor package with SNL’s deployment tool for a combined high-temperature seismic monitoring system. The full system was tested in a borehole at SNL’s Ground-Based Monitoring Research and Evaluation Center. Based on the success of their Small Business Innovation Research project (Phase II), MagiQ is now commercializing their technology and expects a pilot deployment early in 2014. To date, the project has hired five new employees and expects to hire an additional five full-time equivalents next year. * The Small Business Innovation Research (SBIR) program engages in highly competitive federal research and development that has commercial-scale potential. SBIR seeds capital in small businesses to stimulate technological innovation, and awards are based on feasibility of innovative concepts, strength of the scientific/technical approach, cost efficiency, and the potential impact for replicable commercialization. Downhole Sensor Holds Transformative Potential Long-term operation of electronics at high temperatures remains a challenge for the geothermal sector; many downhole sensors are prone to failure when deployed in high-temperature wells, which limits the availability and complexity of logging tools available for use in geothermal energy extraction. Funded by a GTO Recovery Act award, GE Global Research has elevated Silicon Carbide (SiC)-based high temperature electronics to a new level of complexity and integration. SiC is a class of wide bandgap semiconducting material that holds transformative potential not only for high-temperature electronics but also for sectors ranging from industrial-scale variable speed drive motors to power electronics for a modern electric grid. Testing of the components developed by GE with the active electronic devices and packaging materials indicates operational lifetimes greater than 2000 hours at 300°C. This technology will help enable the use of more sophisticated electronics in drilling systems, sensor packages, and logging tools—all for deployment in geothermal environments. Televiewer Maps Fractures GTO partnered with Baker Hughes in 2008 to design, build, and test a downhole acoustic televiewer to map fractures in geothermal wellbores at temperatures up to 300°C. Following several years of component-level design and testing, Baker has integrated the components into two prototype tools. Successful testing was completed in large-scale, laboratory high-temperature/high- pressure test pits at temperatures up to 287°C in 2013, and the prototypes have also been field tested at Baker’s BETA site in Oklahoma. Efforts are now underway to locate a suitable field testing site where the prototypes can be tested in actual geothermal wells under high temperature and pressure conditions. The EGS team is also working with Baker Hughes to conduct a side-by-side comparison of their newly developed, advanced televiewer with existing wellbore characterization tools. Following successful qualification and testing, development of this acoustic televiewer could create a new commercial service opportunity for Baker Hughes in the geothermal industry. Turbine welding, courtesy of Ormat (lower left); miles of pipe at a geothermal power plant (below). Through funding by the Energy Department, Sandia National Lab has refined a useful percussive hammer tool for harsh geothermal applications. Percussive Hammer Enables Drilling In 2013, Sandia National Laboratories (SNL) successfully completed the development of a high-temperature drilling technology able to withstand the harsh conditions present in geothermal reservoirs. SNL developed and tested a high-temperature downhole motor that includes an indexing tool for use with commercially available percussive hammers. Conventional pneumatic down-the-hole-hammer drilling systems—widely used in the mining and oil and gas sectors—perform well in hard rock environments and are capable of removing a volume of rock with low energy input. As a result, SNL identified the percussive hammer as a candidate technology for efficiently and effectively drilling geothermal wells. Hammer technology can lower the cost of drilling geothermal wells and improve well construction capabilities, including directional drilling. Generating downhole rotation of the hammer, or downhole torque, has long been a challenge in high-temperature geothermal environments. Downhole rotation allows the face of the hammer to rotate and strike new rock instead of continuously striking the same, already rubbelized region. At high temperatures, elastomers—common components of oil and gas drilling systems and used to generate downhole torque—can fail to operate as designed within a short time. With this in mind, SNL designed components without any elastomeric materials, allowing efficient and continuous operation at 250°C. The vein motor and indexing tool that can be easily integrated with existing pneumatic hammer bits. 2013 saw the successful characterization of the system’s performance, which was comparable to positive displacement motors commonly used in oil and gas drilling. The project included a first stage analytical design followed by prototype development, further improved with a series of laboratory tests and material refinements. In 2013, SNL successfully characterized the tool’s performance, generating greater than 2000 lb/ft of torque at 300 pounds per square inch of pressure. A provisional patent has been filed for the tool’s design, and SNL has entered negotiations with a commercial partner to license this technology. GEOThERmAl TEChNOlOGIES OffICE 12 13 2013 ANNuAl REpORTPDF Image | Geothermal Technologies Office Annual Report
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