geothermal technologies office 2017 peer review...“surface acoustic wave devices for harsh...

1 | US DOE Geothermal Office eere.energy.gov

Public Service of Colorado Ponnequin Wind Farm

Geothermal Technologies Office 2017 Peer Review

Embedded Sensor Technology Suite for Wellbore Integrity Monitoring

Principal Investigator

Dr. Paul R. Ohodnicki, Jr.

National Energy Technology Laboratory

Track 2

Project Officer: Erik Albenze

Total Project Funding: $4,496,319

November 14, 2017

This presentation does not contain any proprietary

confidential, or otherwise restricted information.

Distributed Optical Fiber Chemical Sensors

(Embedded in Cement)

Silicon IC Wireless Devices

in Cements


- Low Cost, Complementary Device Platforms (Optical, Microwave)- Multi-Functional (pH, Other Chemical Proxies, Temp., Strain)- Early Detection of Leakage Onset BEFORE it Happens- Detection and Localization of Leaks That Occur

Distributed Optical Fiber Sensors(Additively Embedded in Casing)

Indicator

Molecule

Core

Optical Fiber

Cladding

Evanescent

Field

Excitation

Transmission

Attenuation

a)

b)

d)

e)

c)

Fiber Optic Chemical SensorAdditively Embedded

Fiber Optic Sensor

Functionalized SAW Sensor

Silicon Integrated Circuit Sensor

SAW Wireless Devices on

Casing Surfaces

f)

Placeholder for Coaxial Cable

Based Wireless Communication in Wellbore Concept

Graphic

Novel Wireless Telemetry Leveraging High Temperature

Coaxial Cables and Antenna Designs

Patch Direction

f1

f2

Res

onan

t A

nten

naf 1

Res

onan

t A

nten

naf 2

Wireless Sensors Operating at f1 and f2

High Temperature Coaxial Cable

Patch Antennas


Relevance to Industry Needs and GTO Objectives

Problem Statement:

A need exists for embedded sensor technologies capable of ubiquitous,

real-time monitoring of wellbore integrity.

Primary Challenges:

– Sensor technologies must be robust and capable of operation in geothermal wellbore conditions.

– Electrical wires, contacts, and batteries are the most common point of failure for sensors.

– Embedded sensor technologies should not create additional potential sources of wellbore failures.

Proposed Solution:

A complementary set of technologies based on optical and microwave platforms

that eliminate the need for electrical wires or active power at the sensing location.




in Cements




Indicator

Molecule

Core

Optical Fiber

Cladding

Evanescent

Field

Excitation

Transmission

Attenuation

a)

b)

d)

e)

c)


Fiber Optic Sensor




Casing Surfaces

f)



Graphic



Patch Direction

f1

f2

Reso

nant

A

nten

naf 1

Reso

nant

A

nten

naf 2



Patch Antennas




in Cements




Indicator

Molecule

Core

Optical Fiber

Cladding

Evanescent

Field

Excitation

Transmission

Attenuation

a)

b)

d)

e)

c)


Fiber Optic Sensor




Casing Surfaces

f)



Graphic



Patch Direction

f1

f2

Re

son

an

t A

nte

nn

af 1

Re

son

an

t A

nte

nn

af 2



Patch Antennas




in Cements




Indicator

Molecule

Core

Optical Fiber

Cladding

Evanescent

Field

Excitation

Transmission

Attenuation

a)

b)

d)

e)

c)


Fiber Optic Sensor




Casing Surfaces

f)



Graphic



Patch Direction

f1

f2

Res

on

ant

An

ten

naf 1

Res

on

ant

An

ten

naf 2



Patch Antennas


Relevance to Industry Needs and GTO Objectives

Knowledge Gaps to Be Addressed and Industry / GTO Relevance:

- Chemical sensing is a key gap in industry, yet monitoring of pH and early

corrosion on-set yields insights into early signs of failure.

- Embedding sensors present technical challenges, including telemetry, but

enables condition based maintenance rather than periodic inspections.

- Promotes environmentally responsible, economic geothermal energy.

Innovative Aspects of the Project:

- Functionalization of optical and microwave

sensors with a focus on pH and corrosion

- Sensor embedding in wellbore materials

- Successful telemetry with embedded sensors.




in Cements




Indicator

Molecule

Core

Optical Fiber

Cladding

Evanescent

Field

Excitation

Transmission

Attenuation

a)

b)

d)

e)

c)


Fiber Optic Sensor




Casing Surfaces

f)



Graphic



Patch Direction

f1

f2

Res

onan

t A

nten

naf 1

Res

onan

t A

nten

naf 2



Patch Antennas


Methods/Approach

Project Task Structure:Task 1: Project Management

Task 2: Technology Maturation Plan & Industry Engagement

Task 3: Chemical Sensing Layer Research & Development

Task 4: Multi-Functional Optical Fiber Sensor Development & Deployment

Task 5: Multi-Functional Wireless Based Sensor Device Development

Task 6: Sensor-Infused Wellbore Material Performance Characterization

The Team:

DOE Laboratory

Industry

Academia

State Research Institute


Methods/Approach


Approach:

High temperature stable pH sensitive layers and corrosion proxy materials

will be developed and integrated with the various device platforms.

Other parameters may also be explored (CO2, hydrocarbons,

water/humidity, etc.) based on inputs from the industry partnership group.

Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 Q10 Q11 Q12

Budget Period 1 Budget Period 2 Budget Period 3

pH Sensor

Layer, pH 5-10pH Sensor

Layer, pH 5-10pH Sensor

Layer, pH 5-10

Corrosion

ProxyCorrosion

Proxy

Corrosion

Proxy

T=20oC, p=1atm T=80oC, p=1atm T=150oC, p=3000psi


Au-Nanoparticles

Methods/Approach


System Properties:

pH, Corrosion

(Input Variables)

Functional Thin Film:

Optical, Electrical,

Electrochemical

(Sensing Element)

Sensor

Technology:

Optical, RF

(Transducer)

Sensor Response (Sensitivity, Selectivity, Stability)

Key Challenge:

Functional

Sensor Materials

Embedded Chemical Sensing Requires

Advances in Sensing Materials

Engineered Corrosion Proxies Materials

Au-Nanoparticles

High Temperature pH Sensing


Ambient Conditions

Methods/Approach

Task 4: Multi-Functional Optical Fiber Sensor Development

Approach:

Embedding of optical fiber sensors within cements and casings for

monitoring evidence of corrosion on-set or incipient structural failures.

Two stage wellbore field deployment of fiber optic pH sensor technology.

Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 Q10 Q11 Q12


FO pH Sensor in

Cement (Lab)Cement Embedded

Fiber with Adequate

Transmission

Embedded FO Sensor

for Casing Internal

Strain / Temp.1st Wellbore pH

Sensor Testing

2nd Wellbore pH

Sensor Testing


Methods/Approach

Task 4: Multi-Functional Optical Fiber Sensor Development

Time (minutes)

0 20 40 60 80 100 120 140

Dis

so

lve

d C

O2 (

g/L

)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

Lower Sensor

Upper Sensor

CO2

InjectionCO2

InjectionN2

Injection

Test 3-AExternal strength

member(tubing for gas

release)

Cable head

Depth: 3,000 FeetPressure: 800 psi.

Time (minutes)

0 20 40 60 80 100 120 140

Dis

solv

ed

CO

2 (

g/L

)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

Lower Sensor

Upper Sensor

CO2

InjectionCO2

InjectionN2

Injection

Test 3-AExternal strength

member(tubing for gas

release)

Cable head

Depth: 3,000 FeetPressure: 800 psi.

Reel-to-Reel Optical Fiber Coating System

Multi-Fiber Bundles and Interrogators

Previous Wellbore Deployments

Previous Wellbore Testing of CO2 Sensors


Ambient Conditions

Methods/Approach

Task 5: Multi-Functional Wireless Sensor Development

Approach:

Development, functionalization, and embedding of Surface Acoustic Wave

(SAW) and Silicon Integrated Circuit (SiIC) based sensor devices.

Theoretical and experimental demonstrations of wireless telemetry.

Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 Q10 Q11 Q12


Corrosion Proxy

Functionalized

SAW Sensor

Simulation of SAW

and SiIC Operation

in Fluid Phases

Wireless Telemetry

with SiIC Sensors

Embedded in Cement

pH Functionalized

SiIC SensorCement

Embedded

SiIC Sensor


Methods/Approach

Task 5: Multi-Functional Wireless Sensor Development

RF-DC

Rectifier

PMU

Enable

RX

Ant

TX

Ant

Sub-IL

Ant

Vref

VDivider

LDOVreg

Vdd

CapMatching

Circuit

On-chip

Sensor

Data

Processing

This Chip

Sub-IL

Osc

Vdd

Data

Base

Station

RX

TX

IoT Sensor Node 1

IoT Sensor Node 2

IoT Sensor Node 3

IoT Sensor

Node 4

Power and

Ref. Freq

Data

Data

Data

Data

RF-DC

Rectifier

PMU

Enable

RX

Ant

TX

Ant

Sub-IL

Ant

Vref

VDivider

LDOVreg

Vdd

CapMatching

Circuit

On-chip

Sensor

Data

Processing

This Chip

Sub-IL

Osc

Vdd

Data

Base

Station

RX

TX

IoT Sensor Node 1

IoT Sensor Node 2

IoT Sensor Node 3

IoT Sensor

Node 4

Power and

Ref. Freq

Data

Data

Data

Data

Example of a Wireless Sensor Base Station

Layout and Interrogation Methodology

Pressurized Flow Through System and

Electromagnetic Chamber for Testing.

Functionalized Surface Acoustic Wave

Based Sensors Approach.

Novel Antennae Designs and Advanced

Wireless Interrogation Methodologies.

“Surface Acoustic Wave Devices for Harsh Environment Wireless

Sensing,” D. W. Greve et al., Sensors 2013, 13(6), 6910-6935


Methods/Approach

Task 6: Sensor-Infused Wellbore Material Characterization

Approach:

Mechanical property, corrosion, and fluid permeation testing of baseline

and sensor integrated cements and casings under relevant conditions.

CT scanner based imaging of sensor embedded cements and casings.

Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 Q10 Q11 Q12


Characterization of 1st

Generation Optical Fiber and

Wireless Sensor Integrated

Cements and Casings.

Characterization of 2nd

Generation Optical Fiber and

Wireless Sensor Integrated

Cements and Casings.


Methods/Approach

Task 6: Sensor-Infused Wellbore Material Characterization

CT Scan of Additively

Embedded Optical Fibers.

NETL Research & Innovation Center Laboratory Facilities are Well Equipped for

Mechanical Property, Corrosion, Permeation Testing and CT Scans.

CT Scan Capability Over a

Broad Range of Scales

Permeation Testing

Mechanical

Property Testing


Research Collaboration and

Technology Transfer

Task 2: Technology Maturation Plan & Industry Engagement

Approach:

An industry partnership group will be established at the beginning of the

program to review the proposed technology development and to provide

industrial perspective and insight into the proposed metrics and objectives.

Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 Q10 Q11 Q12


Draft Technology

Maturation Plans

Delivered to DOEEstablish

Industry

Partnership

GroupUpdate

TM PlansUpdate

TM PlansUpdate

TM Plans

Convene

IP GroupConvene

IP Group


Technical Progress / Future Directions

• Contract Negotiations are Undergoing Finalization

• Anticipated Project Start Date is January 1, 2018

• Key Project Milestones and Deliverables to Be Satisfied Include:

– Budget Period 1:

• A Technology Maturation Plan for Each Technology to Be Developed

• Successful Simulations and Designs of SAW and SiIC Devices in Fluids

• First Optical Fiber Based pH Sensors Demonstrated


• Functionalized Optical Fiber Sensors in Cements at Laboratory Scale

• Successful Experimental Demonstration of SAW and SiIC Devices in Fluids

• First Field Deployment of an Optical Fiber pH Sensor


• Wireless Telemetry with Embedded SiIC Devices in Cements

• Demonstration of Robust Sensor-Infused Cements and Casings

• Second Field Deployment of an Optical Fiber pH Sensor


• Ubiquitous embedded sensors can enable early detection of incipient

failures, chemical sensing (i.e. pH and corrosion) is a key technology gap

• We have established an integrated DOE laboratory, industry, academia and

state laboratory team to address the challenge

• Three sensing technologies will be pursued which eliminate the wiring and

electrical contacts at the sensing node

– Optical fiber based sensors

– Surface acoustic wave based sensors

– Silicon integrated circuit based sensors

• The team will pursue field deployments of the optical fiber based pH sensor

technology to move the technology into the field

• An industry partnership group is being established to inform and guide the

technology development, please contact me to join!

Dr. Paul R. Ohodnicki, Jr., [email protected], 412-386-7389

Mandatory Summary Slide

mailto:[email protected]


J. Delgado, R.A. Lieberman, "Extended-length fiber optic carbon dioxide monitoring," Proc. SPIE Vol. 8718, Advanced Environmental, Chemical, and

Biological Sensing Technologies X, T. Vo-Dinh, R.A. Lieberman, G. Gauglitz (Eds.), 2013;

F. Hingerl, S. Marpu, N. Guzman, S. M. Benson,J. Delgado-Alonso “Development and Testing of a New Fiber Optic System for Monitoring CO2

Solubility in Aqueous High-Pressure Geological Systems”, Energy Procedia, 63, 4134 – 4144, 2014.;

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sequestration sites”, Green Gas Sci. Technol. 5:1-16, 2015;

J. Devkota, P. R. Ohodnicki, and D. W. Greve, “SAW Sensors for Chemical Vapors and Gases”, Sensors 17 (4) 801 (2017);

D. W. Greve, T. L. Chin, P. Zheng, P. Ohodnicki, J. Baltrus, and I. J. Oppenheim, “Surface Acoustic Wave Devices for Harsh Environment Wireless

Sensing”, Sensors 13 (6), 6910-6935 (2013).

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Microwave Symposium, May 2016;

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IEEE MTTT-S Int. Microwave Symposium, June 2017;

Y. Sun, A. Babakhani, “Wirelessly Powered Implantable Pacemaker with On-Chip Antenna”, in IEEE MTT-S International Microwave Symposium, June

2017.

Plasmonics-enhanced metal-organic framework nanoporous films for highly sensitive near-infrared absorption”, K. J. Kim, X. Chong, P. B. Kreider, G.

Ma, P. R. Ohodnicki, J. P. Baltrus, A. X. Wang, Chih-Hung Chang, Journal of Materials Chemistry C (2015) Advance Article, DOI:

10.1039/C4TC02846E.

Ultra-sensitive CO2 Fiber Optic Sensors Enhanced by Metal-Organic Framework Film”, X. Chong, K. Kim, E. Li, Y. Zhang, P. Ohodnicki, C. Chang, and

A. X. Wang, CLEO: Applications and Technology, JTu5A 138 (2016).

“Novel Silica Surface Charge Density Mediated Control of the Optical Properties of Embedded Optically Active Materials and Its Application for Fiber

Optic pH Sensing at Elevated Temperatures”, C. Wang, P. R. Ohodnicki, X. Su, M. Keller, T. D. Brown, and J. Baltrus, Nanoscale 7, 2527-2535 (2015).

“The effect of ionic species on pH dependent response of silica coated optical fibers”, J. Elwood, P. R. Ohodnicki, SPIE Defense + Security, 98360I-

98360I-8 (2016).

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