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At least 37 records · Page 2

Wellbore cement alteration and roles of CO 2 and shale during underground hydrogen storage

To mitigate climate change and adopt renewable energy, energy storage is crucial and can be done in the form of hydrogen gas (H 2 ). Subsurface geologic reservoirs are positioned to store H 2 on the largest scales for the longest terms of all potential options. However, H 2 injection may boost reactions that consume hydrogen, generate undesired gases, and alter pore structures of geomedia. To explore the extent of H 2 -associated biotic reactions at a near wellbore location, four experiments were conducted under underground storage conditions with wellbore cement cores and, in most instances, shale samples submerged in synthetic formation brine. Post-reaction gas, aqueous, and solid phase samples were analyzed using olfactory screening and, later, gas chromatography (GC-MS), inductively coupled plasma optical emission spectroscopy (ICP-OES), scanning electron microscopy (SEM), and synchrotron micro-scale x-ray fluorescence (μ-XRF). Within a period of 16 weeks, hydrogen sulfide (H 2 S) was generated in systems containing both H 2 and shale. XRF mapping identified a zone enriched in iron(II) and reduced sulfur along the rim of cement cross sections that was largely associated with CO 2 -induced cement carbonation. Shale did not show noticeable alteration, but there is evidence it contributed to the initial inoculation of the system and provided nutrients for microbes via water-rock interactions. Here, this study considers both rock formations and wellbore cement not previously evaluated concurrently. Findings support understanding and modeling of H 2 -associated biogeochemical reactions during underground hydrogen storage.

36 MATERIALS SCIENCE↗

Enabling site-specific well leakage risk estimation during geologic carbon sequestration using a modular deep-learning-based wellbore leakage model

Geologic carbon sequestration (GCS) is a promising technology for mitigating net carbon emissions and growing climate concern by storing CO 2 in reservoirs. Oil and gas brownfields are an attractive option for CO 2 storage, but these sites have many historical wellbores from petroleum production and can be a potential leakage pathway for CO 2 or formation brine. Therefore, risk management of GCS operations requires an assessment of potential well leakage. Due to the high uncertainty of the system, stochastic approaches are ideal for quantifying the range of risk behaviors, but they must be computationally efficient in the face of complex physics. Here, we develop a new physics-centric deep learning wellbore model to predict the leakage of CO 2 and brine through leaky wellbores. Multi-physics numerical simulations were used to generate data sets, and physics-informed features were introduced. Neural networks were optimized with an automated searching algorithm. Feature analysis quantifies the impact of each feature on model prediction and confirms the role of physics-inspired parameters. The model shows high predictive performance across a wide range of geologic and injection conditions and well attributes. In conclusion, a case study illustrates how the model is applied to assess well leakage in GCS operations.

58 GEOSCIENCES↗

Risk assessment of wellbore leakage during underground hydrogen storage

The expansion of renewable energy sources would require large-scale energy storage options to overcome the intermittent nature of these sources. Underground hydrogen storage (UHS) in depleted hydrocarbon reservoirs offers a scalable and practical energy storage solution. These reservoirs are chosen for their availability and large capacity, but the unique properties of hydrogen raise concerns about potential leakage pathways, particularly through wellbores. In this study, we develop and apply, for the first time, reduced-order models (ROMs) specifically designed for efficient leakage risk prediction in UHS systems operating in depleted hydrocarbon reservoirs. Using 3,000 high-fidelity simulation scenarios, we examine the influence of 11 key parameters, including reservoir and aquifer depths, wellbore permeability and porosity, initial saturations of water, oil and gas fractions (hydrogen, light, intermediate, and heavy hydrocarbons), reservoir pressure multiplier, and the aquifer-to-reservoir volume ratio, to simulate leakage behavior over a 1,000-year timescale. We train ROMs using a two-step classification-regression approach, achieving R 2 values exceeding 99 % across all targets. These ROMs effectively capture the leakage evolution and identify critical controls of leakage, guiding the design of mitigation strategies. Results indicate that gas leakage occurs in about 27 % of scenarios as early as five years post-operation, reaching volumes of up to 106 ft3. Oil leakage is less frequent (~17 %) and typically begins decades later. Our findings also show that hydrogen often migrates first, owing to its smaller molecular size and higher buoyancy, followed by heavier hydrocarbons. Over time, these heavier components contribute significantly to the total leaked volume, reinforcing the need for targeted monitoring and remediation strategies. Our analysis highlights that deeper storage reservoirs, shallower aquifers, and low-permeability wellbores significantly reduce leakage risks. In conclusion, this work offers a robust framework for risk-informed UHS deployment, supporting energy security through reliable large-scale hydrogen storage while safeguarding environmental integrity.

08 HYDROGEN↗

Characterization of the mud displacement in an enlarged wellbore: An integrated rock-fluid model

Cement-mud displacement plays a crucial role in the sealability of cement sheaths. Irregular geometric features of a wellbore due to washout can have a negative impact on mud and cement mobilization. An unstable interface between two fluids always leads to mud channeling, interfluid mixing, and cement contamination, degrading the cement quality. Many factors, such as mechanical and rheological properties of fluids, annulus geometry, flow pattern, and flow rate, significantly influence the displacement efficiency. This study investigates the characterization of the mud displacement in an irregular horizontal well using a 3D computational fluid dynamics (CFD) model. Mud is displaced in an enlarged wellbore by geopolymer and neat class G cement. The wellbore geometry is developed based on the caliper log data from an unconventional shale well in the Tuscaloosa Marine Shale (TMS) lithology. The effects of pump rate, density difference, and mud contamination are evaluated by numerical simulations. The results present those residual muds mainly exist in the upper annulus of the enlarged section. Geopolymer has a better sealing performance and can resist more water-based mud (WBM) contaminations than neat class G cement. The scenario with a low mud-cement density difference and high cement injection rate results in a high cement volume fraction, mitigating the gas migration.

58 GEOSCIENCES↗

Damage detection in a laboratory-scale wellbore applying Time Reversal and Nonlinear Elastic Wave Spectroscopy (TR NEWS)

We report Time Reversal and Nonlinear Elastic Wave Spectroscopy (TR-NEWS) has been used to focus acoustic energy, and make measurements correlated with damage in a variety of industrial materials. Most studies using TR-NEWS have focused on relatively small objects and may have multiple acoustic sources. In Earth, within energy extraction and carbon sequestration settings, the structure and scale of wellbores makes acoustic focusing challenging, as has been demonstrated through numerical simulations. This paper explores the feasibility of applying TR NEWS for damage detection in wellbores by constructing a laboratory-scale wellbore, and using TR to focus and make dynamic linear and nonlinear elastic measurements on it. During successive cycles of localized mechanical damage induced in the sample, the hysteretic nonlinear elastic parameter α increased with progressive mechanical damage. In addition to these strain-dependent changes in α, the width and peak amplitude of the time reversal focused energy changed near the damage site.

58 GEOSCIENCES↗

Characterization of wellbore casing corrosion product as a permeable porous medium

Leakage along wellbores is of concern for a variety of applications, including sub-surface fluid storage facilities, geothermal wells, and CO 2 storage wells. We have investigated whether corroded casing is permeable to gas and can serve as a leakage pathway along wellbores. Three specimens were prepared from laboratory steel plates corroded using different mechanisms to reflect different possible field conditions and produce a variety of corrosion rates. Single-phase gas flow measurements were made under a range of gas pressures to investigate flow in both the viscous and visco-inertial flow regimes. Tests were conducted at different confining stresses (range from 3.45 to 13.79 MPa) following both loading and unloading paths. The gas flow test results imply corroded casing can serve as a significant leakage path along the axis of a wellbore. Transmissivity was discovered to be sensitive to the variation in confining stress suggesting that the corrosion product is deformable. Gas slip factors and the coefficients of inertial resistance of the corrosion product were comparable to those available in the literature for other porous media. Post-test examination of the corrosion product revealed it to be a heterogeneous, mesoporous material with mostly non-uniform slit type porosity. There was no discernable difference in the composition of corrosion product from specimens corroded by different mechanisms.

02 PETROLEUM↗

Polymer-cement composites with adhesion and re-adhesion (healing) to casing capability for geothermal wellbore applications

Deterioration of cement/casing adhesion in wellbore scenarios can result in unwanted and potentially harmful leakage with the potential of serious repair costs. In this work, we explore the use of self-healing polymers added to conventional wellbore cements as a way to bring about self-healing and readhering (to steel casing) properties to the composite material. The polymers are pH resistant and seem to improve the cement integrity after exposure to typical chemical and thermal stresses encountered under geothermal wellbore conditions. We find that addition of about 10-15 wt% of polymer to the cement visually increases its resistance to fracturing from exposure to geothermal conditions, while the adhesive strength of cement/stainless steel increases with curing time for a period of about 10 days. Self-healing capability was demonstrated by permeability analysis showing that polymer-cement composites reduce flow by 50-70% at cement bulk and at the cement/steel interface. Use of atomistic simulations imply that these polymers have good wetting properties on the steel surfaces. Analysis of the interactions between steel/polymer and cement/polymer show that they are complementary, resulting in a wider range of bonding patterns. Cracks are likely to expose under-coordinated sites that result in more bonding interactions, which agrees well with the permeability measurements showing high degree of healed cracks and healed (cement-steel) interfacial gaps together with an overall increased in structural integrity of these advanced polymer-cement composite materials.

Rod, Kenton A.↗

Experimental study on nanoparticle injection by using a lab-scale wellbore system

After long-term underground storage of CO 2 gas, leakage generated from the cement annulus in the wellbore system is often detected due to unbalanced pressure, chemical attack, etc. Here in this paper, nanoparticle injection technology is introduced to inject different types of nanoparticles into the cementitious material for repairing the leakage paths through electrochemical means. The pressure vessel is designed and built to provide a realistic underground environment with high pressure and high temperature. The testing results are evaluated by the saturate-drying method, charge-passed method, and X-ray microscopy (XRM) test. The results consistently show that all types of nanoparticles tested in this paper can be successfully driven into the cement annulus within the wellbore system. The pressure (6.89 MPa) and temperature (80 °C) in the pressure vessel, and the surrounding rock can directly affect the injection effectiveness. The nanoparticle injection technology is proven to be beneficial to the cracked cement annulus for preventing the leakage of CO 2 gas through the lab-scale wellbore system.

36 MATERIALS SCIENCE↗

The effects of well damage and completion designs on geoelectrical responses in mature wellbore environments

Well integrity is one of the major concerns in long-term geologic storage sites due to the potential risk of well leakage and groundwater contamination. Evaluating changes in electrical responses due to energized steel-cased wells has the potential to quantify and predict possible wellbore failures because any kind of breakage or corrosion along highly conductive well casings will have an impact on the distribution of the subsurface electrical potential. However, realistic wellbore-geoelectrical models that can fully capture fine-scale details of well completion design and the state of well damage at the field scale require extensive computational effort, or they can even be intractable to simulate. To overcome this computational burden while still keeping the model realistic, we have used the hierarchical finite-element method that represents electrical conductivity at each dimensional component (1D edges, 2D planes, and 3D cells) of a tetrahedral mesh. This allows well completion designs with real-life geometric scales and well systems with realistic, detailed, progressive corrosion and damage in our models. We have developed a comparison of possible discretization approaches of a multicasing completion design in the finite-element model. The effects of the surface casing and the coupling between concentric well casings as well as the effects of the degree and the location of well damage on the electrical responses are also examined. As a result, we analyze real surface electric field data to detect wellbore integrity failure associated with damage.

58 GEOSCIENCES↗

Advanced Detection of Wellbore Failure for Safe and Secure Utilization of Subsurface Infrastructure

The main goal of this project was to create a state-of-the-art predictive capability that screens and identifies wellbores that are at the highest risk of catastrophic failure. This capability is critical to a host of subsurface applications, including gas storage, hydrocarbon extraction and storage, geothermal energy development, and waste disposal, which depend on seal integrity to meet U.S. energy demands in a safe and secure manner. In addition to the screening tool, this project also developed several other supporting capabilities to help understand fundamental processes involved in wellbore failure. This included novel experimental methods to characterize permeability and porosity evolution during compressive failure of cement, as well as methods and capabilities for understanding two-phase flow in damaged wellbore systems, and novel fracture-resistant cements made from recycled fibers.

36 MATERIALS SCIENCE↗

Phase Field Modeling of Near-Wellbore Hydraulic Fracture Nucleation and Propagation

The goal of Task 2 of the project titled "Closing the loop between in situ stress complexity and EGS fracture complexity" is to model fracture nucleation and propagation in the near wellbore region and, in combination with the experimental study conducted as part of Task 4, investigate the relationship between the in situ stress and the near-wellbore fracture patterns. To this end, We have identified phase field as a promising modeling approach to model the nucleation and propagation process in the near wellbore region. In phase field, fractures are represented by a diffuse variable, i.e the damage. Compared to approaches that model fractures as sharp interfaces, phase field does not require any re-meshing or element insertion algorithm, which makes the treatment of complex fracture geometries straightforward, even with simple meshes.

15 GEOTHERMAL ENERGY↗

Thermopile Energy Harvesting for Subsurface Wellbore Sensors (Final Report)

Robust in situ power harvesting underlies all efforts to enable downhole autonomous sensors for real-time and long-term monitoring of CO 2 plume movement and permeance, wellbore health, and induced seismicity. This project evaluated the potential use of downhole thermopile arrays, known as thermoelectric generators (TEGs), as power sources to charge sensors for in situ real-time, long-term data capture and transmission. Real-time downhole monitoring will enable “Big Data” techniques and machine learning, using massive amounts of continuous data from embedded sensors, to quantify short- and long-term stability and safety of enhanced oil recovery and/or commercial-scale geologic CO 2 storage. This project evaluated possible placement of the TEGs at two different wellbore locations: on the outside of the casing; or on the production tubing. TEGs convert heat flux to electrical power, and in the borehole environment, would convert heat flux into or out of the borehole into power for downhole sensors. Such heat flux would be driven by pumping of cold or hot fluids into the borehole—for instance, injecting supercritical CO 2 —creating a thermal pulse that could power the downhole sensors. Hence, wireless power generation could be accomplished with in situ TEG energy harvesting. This final report summarizes the project’s efforts that accomplished the creation of a fully operational thermopile field unit, including selection of materials, laboratory benchtop experiments and thermal-hydrologic modeling for design and optimization of the field-scale power generation test unit. Finally, the report describes the field unit that has been built and presents results of performance and survivability testing. The performance and survivability testing evaluated the following: 1) downhole power generation in response to a thermal gradient produced by pumping a heated fluid down a borehole and through the field unit; and 2) component survivability and operation at elevated temperature and pressure conditions representative of field conditions. The performance and survivability testing show that TEG arrays are viable for generating ample energy to power downhole sensors, although it is important to note that developing or connecting to sensors was beyond the scope of this project. This project’s accomplishments thus traversed from a low Technical Readiness Level (TRL) on fundamental concepts of the application and modeling to TRL-5 via testing of the fully integrated field unit for power generation in relevant environments. A fully issued United States Patent covers the wellbore power harvesting technology and applications developed by this project.

47 OTHER INSTRUMENTATION↗

Wellbore Fracture Imaging Using Inflow Detection Measurements

One of the most striking measurements taken during DOE’s EGS Collab project at the 4850-foot depth location was the so-called ‘sewer cam’, which enabled direct visualization of the flow of water into the production well through fractures during the stimulation. The ability to see directly which fractures were flowing and (roughly) how much was a breakthrough in understanding the topology of the created fracture network. Achieving this kind of fracture flow imaging at FORGE would be more challenging because of the 225°C temperature, but equally or even more valuable if it could be achieved. In 2017, a joint project between Sandia and Stanford developed a downhole tool concept to measure the enthalpy of multiphase fluid entering a geothermal well from individual fractures (Gao et al., 2017). For the FORGE project, measuring enthalpy is of less interest because the fluid is expected to be single-phase liquid water. However, the foundation of the device was the measurement of chloride ion concentration, which could form the basis for a direct measurement of inflow from fractures. During the 2017 project, this novel chloride sensing system was implemented into a laboratory test instrument, and we confirmed the capability of the system to measure the ion concentration of fluid entering a model wellbore through a small entry port. The wellbore was a 6-inch diameter model well, and the port was approximately 0.08 inch (2mm) in diameter. The device could measure the chloride concentration accurately even when the well was flowing in a bubbly flow. Given its accuracy, the tool should be able to identify locations of water entering the wellbore even if the ion concentration differs only slightly from that of the water in the well. It is likely that different fractures may flow slightly different chloride concentrations, which would make it feasible to detect individual fractures as well as to estimate the volume of their flow. Ultimately, we could also recognize different fractures flowing back significantly different ion concentrations after fracturing in the FORGE wells. This could be realized by adding different ions in the fracturing fluids in different fractures created at different stages of stimulation (and modifying the tool to include different ion specificity). Sandia’s tool was shown during the study to have the capability to withstand the 225°C temperature, and the electrochemical sensing elements were tested in the laboratory to 225°C at 1500 psia for 24 hours. An early implementation of the fully integrated downhole electrochemical tool, including high-temperature electronics, robust housing, and wireline truck interface, had previously been constructed and tested successfully at Sandia; thus, hardware development tasks focused on advancing the technology readiness level (TRL) of this promising technology for FORGE deployment, rather than on developing a new scientific basis for its operation. The data collection electronics in this tool allowed for several other sensors (pressure, temperature, flow spinner) to be implemented in parallel as well. The research was a new collaboration between Stanford and Sandia to modify and refine the tool for FORGE deployment, to make the downhole measurements, and to characterize the evolving fractures.

15 GEOTHERMAL ENERGY↗

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↗

Wellbore integrity assessment with casing-based advanced sensing

Wellbore integrity is of paramount importance to subsurface resource extraction, energy storage 1 and waste disposal. After installation, well casing and cement are subject to mechanical stress due to near-well pressure changes and fluid induced corrosion. This is exacerbated for geothermal wells where produced fluid is at high temperature and corrosive. The current state-of-the-art technologies for wellbore integrity assessments are an array of cased hole logging tools. Wireline deployed acoustic, electromagnetic and mechanical tools are all available to inspect steel casing corrosion and casing-cement bond and these tools can provide high-resolution assessment of borehole conditions. They are intrusive, however, in terms of borehole preparation and interruption to the normal operation of the wells, and not suitable for high temperature or highly deviated well deployments. In addition, these measurements are performed infrequently due to high cost, and are therefore incapable of providing frequent data to better predict borehole degradation trajectory, which can help provide early warning of potential borehole failures. For this project we are developing a suite of novel, non-invasive, casing based tools for wellbore integrity assessment, combining fast/low cost screening with higher-precision investigation. Our approach is based on monitoring the response of the casing when energized at the wellhead, thereby interrogating the casing without well intervention. Lab, field and numerical approaches are used in our study. During the early stage of the research, we focus on numerical simulations, which have shown the sensitivity of the low frequency electromagnetic (EM) signals to changes in borehole depths and have successfully tested the concept at a field site with different length well casings. Initial seismic modeling efforts have also demonstrated our capability to simulate seismic tube wave and seismic field alterations due to borehole breakage and associated fluid leakage. Further numerical, laboratory and field experiments are underway for additional technology sensitivity analysis, particularly the transient EM/Seismic reflectometry methods, data acquisition optimization, and numerical simulation improvements.

Wilt, Michael↗

High-energy X-ray source and detector for wellbore inspection

A system, method, and apparatus for wellbore inspection comprise an electron accelerator to generate X-rays, a rotating collimator assembly configured to produce a cone of X-rays, and at least one detector assembly configured to collect backscattered X-rays. A position assembly can be provided to move the electron accelerator, rotating collimator assembly, and detector through a wellbore. A computer system is configured to receive data from the detector and generate an image of the wellbore.

Kroc, Thomas K.↗

Inspection system of wellbores and surrounding rock using penetrating X-rays

A system, method, and apparatus for wellbore inspection comprise an electron accelerator to generate X-rays, a rotating collimator assembly configured to produce a cone of X-rays, and at least one detector assembly configured to collect backscattered X-rays. A position assembly can be provided to move the electron accelerator, rotating collimator assembly, and detector through a wellbore. A computer system is configured to receive data from the detector and generate an image of the wellbore.

Kroc, Thomas K.↗

Addressing wellbore integrity and thief zone permeability using microbially-induced calcium carbonate precipitation (MICP): A field demonstration

Microbially-induced calcium carbonate precipitation (MICP) is an emerging biotechnology for wellbore integrity applications including sealing defects in wellbore cement and modifying the permeability of rock formations. The goal of this field demonstration was to characterize a failed waterflood injection well and provide proof of principle that MICP can reduce permeability in the presence of oil using conventional oilfield fluid delivery methods. Here we compared well logs performed at the time the well was drilled with ultrasonic logs, sonic cement evaluation, and temperature logs conducted after the well failed. Analysis of these logs suggested that, rather than entering the target waterflood formation, injectate was traveling through defects in the well cement to a higher permeability sandstone layer above the target formation. Sporosarcina pasteurii cultures and urea-calcium media were delivered 2290 ft (698 m) below ground surface using a 3.75 gal (14.2 L) slickline dump bailer to promote mineralization in the undesired flow paths. By Day 6 and after 25 inoculum and 49 calcium media injections, the injectivity [gpm/psi] had decreased by approximately 70%. This demonstration shows that 1) common well logs can be used to identify scenarios where MICP can be employed to reduce system permeability, remediate leakage pathways, and improve waterflood efficiency, and 2) MICP can occur in the presence of hydrocarbons.

42 ENGINEERING↗