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DOE OSTI2025

Wellbore Stability and Mud Loss Management in Geothermal Drilling: Optimizing Mud Weight to Mitigate Tensile Wellbore Fracturing at The Geysers, California

As part of a U.S. Department of Energy (DOE) Geothermal Technologies Office-funded initiative, Geysers Power Company, LLC, a subsidiary of Calpine Corporation, has been working to enhance drilling performance at the world’s largest geothermal field, The Geysers, in northern California. In a recent drilling operation of the GDC-36 well, excessive mud losses were encountered, initially addressed through repeated but largely ineffective cement plugging. Ultimately, the most effective strategy was to drill blind through the loss zones, made feasible by the high rate of penetration (ROP) achieved with PDC bits, allowing significant progress before the mud tanks were depleted and water-sensitive argillic formation layers could collapse. In response to these challenges, the project team explored alternative methods to minimize downtime and risks associated with cement plugging and continuous mud loss and to contemplate the driving mechanisms for the losses. Wellbore imaging using Formation MicroImager (FMI) and Ultrasonic Borehole Imager (UBI) tools revealed longitudinal tensile fractures, which were attributed to mud weights exceeding the minimum circumferential stress resulting from the native stress field and formation pressure. This study examines the mud losses encountered and leverages wellbore imaging data to understand the mechanisms behind mud induced tensile fracturing in specific rock facies. Understanding fracture behavior across different lithologies is crucial, as fractures within the reservoir can enhance steam migration throughout the system. The reservoir at The Geysers lies within the Mesozoic Franciscan Assemblage, a tectonic mélange formed by subduction. It consists of metamorphosed turbidite sandstone (greywacke) and mudstone (argillite), oceanic upper crust (including greenstone and chert), and serpentinized ultramafic rocks - each exhibiting distinct geomechanical fracturing properties. The structural fabric of the Franciscan Assemblage was shaped by low-angle Mesozoic thrust faulting and later overprinted by sub-vertical strike-slip structures related to the Pacific-North American plate boundary. A wellbore stability model was developed using core measurements and logs to simulate fracturing scenarios during drilling under varying stress conditions. These simulations guided the development of an optimized mud weight management strategy that should enable adaptive adjustments during drilling, reducing the likelihood of tensile fracturing and mud losses, ultimately improving operational efficiency.

15 GEOTHERMAL ENERGY↗

DOE OSTI2021

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↗

DOE OSTI2021

Cement stress and microstructure evolution during curing in semi-rigid high-pressure environments

The process of cement slurry curing into a solid has a direct effect on the initial state of stress in a composite concrete and steel structure. Failure models for critical infrastructure and wellbores could benefit from measurements of this initial stress because it greatly influences structural performance. Here, we present measurements of the initial stress state (total stress, effective stress, and pore pressure) of multiple cement formulations cured under a high-pressure of 40 MPa within a semi-rigid steel pipe. Our results show that cements cured in this restrained environment exhibit dense microstructures with low permeability (nano-Darcy), develop an anisotropic stress state greater than zero and less than the curing pressure, and undergo a staged curing process where hydration and mechanical behaviors evolve from a slurry into a pre-stressed porous medium. Both drained and undrained scenarios were investigated, revealing a feedback from the semi-rigid boundary towards improved cement performance.

36 MATERIALS SCIENCE↗

DOE OSTI2021

High-Resolution 3D Acoustic Borehole Integrity Monitoring (Research Performance Progress Report Q2 2021)

Real-time, in-situ, high spatial resolution (sub-cm) imaging of the near-borehole environment would revolutionize wellbore diagnostics and integrity assessment by direct observation of defects. It is becoming increasingly apparent, that better understanding of the near-wellbore environment is required to meet the safety and operational needs in challenging environments such as those present in subsurface energy extraction (geothermal) and storage (CO2 sequestration) applications. Therefore, it is important to have a more robust ability to image the near-borehole and reliably detect defects. It was proposed to further develop and improve our advanced 3D imaging system to evaluate casing defects (e.g. corrosion) and cement quality in either open- or cased-borehole with the ultimate goal to develop a commercially deployable technology. The system consists of a unique acoustic source (LANL) and advanced inversion techniques for image processing (LANL, ORNL). This system will provide comprehensive borehole integrity monitoring with improved resolution over existing techniques. As an application of this imaging system, we will characterize the effectiveness of next-generation wellbore completion technology (NETL, SNL), and will demonstrate that, unlike current technology, the proposed approach can successfully characterize foamed cements.

15 GEOTHERMAL ENERGY↗

DOE OSTI2022

High-Resolution 3D Acoustic Borehole Integrity Monitoring (Final Report)

42 ENGINEERING↗

DOE OSTI2021

Report Q3FY21 - High-Resolution 3D Acoustic Borehole Integrity Monitoring

Real-time, in-situ, high spatial resolution (sub-cm) imaging of the near-borehole environment would revolutionize wellbore diagnostics and integrity assessment by direct observation of defects. It is becoming increasingly apparent, that better understanding of the near-wellbore environment is required to meet the safety and operational needs in challenging environments such as those present in subsurface energy extraction (geothermal) and storage (CO 2 sequestration) applications. Therefore, it is important to have a more robust ability to image the near-borehole and reliably detect defects. It was proposed to further develop and improve our advanced 3D imaging system to evaluate casing defects (e.g. corrosion) and cement quality in either open- or cased-borehole with the ultimate goal to develop a commercially deployable technology. The system consists of a unique acoustic source (LANL) and advanced inversion techniques for image processing (LANL, ORNL). This system will provide comprehensive borehole integrity monitoring with improved resolution over existing techniques. As an application of this imaging system, we will characterize the effectiveness of next-generation wellbore completion technology (NETL, SNL), and will demonstrate that, unlike current technology, the proposed approach can successfully characterize foamed cements.

42 ENGINEERING↗

DOE OSTI2026

Optimization of well design and CO 2 injection strategy for risk reduction in Class VI geological carbon sequestration wells

The safety and durability of Class VI wells are critical for geological carbon sequestration (GCS). However, current GCS operations face unique challenges: unlike traditional Class II wells, Class VI CO 2 injection wells operate at rates up to 100 times higher, dramatically increasing the risk of wellbore leakage and structural compromise due to severe temperature drops and associated mechanical stresses. Despite existing guidelines on material selection, there remains a substantial gap in understanding how rapid CO 2 injection rates, low surface temperatures, and variable reservoir conditions interact to threaten long-term well integrity. This study presents a comprehensive, original workflow integrating advanced analytical and numerical models for both well flow and well integrity analysis. By systematically simulating a wide range of field-relevant scenarios—including variations in injection rate, CO 2 temperature, and reservoir pressure—this work provides the first cross-validated assessment of cooling effects on wellbore. The results reveal that extreme temperature drops, up to 60 °C, can occur under high injection rates, particularly in depleted reservoirs, significantly increasing the risk of cement failure. Building on these insights, the study proposes innovative, practical well design and operational strategies, including ductile cement formulations, pre-stressing techniques, advanced insulation coatings, and proactive management of injection rates. The safety of Class VI well extends beyond simply using CO 2 resistant materials. Cement materials should possess optimal thermo-hydraulic-mechanical-chemical properties for effective performance. This work provides a scientific basis for optimizing Class VI well designs, with direct benefits for minimizing environmental risk, lowering operational costs, and enhancing the long-term reliability of GCS.

25 ENERGY STORAGE↗

DOE OSTI2020

Completion Effects on Diagnosing Multistage Facture Treatments with Distributed Temperature Sensing

Summary Distributed temperature sensing (DTS) is a valuable tool to diagnose multistage hydraulic fracture treatments. When a stage interval is shut in, the clusters that take more fluid during pumping warm up more slowly. Therefore, the fluid volume injected into each cluster can be quantitatively interpreted by numerical inversion of the warm-back temperature behavior. This general concept assumes that the different warm-back behavior is controlled by only the injected fluid volume; however, recent observations of DTS data indicate that completion configurations significantly influence the warm-back behavior. This paper investigates the completion effects on the DTS interpretation. In ideal conditions, when a stage is fractured, the upstream stage intervals should show an almost uniform temperature that is close to the injected fluid temperature. This is due to the high fluid velocity of injected fluid in the wellbore, and the upstream intervals have not been perforated (noncommunicating intervals), so the only heat transfer is heat conduction between the wellbore fluid and the surrounding reservoir. But the field DTS data show considerably irregular variations in temperature along the upstream stage intervals. These variations are caused by the completion effects. The nonuniform temperature profile is caused by different heat transfer behavior induced by completion hardware along the production casing string, such as joints, clamps, and blast protectors, and by the sensing cable location in the cement, as well as the cement quality. Because the varying heat transfer behavior impacts the warm-back behavior as well as the temperature profile, the completion effects need to be considered in DTS interpretation. A method of DTS interpretation considering the completion effects to diagnose multistage fracture treatments was developed. Because the heat transfer between a wellbore and a reservoir depends on the overall heat transfer coefficient describing heat conduction through the completion in a forward model, this parameter needs to be tuned all along the wellbore. To calibrate the completion effect, the temperature inversion is conducted using the temperature measured at a stage interval that is upstream of a stage interval currently being treated. Because the interpreted stage interval is not perforated at that time, the thermal behavior at the noncommunicating interval is governed by only the heat conduction through the completion environment. Once the effective values of the overall heat transfer coefficient are estimated along the interpreted stage interval, they can be assumed to be constant physical parameters. Then, the fluid volume distribution is interpreted by using the effective overall heat transfer coefficient profile along each interval. This study provides a field application of the developed interpretation method. The new interpretation method provides more accurate diagnosis of fracture treatments by DTS interpretation.

Engineering↗

DOE OSTI2023

Utah FORGE 1-2551: Multi-Stage Fracturing System and Well Tractor to Enable Zonal Isolation During Stimulation and EGS Operations in Horizontal Wellbores - Workshop Presentation and Report

Included here are a presentation recording, slides, and report on the Multi-Stage Fracturing System and Well Tractor to Enable Zonal Isolation During Stimulation and EGS Operations in Horizontal Wellbores project by Colorado School of Mines, presented by Dr. William W. Fleckenstein. One goal of the project is to develop and demonstrate the use of low-cost, rapid multistage fracture stimulation technology with cemented casing frac sleeves that eliminates packers used in both conventional stimulation and injection flow control. The second goal is to develop and demonstrate the devices to effectively detect and control the flow of heat-carrier fluid solely from a long-reach injector through the network of induced and existing fractures and produced from an open-hole long-reach well to improve heat recovery. This presentation was featured in the Utah FORGE R&D Annual Workshop on September 7, 2023. The workshop provided a valuable opportunity to explore the progress made in each of the 17 Research and Development projects funded under Solicitation 2020-1 which aim to enhance our understanding of the crucial factors influencing the development of Enhanced Geothermal Systems (EGS) reservoirs and resources.

15 GEOTHERMAL ENERGY↗

DOE OSTI2023

Legacy Well Leakage Risk Analysis at the Farnsworth Unit Site

This paper summarizes the results of the risk analysis and characterization of the CO 2 and brine leakage potential of Farnsworth Unit (FWU) site wells. The study is part of the U.S. DOE’s National Risk Assessment Partnership (NRAP) program, which aims to quantitatively evaluate long-term environmental risks under conditions of significant geologic uncertainty and variability. To achieve this, NRAP utilizes risk assessment and computational tools specifically designed to quantify uncertainties and calculate the risk associated with geologic carbon dioxide (CO 2 ) sequestration. For this study, we have developed a workflow that utilizes physics-based reservoir simulation results as input to perform leakage calculations using NRAP Tools, specifically NRAP-IAM-CS and RROM-Gen. These tools enable us to conduct leakage risk analysis based on ECLIPSE reservoir simulation results and to characterize wellbore leakage at the Farnsworth Unit Site. We analyze the risk of leakage from both individual wells and the entire field under various wellbore integrity distribution scenarios. The results of the risk analysis for the leakage potential of FWU wells indicate that, when compared to the total amount of CO 2 injected, the highest cemented well integrity distribution scenario (FutureGen high flow rate) exhibits approximately 0.01% cumulative CO 2 leakage for a 25-year CO 2 injection duration at the end of a 50-year post-injection monitoring period. In contrast, the highest possible leakage scenario (open well) shows approximately 0.1% cumulative CO 2 leakage over the same time frame.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Mechanical Characterization of Low Modulus Polymer-Modified Calcium-Silicate-Hydrate (C-S-H) Binder

Calcium-silicate-hydrate (C-S-H) represents a key microstructural phase that governs the mechanical properties of concrete at a large scale. Defects in the C-S-H phase are also responsible for the poor ductility and low tensile strength of concrete. Manipulating the microstructure of C-S-H can lead to new cementitious materials with improved structural performance. This paper presents an experimental investigation aiming to characterize a new synthetic polymer-modified synthetic calcium-silicate-hydrate (C-S-H)/styrene-butadiene rubber (SBR) binder. The new C-S-H/SBR binder is produced by calcining calcium carbonate and mixing this with fumed silica (SiO 2 ), deionized water and SBR. Mechanical, physical, chemical and microstructural characterization was conducted to measure the properties of new hardened C-S-H binder. Results from the experimental investigation demonstrate the ability to engineer a new C-S-H binder with low elastic modulus and improved toughness and bond strength by controlling the SBR content and method of C-S-H synthesis. The new binder suggests the possible development of a new family of low-modulus silica-polymer binders that might fit many engineering applications such as cementing oil and gas wells.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Final Technical Report Wireless Microsensors System for Monitoring Deep Subsurface Operations

This final technical report describes the main findings of the project Wireless Microsensors System for Monitoring Deep Subsurface Operations (FE0031850). The project was part of the U.S. Department of Energy National Energy Technology Laboratory FOA 1998 program to develop new sensor systems for direct observation of parameters associated with CO2 injection and to provide data collection without being disruptive to operations. The overall DOE program was aimed at developing and validating innovative transformational sensor systems, amenable for integration with autonomous intelligent monitoring systems, that are capable of being deployed within the casing annulus and do not have casing perforation or wires/cables in the annulus for installation, power supply, or data transmission needs. Project accomplishments included 1) design and fabrication of a wireless downhole sensor system to monitor parameters for CO2 storage, 2) field testing of the sensor system in two legacy oil & gas wells, and 3) development of an analysis approach that validates the measurements and demonstrates the application of the technology to depict CO2 movement in the subsurface. The project leveraged new sensor technologies along with specialized wellbore telemetry, deployment, and analysis methods designed to address the challenges and risks related to CO2 storage in the subsurface. Results from field testing were a mixture of successes and challenges. The temperature sensor rings, installation procedures in legacy oil & gas wells, wireless powering demonstration, automated data collection, and material compatibility were successful. The wireless data transfer through cement to the wellhead via the sensor relays was not functional beyond the first relay. Consequently, work in the last year of the project included some additional testing of data transmission through different materials along with modeling and analysis of field data for CO2 monitoring applications. This work suggested there are options like polymer cements and open hole annuli that may allow point-to-point transmission along the borehole. The techno-economic analysis suggests that the sensor system is ~40% less expensive than fiber optic distributed temperature system. Modeling of CO2 storage applications suggests temperature can provide an indicator of CO2 saturation but would be best combined with pressure sensors.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

Laboratory evaluation of cyclic underground hydrogen storage in the Temblor sandstone of the San Joaquin Basin, California

Underground Hydrogen Storage (UHS) in depleted oil and gas reservoirs could provide a cost-effective solution to balance seasonal fluctuations in renewable energy generation. However, data and knowledge on UHS at subsurface conditions are limited so it is difficult to estimate how effective this type of storage could be. In this study, we perform high pressure experiment to measure the effectiveness of cyclic hydrogen (H 2 ) storage in a specimen of Temblor sandstone retrieved from the San Joaquin Basin of California. Our experiment mimics reservoir pressure conditions to measure H 2 -brine relative permeability and fluid-rock interactions over the course of ten charging and discharging cycles. Initial gas breakthrough occurred at 15 % to 25 % H2 saturation in the specimen with 3 % NaCl brine as the resident fluid. Continuing injecting to 4 pore volumes (PV) of H 2 yielded an asymptotic H 2 saturation of 38 % to 41 %, a level often referred to as the irreducible gas saturation based on two-phase flow. The boundary condition in this study mimics the near wellbore region, which experiences bi-directional H 2 flow. This bi-directional flow led to evaporative drying of the specimen resulting in 94 % H 2 saturation at the end of 10th cycle. This indicates that cyclic flow and evaporative drying can lead to more efficient reservoir storage where a larger fraction of the reservoir porosity is usable to store H 2 . The produced gas stream consisted of H 2 mixed with 8 % to 22 % H 2 O, indicating formation dry-out by evaporation. Meanwhile, produced water chemistry indicated calcite and silicate dissolution, with calcite sourced from fossil fragments. This led to a loss of cementation and weakened the rock sample. Combined, our results indicate dry-out, compaction, increased H 2 saturation, rock weakening, and permeability loss during cyclic UHS. Overall, we anticipate that the combined effects should lead to higher than anticipated UHS storage efficiency per volume of sandstone reservoir rock.

08 HYDROGEN↗

DOE OSTI2023

HFTS-1 (Final Report)

Despite the long history of hydraulic fracturing, the optimal number of fracturing stages during multi-stage fracture stimulation in horizontal wells can be a complex subject. In addition to the increased expense of multistage fracturing in horizontal wells, increasing the number of fracturing stages does not always correlate with a commensurate increase in production. The problem is the application of a uniform fracture stimulation design to all stages with no consideration for geological variations along the wellbore. The result is an inefficient use and costly waste of energy and water. Optimization of the fracturing process requires an understanding of the cause-and-effect relationship between fracturing parameters and local geological properties at a given location along the wellbore. Realizing that the generalized rock mechanics theories and hypotheses are not truly applicable to fractured and laminated shales, quantifiable impacts of a shale’s geomechanical and depositional features are a prerequisite for design and implementation of optimized hydraulic fractures. The overarching goal of this project is to understand and define the relationships of shale geology and fracture dynamics using detailed field data that includes coring of the fracture domain. Finally, resource recovery from shale formations is estimated to be less than fifteen percent. Research proposed in this project will establish the foundations for investigating enhanced recovery techniques for increased resource recovery in existing fracture treated wells. Natural gas as an EOR fluid is in the initial stages of being used broadly in the oil and gas industry and as such, many aspects of the process need to be researched and addressed prior to widespread acceptance. In addition, re-fracturing techniques, particularly using cemented liners also need to be further investigated. This project explores several of these EOR techniques in greater detail, not just at the theoretical level, but through actual field test sites. This report delves into the research program, identified tasks, several studies, observations, results, and conclusions under the Hydraulic Fracturing Test Site (HFTS) project. This test project is subdivided into three distinct phases and each phase is discussed in detail under separate sections. The original test site for Phase 1 as well as the Phase 2 site are in Midland Basin in Texas and operated by Laredo Petroleum. In the first two phases, the program targeted the Wolfcamp formation in Midland Basin. Phase 3 of the study targeted the EagleFord play in South Texas with Devon Energy as the operator. Significant conclusions from this study include: 1) lateral and vertical fracture growth mapping as well as proppant transport behavior, 2) Use of field gas and its applicability for huff n puff EOR injection in the Midland Basin, 3) Development and validation of proppant log, both at core scale as well as in-fill well implementation by analyzing drilling mud return samples, 4) Applicability of liner refracturing including best practices for enhanced unit level productivity. This report will detail all these studies as well as technical results and conclusions from said studies. These include general subsurface characterization work, completion designs as implemented, studies looking at fracture geometry, high resolution microseismic study, advanced crosswell strain mapping studies including drainage characterization, core characterization results, proppant analysis (core and observation wells), geochemistry, etc. to name a few.

02 PETROLEUM↗