HADES Workshop May 24-26, 2011 Perma Works LLC My thanks to the GNS and Tiger Energy Services Randy Normann, CTO randy@permaworks.com
Perma Works LLC Albuquerque, New Mexico, USA Perma Works Acquiring Schlumberger the old fashion way, one customer at a time
Perma Works Stays In The Well While others log the geothermal well using electronics in a thermos bottle, we take the heat continuously No heat shield No time limits No worries
New markets are driving the development of HT Electronics BACKGROUND ON HT ELECTRONICS
Energy and HT Electronics New HT electronics benefit both sides of the energy equation.
HT Industry is a Growing Market The good news: All HT applications are also high reliability! Transmission Brakes SOI Silicon-On-Insulator Electronics are Designed for These Applications
What is HT SOI? Silicon-On-Insulator (SOI) isolates transistors on an insulating material providing: Isolation reduces leakage currents by ~100 times! Latchup immunity 25% Faster Switching Better isolation for analog and digital on the same die SOI is the same process as used for Radiation Hardened silicon P+N+ N+ P-well P+ P+ N-Substrate A: Cross-section of bulk CMOS inverter N+ P+ N+ P+ P P+ Buried oxide Si-substrate B: Cross-section of a SOI CMOS inverter In short, SOI is just a better way to build silicon electronic devices
Making SOI Reliable LIFETIME (YRS) 100 Time for 1% of the parts to fail 10 1 Failure = 10% Increase in Stripe Resistance Now > 5 Year Life at 225 C AlCu: 0.5 ma/µm2 Future W: 2 ma/µm2 W: 1 ma/µm2 0 Commercial Parts: Est. for 5 ma/µm2 AlCu: 1mA/µm2 150 170 190 210 230 250 270 290 310 330 350 TEMPERATURE ( C) Metal migration is a function of Current Density, Metal, Temp. Plot is from Honeywell SOI group, Bruce Ohme
High Temperature Electronic Designs Eliminate Aging Doing everything right to stop aging No right angle metallization paths No on chip metal bridges No voids in the die attach Keep TCEs matched Ideal wire bonds Eliminate intermetallic growth Show me a 225C/5yr electronic device and I will show you a 125C/30yr device
An Example: HT SOI Precision Amplifier Achieved 18-bit dynamic range Achieved high input impedance: < 1nA input offset current at 225 C Ideal for pressure measurements Offset Voltage (micro- volts) Input Offset Voltage @ 300C (after 438 Hrs. Operation @ 300C) Offset comparable to LTC1049 over a 350 C Temperature Range!! -55 C to 300 C 125 100 75 50 25 0-25 -50-75 -100-125 0 0.5 1 1.5 2 2.5 3 3.5 Input Common-mode Voltage (Volts) 250x improvement in offset accuracy vs. previous High-temp amplifier Demonstrated operation: -55 C to 375 C
Creating the Ideal HT Electric Circuit Bandgap: Temp Limit Breakdown Field Thermal Conductivity Electron Mobility Silicon (SOI) Silicon Carbide(SiC) Gallium Nitride(GaN) 1.12 ev 3.26 ev 3.4 ev 400C 800C 1000C 30 V/um 250 V/um 250 V/um 1.5 W/cmK 3.3-4.8 W/cmK 1.5 W/cmK 600 400 1000-2000
It takes more than SOI to build a geothermal tool EXAMPLES OF FAILED ELECTRONICS
250C Silver-Plated Copper - Fails Top image shows a clean cut silverplated copper. However, silver-plating copper wire has no protection from inter-metallic growth. The copper migrates through the silver to react with the tin (found in the solder) to form bronze crystals. This is a solid-phase interaction which leaves the wire joint fragile as can be seen in the lower photo.
Conventional Tinned Copper Lead The top photo is of an untested new capacitor lead designed for automotive use, 125C continuous with 200C extrusions. The photo below is of a capacitor lead coming out of the Coso tool. The automotive industry can sneak by with conventional solder tinned copper leads the drilling industry cannot.
HT Electronic Components Work To Very High Temperatures HT Component Testing A commercial SOI voltage reference We must calibrate for system drift
Perma Works is building complete tool solutions EXAMPLES OF SUCCESS
New Extreme Temperature Circuit Boards Lab tested to 400C! Absolutely no organic materials! Traces are etched ceramic! Flame blasted metal conductors Aircraft circuit boards are not good enough for geothermal. PW had to make improvements now benefiting aerospace
300,400 & 550C Metal to Ceramic Bonds Samples 1-RT, 2-300C, 3-400C 4-550C Patents Pending Confocal optical images, taken by NASA
New Ceramic Circuit Construction 5 Patents Pending New circuit board with metal traces tested at 500C! New CNC construction New tool mounting system HT Circuit boards geothermal brine ready Unequaled HT Technology 500C Solder Joint! Under development It continues to work following this gross over heating!
Geothermal Well Qualification System ¼ in.wired Tubing SOI Tool Instrumentation Housing with Batteries Solar Cells For power The instrumentation housing contains: Batteries charged by the solar cells Receiver for tool data On board memory to storage data The downhole tool contains: Silicon-On-Insulator (SOI) electronics RTD (Resistive Temperature Device) Pressure transducer Hydrogen monitor (PW) Optical DTS system (DRAKA) Solid-State Liquid Flow Sensor (PW) Unparalleled Geothermal Well Characterization
Enabling new concepts in supercritical power production SC GEOTHERMAL APPLICATIONS
Supercritical Tools Placing HT tool electronics inside an improved heat-shield, supercritical logging tools can be built much like conventional slickline geothermal logging tools The Dewar heat-shield will protect the tool from supercritical temperatures The 250-300C operating temperature of the electronics greatly increases the operating time in the well Pressure transducer will see SC temperatures Lack of a high temperature battery is an issue
>400C SiC Pressure Transducer Net Bridge Output (mv) 20 18 16 14 12 10 8 6 Vin = 5 V BQ0345-13-R10-C09-PS02-1-29 Sensitivity: 36.60 µv/v/psi @ 25 o C 25 o C 100 o C 200 o C 300 o C 400 o C 4 2 0 0 10 20 30 40 50 60 70 80 90 100 Applied Pressure (psi) Flush-mounted SiC Pressure Transducer Typical Performance Characteristics Sensitivity: 5-36.60 µv/v/psi @ 25 o C; 3-18 µv/v/psi @ 600 o C Input Voltage: 5-10 mv Contact: Dr. Robert Okojie, (216)433-6522; robert.s.okojie@nasa.gov
Potential HT Battery Battery & test data from Electrochemical Systems
HT Battery Issues Working with Electrochemical Systems Inc. PW demonstrated a 125C to 250C battery technology Unfortunately, the first commercial builds had production issues These issues may have been resolved waiting on second production run (4 cells) The tool design is complicated because the battery does not start working until 125C Use of an internal heater to start the battery Battery needs to be thermally isolated from the electronics to allow for longest possible operating time inside the SC well
Recent Development 200C/1000hrs PW just completed the design and manufacture of general data collection set of electronics for 200C, 1000hrs This new technology is designed for high end applications using Texas Instruments HT chips 60MHz, 32Bit, ARM7 microprocessor! 8 parallel, 24Bit analog to digital converter! 32Mbit flash memory (not yet commercial) This is a major advancement for Dewared geothermal tools and is commercially available from Perma Works.
Conclusion Perma Works has a new well monitoring system ready for deployment New HT electronics enable the construction of basic supercritical logging tools by using heat-shields and HT electronics HT batteries are an issue Batteries exist with limited operating range and high costs Perma Works is working toward a complete geothermal well control solution matching the complexity of the oil industry for cost effective reservoir management