# Presentation: 289978

## Sandia National Laboratories

**Developments in High-Temperature Long Life Electronics to Support the Upstream Industry**

**Randy A. Normann**

** **

**Sandia National Laboratories**

**Emerging Technology Forum**
**Sept 2002**

## Program Goal 

**To make high-temperature long life components commercially viable for those who produce them.  In order to reduce production cost of both geothermal and fissile fuel energy.**

## HT Wellbore Applications Are Not Alone

**Max. Temperature for HT Industries**

- 0

- 50

- 100

- 150

- 200

- 250

**Max Temperature**

- Geothermal

- Military

- Auto

- Oil Wells

- Aircraft

- The need for high-temperature electronics above the military specification is growing while commercial components are becoming increasingly temperature intolerant.

- To meet that need new HT components are being developed commercially between 150-225 oC!  However, each company is setting their own requirements.

- Deep
- Drilling

**Notes:**
The HT electronics industry needs are growing.  Here are the temperature of three industries.  If Geothermal were show then it would the highest.

## Why Sandia’s Program Is Based On Improving HT Components

- Industrial grade electronics are designed for 85°C and a 1-2 year operating life at temperature
- These components are being screened by the service companies
- MWD tool designers shoot for 100 hrs@ 200C of operational life at temperature
- Electronic industry rolls over ~ every 6 years
- HT capabilities are lost when manufacturers only support 85°C
- Service companies do life of program buys
- If a complete HT solution exists _engineers will use it,_ if not then _nothing in the industry will change_

## Demonstrating a Complete Solution

- Sandia built a 250oC logging tool
- We built a complete working 250 oC logging tool by working with _Silicon-On-Insulator_ (SOI) technology!
- We are using this tool to further evaluate new High-Temperature Long Life (HT2L) components
- We are openly publishing our design
- Working to create new industry standards for the component industry
- Helping consumers to understand the value of HT2L designs

**Notes:**
Step1.  Building a 250C pressure/temperature tool gives Sandia the ability to demonstrate continuing developments in new HT2L components.  I have not signed any NDA with service companies because the component manufacturers need to sell to all service companies.

## SOI vs Bulk Silicon

- SOI electronics build transistors on a non-conducting layer to greatly reduce thermal generated error current (~100X)
- This is simply the best method for reliable integrated circuits

## Silicon-On-Insulator Technology

- Much of the silicon technology already exists!
- SOI (silicon-on-insulator) has been known for ~ 20 years
- In 1993 Honeywell started product development of SOI to support commercial aircraft electronic engine controls
- First of 13 components became available in 1995
- Electronic components qualified to 225 oC (437 oF)
- Components go through a 250 oC (482 oF) burn-in
- Directed toward commercial aircraft engines controls
- Aircraft engines require 44,000 hrs (5 yrs) of operation at 200 oC (392 oF) without failure!

## First Application: Turbine Engine Controllers 

**First Application: Turbine Engine Controllers **

-     In general, aircraft engine controller contains most of the electronics needed for building a logging tool.

- Swenson, Gregg and Ohme Bruce, “HTMOS: Affordable High Temperature Product Line”, HiTEC 1996, pg P89-P94.

- Sensor

- Signal
- Conditioning

- A/D
- Converter

- Digital
- Processor

- D/A
- Converter

- Actuator

- _Batteries_

- _Variety_
- _Of Sensors_

- _Power Devices_

- However, MWD tools require batteries and power devices

- The upstream industry uses a large variety of sensors

- In general, tools are scientific in nature using 16 bit data

## First SOI 250C Unshielded Tool

**5 Volt **
**Regulator**

**10 Volt **
**Regulator**

**32 KB RAM**

**Crystal**
**Oscillator**

**5 Volt **
**Reference**

**Transmit**
**Circuit**

- High-Temp.
- Batteries

**HT83SNL00 with internal**
**“****boot strap” program**
**and interface circuits**

**Analog-to-Digital Converter**

**Signal Conditioners**

**Sensors**** **
**(Temp., Pres., Spinner)**

**(HTANFET)**

**512 KB RAM**

**Microprocessor**

**(Quartzdyne Crystal**
**& HTCCG)**

**(Sandia)**

**(HTVREF05)**

**(HTPLREG)**

**(HTPLREG)**

**(HT6256 X 16)**

**(HT6256)**

**(HT83C51)**

**(HT574)**

**(HT1104 & HT508)**

- 300°C Pressure sensor: Kulite, (Quartzdyne)
- 250°C Printed wiring boards: Multilayer
- 200°C Capacitors: Novacap, Rybon ceramic

## The HT83SNL00 

- Nine 16-bit
-  counters

- Address
-  500 Kbytes
- Data Storage

- Three 32-bit
- counters

- Three Programmable
- Clock Frequencies

- Spinner
- Interface

- 8-bit Aux.
- Data Bus

- FM Data
- Transmission

- 8051 Interface
- Circuits

- RS 232
- PC Interface

- Bootstrap
- Program

- Converter interface
-  to 48 Channels of
- Analog Signal Input

- The package will have a 0.7in (17.7mm) width in order to keep board size down and have a 0 to 300°C operating range.

- HT83SNL00

- 17.7mm

- 50.1mm

- 8 Logical
- Pins

## New Chip Enables Tool Development 

**New Chip Enables Tool Development **

- March 2001, the Sandia designed HT83SNL00 was delivered!  This device is commercially available through Honeywell.
- Nov 2001, completed a downhole test inside a 240°C well for some 40 hrs (two other wells at 200°C, 210°C also were logged).
- After well log, the tool was placed within an oven at 225°C for 1200 hrs and then 500 additional hrs at 250°C!!!

- The ASIC

- Bearfoot Log, 240°C

## Laboratory Testing of Honeywell SOI

- Reliable Operation Demonstrated For 225oC
- Over 2.2M Devices Hours at 225oC with 300K hours MTBF
- Established wear out times of greater than 5 Years at 225oC
- TRW has presented similar data independent of Honeywell
- Apparent MTBF of 10 years at temperatures < 175 oC
- Potential for 15-20 year MTBF at temperatures < 125 oC
- Conventional “Bulk” silicon electronics can not compete with temperature and life performance

## Commercialize to Jump Start Industry

- Sandia is working with 8 companies to develop new products from PTS tools and gamma tools to intelligent well completion systems in the North Sea.
- By helping a few companies develop new high-temperature long life tools, we hope to jump start component industry while educating consumers to expect more from the service providers.

## Education to Aid Commercialization

- Technical learning aids are extremely important to small service companies
- Giving the industry a low temperature evaluation board to simulate HT2L designs
- Documentation is good but a prototype is worth a 1000 man-hours.
- Jump start selected service companies with a high-temperature components to get them fully started.

## Ongoing Initiatives In Support Of HT Tools

- Composite battery starting next year
- 175-250°C Batteries: Eagle-Picher Industries
- 25-300°C Keep-A-Live Batteries: General Atomics
- +200C HT Polymer capacitors: Sigma Technologies
-  Micro-Machine / SOI
- inclination sensor: Silicon Designs
- Other components: solders, fiber optic driver, voltage and clock references

## New for FY 2003

- Planning two permanently installed (cemented in place) wellbore monitors for earthquake research at +100 °C
- Planning one 175-200 °C, high pressure well for permanently installed PT measurements. This is a three year program.
- All three wells are to be connected to the internet for continuous monitoring.

## Future Developments

- Component standard for HT2L components is needed
- Encourages across industry development
- Greatly eases writing development specifications
- First standard meet is scheduled for Oct 2, 2002
- Mostly needed components (in order of ranking)
- Field Programmable Gate Array
- Batteries/Capacitors
- EEPROM, 16 bit uP, Power Driver
- Potential for a consortium to develop new components listed above

## The Last Word

- Sandia is focusing on component development needed for greatly improved downhole tools and systems
- We are on steep growth curve to establish a viable high-temperature and long life electronics industry to support a wide range of high-temperature applications