The development of underground battery monitoring technologies by Ultralife enables drilling operators to access valuable data about underground conditions and tool performance beyond just estimating the remaining battery life.
Optimizing Battery Management
Traditional battery management systems primarily operated based on capacity estimates to determine the remaining battery life, which led operators to replace batteries prematurely. According to Ultralife's information, one drilling operator found that batteries were taken out of service at about 50 to 60 percent of their usable capacity, resulting in approximately $1.9 million in unnecessary annual costs.
Read more: Thordon Bearings opens a new manufacturing plant
New Technologies and More Information
The new monitoring systems include measurements of electrical current, temperature, vibration, shock, and rotation, providing more accurate predictions of remaining battery life and assisting operators in assessing conditions affecting underground equipment. Bob Fee, Ultralife's regional manager at the Houston facility, stated that these expanded capabilities have turned battery monitoring into an additional source of operational information.
Fee said, "When battery monitoring systems incorporated these additional metrics, operators could use them to manage their tools as well as the batteries. This data can not only indicate faster battery drain but also alert engineers to extreme underground conditions that require tool retrieval."
Identifying Adverse Conditions
High vibrations and shocks can increase energy consumption and accelerate battery drain. Monitoring these conditions can help engineers identify abnormal tool behavior and assess whether intervention is needed before equipment damage or premature battery failure occurs.
Some systems also provide additional measurements related to drilling operations. For example, Ultralife's Criterion 5 technology offers deviation reporting with an accuracy of 1 degree, allowing operators to monitor wellbore paths and identify changes in drilling angles. Data can be accessed through Criterion software or the EFR100 Compact Field Reader device.
Advanced Applications
Underground battery monitoring systems typically use compact gauges housed within lithium thionyl chloride (LiSOCl₂) battery packs to record battery performance and environmental conditions during drilling operations. Previous generations primarily stored this information for retrieval after the tool returned to the surface. However, more advanced systems can support continuous data transmission during underground operations, providing near real-time insights into battery performance and operational conditions.
This additional information allows engineers to investigate potential tool issues during execution rather than relying solely on post-operational analyses. Early identification of abnormal conditions can aid maintenance decision-making, improve equipment reliability, and reduce non-productive time (NPT).
However, smart battery monitoring is not designed to replace underground tool control systems. Instead, this system serves as a complementary source of data that can be used alongside existing diagnostics to enhance operational awareness.
As drilling operations move into deeper, hotter, and more challenging environments, including geothermal applications, the need for reliable underground monitoring is expected to increase significantly. Combining high-temperature battery technology with advanced monitoring capabilities can help operators extend the usable life of batteries and gain a better understanding of underground conditions.
Read more: The United States invests in virtual power plants to reduce network costs · HD Hyundai makes management changes to strengthen the shipbuilding and renewable energy industry
