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At least 19 records

The Atomic Drill Bit: Precision Controlled Atomic Fabrication of 2D Materials

The ability to deterministically fabricate nanoscale architectures with atomic precision is the central goal of nanotechnology, whereby highly localized changes in the atomic structure can be exploited to control device properties at their fundamental physical limit. Here, an automated, feedback-controlled atomic fabrication method is reported and the formation of 1D–2D heterostructures in MoS 2 is demonstrated through selective transformations along specific crystallographic orientations. The atomic-scale probe of an aberration-corrected scanning transmission electron microscope (STEM) is used, and the shape and symmetry of the scan pathway relative to the sample orientation are controlled. The focused and shaped electron beam is used to reliably create Mo 6 S 6 nanowire (MoS-NW) terminated metallic-semiconductor 1D–2D edge structures within a pristine MoS 2 monolayer with atomic precision. From these results, it is found that a triangular beam path aligned along the zig-zag sulfur terminated (ZZS) direction forms stable MoS-NW edge structures with the highest degree of fidelity without resulting in disordering of the surrounding MoS 2 monolayer. Density functional theory (DFT) calculations and ab initio molecular dynamic simulations (AIMD) are used to calculate the energetic barriers for the most stable atomic edge structures and atomic transformation pathways. These discoveries provide an automated method to improve understanding of atomic-scale transformations while opening a pathway toward more precise atomic-scale engineering of materials.

2D materials↗

Real-Time Drilling Optimization System for Improved Overall Rate of Penetration and Reduced Cost Per Foot in Geothermal Drilling

The key to success in geothermal drilling is economic feasibility, and a major cost in the development of geothermal resources is the actual drilling of the wells. In this project, a real-time drilling optimization system for geothermal drilling was developed. The system couples three individual components while drilling. The first component is a drill stem vibration analysis model, the second is Mechanical Specific Energy (MSE) analyses, and the third is a detailed PDC Rate of Penetration (ROP) drill bit model for optimum RPM and WOB combinations. The benefit of the coupled system is that the range of WOB and RPM could be selected to avoid drill stem vibrations. Secondly, MSE is used as an efficiency measure and the detailed PDC drill bit model ensures the drill bit does not endure temperatures that exceed the temperature at which the PDC cutters experience accelerated wear. The new detailed PDC bit model is based on rock/bit interaction that physically tracks the PDC cutter wear flats as the bit drills ahead giving the capability to calculate the temperature being generated underneath the worn cutters to better advise on operational parameters to avoid accelerated cutter wear and failure and to ensure that operational parameters are applied so that overall ROP is maximized. By combining the drill stem vibrations and the detailed PDC bit cutter wear and “safe” non-accelerated cutter wear temperature and optimum ranges of operating parameters, it results in higher ROP and lower cost drilling. Single cutter PDC testing performed in different lithologies at Sandia was utilized to verify the PDC cutter forces and depth of cut for new and worn cutters. Based on single cutter PDC temperature modeling, verification using single cutter data from the testing done by National Oilwell Varco (NOV) was performed. Sandia’s Hard-Rock Drilling Facility (HRDF) was utilized to test different drill bit configurations with different cutter designs and wear status with different induced modes of vibration to obtain the critical bit RPM/WOB ranges resulting in ineffective drilling and low ROP. The collected test data were further used to verify and calibrate the full hole PDC ROP model that was developed based on single cutter interaction data. A full coupled drill stem vibration model was formulated and verified with geothermal field data from the Chocolate Mountain Aerial Gunnery Range (CMAGR). A graphical user interface (GUI) was developed using Tkinter library in the computer programming language Python, which integrates all the developed models in one system. The developed system consists mainly of the PDC ROP model, PDC bit wear model, PDC cutter temperature model, Mechanical Specific Energy (MSE) model, and drillstring vibration model integrated into one system. The developed system can be used for both, post well analysis and real-time optimization using different criteria such as ROP maximization or MSE minimization. The software uses Differential Evolution Algorithm (DEA) to find optimum values for operational parameters based on last foot drilled while avoiding the drillstring vibration and cutter temperature critical operating parameters.

15 GEOTHERMAL ENERGY↗

Fixed Bit Rotary Drilling Failure Criteria Effect on Drilling Vibration

Polycrystalline diamond compact (PDC) bit use has been expanded to geothermal drilling applications due to their improved performance in drilling compared to roller cone bits. Multiple vibration models have been developed yet and there are limited use of field data to study the ability of numerical vibration model to predict recorded vibration in the field. The objective of this paper is to evaluate the capabilities of two different rock-bit interaction models with two different ROP formulations for predicting the actual behavior seen in the field. The first model (Model-I) considers the rock-bit interaction, incorporating the effect of subsurface formation characteristics. The second model (Model-II) is a PDC bit model that uses calculated threshold weight-on-cutter (WOCt) to study the interaction of the bit with the rock surface. The models, which couple the drill stem axial and torsional motions, are solved numerically using the fourth-order Runge-Kutta method and compared with recorded downhole drilling data from the Chocolate Mountain Aerial Gunnery Range (CMAGR) geothermal well located in California. An 8–½" PDC bit with 8 blades was modeled and vibration simulation was performed to investigate stick-slip vibrations at 1400 ft. depth. Simulation results using field data indicate that Model-II encounters a low range of stick-slip severity (SSV) as compared to Model-I, which is in the moderate range. Comparison with the field value for SSV shows Model-II is the best representative of the field case for this depth. The sensitivity analysis shows that results are sensitive to model constants making prediction of SSV from models uncertain.

15 GEOTHERMAL ENERGY↗

Use of Rig Parameter Data in Bit Constraint Models for Improved Drilling Performance at The Geysers

Surface parameter measurements are routinely used during deep well construction to monitor and guide drilling conditions for improved performance and reduced costs. However, these measurements are of reduced value without a standard to aid in evaluation and decision making. A method is demonstrated whereby drill bit constraint models are used to interpret drilling response parameters. Drill rig parameter data for well GDC-36 at the Geysers Geothermal Field Power were acquired by Geysers Power Company and drilling contractor Kenai Drilling using Pason US DataHub and evaluated. Drilling parameters are evaluated using laboratory-validated rock reduction models for predicting the phenomenological response of drag bits (Detournay and Defourny, 1992) along with other model constraints in computational algorithms. The method is used to evaluate overall bit performance, monitor bit integrity, and detect the presence of drillstring vibrations and other conditions contributing to bit failure; comparisons are made to observations of bit wear and damage. The method will be applied in real-time to improve decision-making on subsequent wells and has applicability to development of advanced analytics on future geothermal wells using real-time electronic drilling recorder (EDR) data for improved performance and reduced drilling costs.

15 GEOTHERMAL ENERGY↗

Mitigation for Removal of Building 01-103 in the Area 1 Subdock, Nevada National Security Site, Nye County, Nevada

Building 01-103, the Drill Bit Repair Building was originally recorded as SHPO Resource No. B18848 in 2020 during an architectural survey of the Area 1 Subdock (Collins et al. 2022). It was recommended individually eligible for listing in the NRHP under Criteria A and C and contributing to the significance of the Area 1 Subdock Historic District. The SHPO concurred with these determinations in a letter dated April 29, 2022 (Reed 2022). The Drill Bit Repair Building retains all seven aspects of integrity. The location, materials, workmanship, feeling, and association have not changed since its original construction. The design was modified slightly in 1996 with the addition of a removable and non-destructive chain-link fence. Nearby buildings 01-101 and 01-102 were removed (Collins and Menocal 2020) but the other buildings and storage yards remain. Therefore, the integrity of setting has been changed, but not to the degree that the building no longer conveys its significance (see Figures 4 and 5 for comparison). Building 01-103 was constructed in 1985 to coincide with the relocation of the Area 3 Subdock to Area 1. The design for the new Subdock provided a centralized cluster of buildings surrounded by two large storage yards. The buildings included administrative and engineering office space, warehouses, a radiograph building, and Building 01-103 as the drill bit maintenance and repair building, among others. The Drill Bit Repair Building was critical to the success of underground nuclear testing and is eligible under Criterion A for its contribution to broad patterns of history by maintaining specially designed equipment for underground nuclear testing at the NNSS. It is also eligible under Criterion C as it is the only recorded example of a facility built specifically for the maintenance of big-hole drill bits on the NNSS. As it retains both significance and integrity, it remains individually eligible under Criteria A and C. In addition to its individual significance, the Drill Bit Repair Building also contributes to the significance of the Area 1 Subdock Historic District as a representative of a big-hole drilling support facility necessary for underground nuclear testing. The building and the equipment therein were designed specifically for testing at the NNSS, where much of the early technology and methods for big-hole drilling were developed. Its removal will result in not only the demolition of a contributing element but also a change in the physical features of the district’s setting that contribute to its historic significance. The change in setting will diminish the district’s integrity. However, the district still contains numerous examples of other buildings constructed for the purpose of supporting big-hole drilling and remains eligible under Criteria A and C.

54 ENVIRONMENTAL SCIENCES↗

Systems and methods for forming a subterranean borehole

Systems and methods for drilling a borehole are disclosed. In an embodiment, the system includes a drill bit and a plasma inducing apparatus coupled to the drill bit. The plasma inducing apparatus is configured to generate plasma.

Staack, David↗

Mode I fracture testing fixture

An apparatus and method for preparing Double Cantilever Beam (DCB) specimens are disclosed as an apparatus and method for conducting Mode I fracture resistance testing using the DCB specimens. In a first embodiment, a drill jig is used to locate the DCB specimen and guide a drilling process during creation of at least one through-hole in the DCB specimen. The drilling process may employ a traditional drill and drill bit, a laser drill, or a water jet. In another embodiment, a set of rotating pin blocks, each with a full-round or a half-round specimen pin at one end and a hanger full-round pin at the other end, engage the DCB specimen and facilitate the internal application of a fracturing load to the DCB specimen for the Mode I fracture resistance test. The present invention may significantly reduce the time and materials needed to prepare and test a DCB specimen.

Briggs, Timothy↗

Mode I fracture testing fixture

An apparatus and method for preparing Double Cantilever Beam (DCB) specimens are disclosed as an apparatus and method for conducting Mode I fracture resistance testing using the DCB specimens. In a first embodiment, a drill jig is used to locate the DCB specimen and guide a drilling process during creation of at least one through-hole in the DCB specimen. The drilling process may employ a traditional drill and drill bit, a laser drill, or a water jet. In another embodiment, a set of rotating pin blocks, each with a full-round or a half-round specimen pin at one end and a hanger full-round pin at the other end, engage the DCB specimen and facilitate the internal application of a fracturing load to the DCB specimen for the Mode I fracture resistance test. The present invention may significantly reduce the time and materials needed to prepare and test a DCB specimen.

Briggs, Timothy↗

Self-assembled Seashell Like Coatings for Large Area Robust Debris Shields for Next Generation Pulsed Power Drivers

During this LDRD project, our team developed a technology which enables the fabrication of novel nanostructures replicating seashell – “nature’s toughest material”. The resulting coatings exhibit high thermal stability up to 1650°C, which exceeds the hardness of Spectra® by ~44%, as well as the compressive strength of aluminum by ~57%. Coatings made with this technology are stronger, environmentally friendly, more sustainable, and more versatile than other comparable materials. Beryllium wafers, the current, most favorable shielding material in terms of thermal and mechanical properties, are very toxic and cost hundreds of times more than the new material developed in this project. The coatings on silicon wafer and stainless steel, respectively, have been tested as ride-along on the Z machine and clearly outperform the bare substrate. Use of this technology will have a profound global impact for pulsed power and fusion energy development, debris mitigation for spacecraft and satellites, durability of drill bits used in deep well drilling and tunnel boring operations, thermal protection of aircraft and manned spacecraft, and various other thermal and mechanical protection applications.

36 MATERIALS SCIENCE↗

Optimizing Rate of Penetration and Tripping Decision-Making using Real-Time Bit Wear Monitoring While Drilling Geothermal Wells

Understanding bit wear while drilling is critical to minimizing non-productive time (NPT) and optimizing rate of penetration (ROP). Lengthening drilling runs with damaged bits does not only lower the ROP, but also elevates the risk of inducing severe bit damage, which could potentially lead to time-consuming fishing operations. When drillers believe the bit has worn off substantially, the bit is tripped out to be replaced. On geothermal wells, tripping can take up to 20% of the overall well construction time, and this is generally acknowledged as an opportunity for improvement. Ideally, a bit run should be terminated before the bit is damaged beyond repair. At the same time, premature bit pulls are to be avoided as well. This study aims to leverage bit and tooth wear metrics that can be obtained in real time to characterize bit condition in order to optimize ROP and determine the optimal time to pull the bit. Two metrics were explored in this study: a bit wear metric that incorporated depth-of-cut, and a tooth wear metric developed by Bourgoyne & Young characterizing the state of bit teeth dull. Both metrics were computed using recorded data from 12¼ inches roller cone insert bit runs in five geothermal wells targeting a granodiorite formation in the western United States. Together with the actual dull grades, determined after the bits were pulled to surface, the metric trends were interpreted to characterize the downhole bit condition and identify the point at which the bit should have optimally been tripped out. The insights from studying the actual dull grades and how they relate to the two metrics were used to establish a reliable bit pull criterion. The bit wear metric trend correctly showed a noticeable departure from baseline for bits experiencing major dulling behavior. Additionally, the tooth wear model predicted the cutter dull within two dull grades for most runs, with better performance in predicting the inner teeth dull. Moreover, the combination of the bit wear and tooth wear metrics was effective in revealing the cause of the bit performance impairment. Proactive tracking of these two metrics in real-time can facilitate geothermal drilling ROP optimization and better-informed tripping decision-making, thereby avoiding wasted time and cost.

Ashari, Rahmat↗

Downhole to surface communications platform for drilling applications

A drilling assembly for downhole to surface communications is provided. The drilling assembly includes a series of pipe segments coupled in fluid communication between a slip ring assembly and an end pipe portion. The slip ring assembly is coupled in data and fluid communication with the pipe segments. A surface communications link is in data communication with the drilling assembly via the slip ring assembly. An end pipe portion is coupled with the drilling assembly that includes an electronics assembly with electronic components for transferring data to the slip ring assembly via the drilling assembly. A drill bit is operably coupled with the end pipe portion for drilling a borehole. Each pipe segment includes an outer conductor portion, a hollow inner conductor portion, and a dielectric portion for electrical isolation between the outer conductor portion and the inner conductor portion.

Su, Jiann-Cherng↗

Underwater plasma breakdown characteristics with respect to highly pressurized drilling applications

Deep earth drilling is a key technique to extract oil, gas, and geothermal heat from the earth. Many complex energy focusing methods have been explored as an alternative approach to reach these resources but most of them require high energy. However, by utilizing short time span liquid plasma discharges, energy focusing can be achieved within traditional drilling systems. These discharges induce a rapid expansion process and a resulting shockwave. It is believed that this focused energy will lower the required cutting force to progress through the rock. Lowering the required cutting force will allow for lower drill bit wear, quicker rate of penetration, and an overall cost savings of the project. Plasma breakdown characteristics at drilling relevant pressures, ranging from 1 to 350 atm, were studied. A resistance–capacitance circuit with an air gapped spark switch was utilized to generate pulsed plasma between the pressurized electrodes. It was found that the required breakdown voltage increases as the pressure increases. It was also found that a plasma channel formation and an associated breakdown may or may not occur between the electrodes at different pressures due to variation in required breakdown voltages. Breakdown time-lag in the dielectric medium (tap water, 780 μS cm –1 ) increased as the pressure was increased, which indicated a higher voltage drop at higher pressures (>100 atm). The plasma generated cavitation bubble with an associated shockwave occurred as pressures were increased. However, the bubble radius and the bubble duration decreased as the pressure was increased. The plasma generated shockwave speeds fall within the expected speed of sound in water. Lastly, preliminary rock cracking tests were performed on granite at high pressures (340 and 272 atm) and it was found that plasma is able to create cracks in the rock.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

The Sensitivity of PBX 9502 to Drilling Operations

Polymer-bonded explosive (PBX) 9502 (95% TATB, 5% Kel-F 800 by weight) is dry-drilled on a CNC milling machine and its thermomechanical response to varying feed rates, drilling speeds, and peck depths with 4 mm and 5 mm diameter drill bits is investigated. The tested samples are affixed to a force sensor that enables recording temporally resolved cutting forces and torques, and a drill-embedded thermocouple yields local temperature data. From the data, an empirical relationship between temperature changes and feed per revolution is developed, which reveals reduced temperatures in higher feed per revolution regimes for PBX 9502. The observed relationship allows extrapolating to temperatures for other hole diameters, indicating increased temperature for smaller diameter drilling across the board. Additional testing was performed with PBX 9501 (95% HMX, 2.5% Estane®, 2.5% BDNPA/BDNPF by weight), albeit over a reduced parameter space, which revealed the opposite behavior for the feed per revolution temperature dependence. It is concluded that both PBX 9502 and PBX 9501 can be dry-drilled efficiently beyond the limits of presently applicable US-DOE standards, where cutting interface temperatures remain far below material critical temperatures. Finally, data reveals that coolant usage in the drilling process for these materials provides a wide safety margin.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Sub-Degree-Per-Hour MEMS Gyroscope for Measurement While Drilling at 300°C

The orientation module of MWD tool offers the critical drill bit orientation information, including azimuth, inclination and toolface in order to control the path of wellbore. Although high end navigation grade gyroscope can meet the accuracy requirement for azimuth finding, the requirements of cost, size and reliability under harsh environment have largely limited the deployment of gyroscopes in MWD tools. To overcome these constraints, GE Research has developed a low cost, MEMS based Multi-Ring Gyroscope (MRG) capable of azimuth-seeking in MWD applications at 300°C. The MRG prototype has been demonstrated to achieve angular random walk (ARW) better than 0.003 deg/rt(hr) and bias instability of 0.01 deg/hr, capable of meeting azimuth finding accuracy better than 0.25 deg. It has further been tested to remain fully operational at 300 °C.

15 GEOTHERMAL ENERGY↗

ROP model for PDC bits in Geothermal drilling

Geothermal energy is a renewable source of energy, where heat extraction is preferentially balanced with the reservoir's natural heat recharge rate. The objective of this paper is to present and validate a novel rate of penetration (ROP) model for drilling hard and abrasive formations including granite formations for polycrystalline diamond compact (PDC) bits. The ROP model was developed based on a derived relationship of a threshold weight on cutter (WOC) and its corresponding depth of cut (DOC) for a single cutter. Laboratory data was used to scale the derived single cutter relationship to a full-hole ROP model for PDC bits. The ROP model includes a non-linear correlation for Phase I (inefficient drilling due to low WOB values) and a linear Phase II (efficient drilling) ROP response to WOB. The ROP model was verified using measured drilling parameter data from Utah FORGE well# 58-32 and data from Chocolate Mountains well # 17-8 in Southern California. When compared to oil and gas well drilling, geothermal drilling in granitic formations can be more difficult and complicated due to rock hardness and high temperatures. PDC bits can increase ROP and optimize drilling for these types of hard formations. This paper provides novel insight into the ROP response of PDC bits to drilling operational parameters.

15 GEOTHERMAL ENERGY↗

Metal Scrap Upcycling with Shear Assisted Processing and Extrusion (ShAPE)

The overarching objective of this project is to convert metal scraps, such as aluminum, titanium, and other alloys provided by the industry, into extruded tubing, wires, and rods. Upcycling of scrap will be accomplished using Shear Assisted Processing and Extrusion (ShAPE). This approach is a new solution for recycling. The specific aims of this project are as follows: 1. Receive metal scrap under a Material Transfer Agreement (MTA), in the form of billets, from select industry partners that meet the following requirements: outer diameter of 1.245 inches (+/-0.003 inches), inner diameter drilled with a 0.404-inch drill bit, and a length of 4.0 inches (+/-0.01 inches). The billet must be cast or compacted to greater than 98% density. If the industry partner does not have the capabilities to prepare the billets, PNNL can make introductions to third-party entities as needed. Industry partners will also provide a composition analysis as weight percent. 2. Extrude metal scrap via the ShAPE process at PNNL. 3. Evaluate and benchmark the extrudate material properties per the ASTM B557-15 – Testing Tubulars Standard or similar wire and rod standards. 4. Characterize the extrudate microstructure for any of the following: grain size, second phase composition, and texture. Additional testing may include corrosion per the ASTM B117 standard and electro-potential. 5. Deliver specimens to industry partners under an MTA for additional third-party evaluations. Industry partners will, in return, provide a non-proprietary report on any testing, including testing per the ASTM B557-15, ASTM B117, and other industry standards. 6. PNNL will develop data and insights to support intellectual property capture, a published non-proprietary technical report, research collaborations, and commercialization opportunities.

36 MATERIALS SCIENCE↗

Time-reversed nonlinear acoustics for downhole pressure measurements

Apparatus (10) and methods for combining time reversal and elastic nonlinearity of formation materials for qualtitatively probing for over-pressured regions down hole in advance of a well drilling bit, to determine the distance to the over-pressured region, and for accurately measuring pore pressure downhole in a formation, are described. Classical and reciprocal time reversal methods may be utilized to achieve these measurements.

Johnson, Paul A.↗

Evaluation of Physics-Based Limiter Redesign Drilling and Alternative Bit Design at The Geysers

As part of a U.S. DOE Geothermal Technologies Office funding opportunity, Geysers Power Company, LLC, an indirect subsidiary of Calpine Corporation, partnered with Sandia National Labs, EGI at the University of Utah, and Texas A&M University to demonstrate increased drilling performance at The Geysers Geothermal Field. The performance target in the drilling demonstrations is at least a 25% improvement in rates of penetration with increased time on bottom for each bit. The project will leverage advances in oil and gas drilling technologies including PDC bits, along with the physics-based limiter redesign techniques championed in drilling demonstrations conducted at the Utah FORGE geothermal site. The planned drilling demonstrations are being conducted as part of an existing drilling campaign intended to enhance reservoir utilization. The wells are typically drilled to the top of the reservoir with mud and then air-drilled to total depth (TD) through fractured zones at temperatures ≥ 450°F. A major goal of the project is to assess the effectiveness of implementing mechanical specific energy (MSE) and drilling dysfunction diagnosis and remediation in these challenging environments, as well as alternate bit technologies. The first demonstration well has been completed, with a total of 15 PDC bit runs in the 17.5”, 12.25” and 8.5” sections. Initial analysis shows ROP gains in all three hole sections, especially in the 17.5” and 12.25” sections, compared with conventional roller cone bit runs in the demonstration well and offset wells. However in the 8.5” hole, wear and damage to the PDC bits resulted in relatively short bit runs. Analysis is underway to take advantage of the positive results and remediate the challenges.

15 GEOTHERMAL ENERGY↗