Autonomous Control of Pneumatically-Powered Percussive Drilling Through Highly Layered Formations.
Abstract not provided.
Mazumdar, Anirban↗
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Advanced Percussive Drilling Technology for Geothermal Exploration and Development
Percussive hammers are a promising advance in drilling technology for geothermal since they rely upon rock reduction mechanisms that are well-suited for use in the hard, brittle rock characteristic of geothermal formations. The project research approach and work plan includes a critical path to development of a high-temperature (HT) percussive hammer using a two phase approach. The work completed in Phase I of the project demonstrated the viability of percussive hammers and that solutions to technical challenges in design, material technology, and performance are likely to be resolved. Work completed in Phase II focused on testing the findings from Phase I and evaluating performance of the materials and designs at high operating temperatures. A high-operating temperature (HOT) drilling facility was designed, built, and used to test the performance of the DTH under extreme conditions. Results from the testing indicate that a high-temperature capable hammer can be developed and is a viable alternative for use in the driller’s toolbox.
15 GEOTHERMAL ENERGY↗
DE-FOA-EE0005502 Advanced Percussive Drilling Technology for Geothermal Exploration and Development Phase II Report.
Percussive hammers are a promising advance in drilling technology for geothermal since they rely upon rock reduction mechanisms that are well-suited for use in the hard, brittle rock characteristic of geothermal formations. The project research approach and work plan includes a critical path to development of a high-temperature (HT) percussive hammer using a two- phase approach. The work completed in Phase I of the project demonstrated the viability of percussive hammers and that solutions to technical challenges in design, material technology, and performance are likely to be resolved. Work completed in Phase II focused on testing the findings from Phase I and evaluating performance of the materials and designs at high- operating temperatures. A high-operating temperature (HOT) drilling facility was designed, built, and used to test the performance of the DTH under extreme conditions. Results from the testing indicate that a high-temperature capable hammer can be developed and is a viable alternative for user in the driller's toolbox.
15 GEOTHERMAL ENERGY↗
Auto Indexer for Percussive Hammers Final Report
Geothermal energy has been underutilized in the U.S., primarily due to the high cost of drilling in the harsh environments encountered during the development of geothermal resources. Drilling depths can approach 5,000 m with temperatures reaching 170 C. In situ geothermal fluids are up to ten times more saline than seawater and highly corrosive, and hard rock formations often exceed 240 MPa compressive strength. This combination of extreme conditions pushes the limits of most conventional drilling equipment. Furthermore, enhanced geothermal systems are expected to reach depths of 10,000 m and temperatures more than 300 °C. To address these drilling challenges, Sandia developed a proof-of-concept tool called the auto indexer under an annual operating plan task funded by the Geothermal Technologies Program (GTP) of the U.S. Department of Energy Geothermal Technologies Office. The auto indexer is a relatively simple, elastomer-free motor that was shown previously to be compatible with pneumatic hammers in bench-top testing. Pneumatic hammers can improve penetration rates and potentially reduce drilling costs when deployed in appropriate conditions. The current effort, also funded by DOE GTP, increased the technology readiness level of the auto indexer, producing a scaled prototype for drilling larger diameter boreholes using pneumatic hammers. The results presented herein include design details, modeling and simulation results, and testing results, as well as background on percussive hammers and downhole rotation.
15 GEOTHERMAL ENERGY↗
Sandia and Ditch Witch Technology Commercialization Fund Integral Motor and Percussive Hammer
This report captures the results of development and testing of a integral downhole motor and percussive hammer used for drilling in near-surface hard rock formations. The work was funded through the DOE Office of Technology Transitions Technology Commercialization Fund. It was a collaboration between Sandia National Labs and The Charles Machine Works (aka Ditch Witch). In the collaboration, Sandia developed a pneumatic motor derived from an indexing tool used in other drilling applications, and Ditch Witch developed the bearing pack tied to the output shaft of the motor as well as the angled beacon housing used for directional control.
15 GEOTHERMAL ENERGY↗
DD6 single-crystal superalloy with thermal barrier coating in femtosecond laser percussion drilling
Not Available
Yu, Yan-qing↗
Advanced Percussive Drilling Technology for Geothermal Exploration and Development DE-FOA-EE0005502.
Abstract not provided.
Su, Jiann-Cherng↗
Advanced Percussive Drilling Technology for Geothermal Exploration and Development.
Abstract not provided.
Su, Jiann-Cherng↗
Event Detection via Acoustic Monitoring of Percussion Primers for Margin Analysis.
Abstract not provided.
Dellinger, Jennifer↗
Test Report for the Qualification Testing of the ORNL-SFC-W-1 Special Form Capsule
Three prototypes the ORNL-SFC-W-1 special form capsules (SFCs) of the same design were evaluated to determine if the requirements of Title 49, Code of Federal Regulations (CFR), Part 173.469, Tests for Special Form Class 7 (Radioactive) Materials, were met. The results of the special form tests are documented in this test report. This report describes the special form testing activities performed on the three ORNL-SFC-W-1 capsules. The test units were designated as TU-1, TU-2 and TU-3. TU-1 was subjected to leak testing, impact testing and percussion testing. TU-1 was leak tested using the leak rate test specified in 49 CFR 173.469(a)(4)(i). The impact test was conducted according to the requirements in 49 CFR 173.469 (b)(1). The percussion test that was carried out on TU-1 was conducted in accordance with 49 CFR 173.469 (b)(2). Both TU-2 and TU-3 were subjected to a leak rate test as specified in 173.469(a)(4)(i) and a heat test as specified in 49 CFR 173.469(b)(4). Each test unit was leak tested before and after these respective tests. The leak rate tests performed were helium back-pressure tests and bubble tests as specified in American National Standards Institute (ANSI) N14.5-2014.The measured leak rates were converted to standard condition leak rates as specified in American Society for Testing and Measurement (ASTM) E 493. The determined standardized leak rates obtained from the test and the calculations for all the test units met the requirements for special form certification. The testing was performed under the direction of the Oak Ridge National Laboratory (ORNL) Package Testing Program (PTP).
42 ENGINEERING↗
Test Report for the Regulatory Testing of the Welded Isotek-SFC-W-3 Special Form Capsule
Two prototypes the welded ISOTEK-SFC-W-3 special form capsules (SFCs) of the same design were evaluated to determine if the requirements of Title 49, Code of Federal Regulations (CFR), Part 173.469, Tests for Special Form Class 7 (Radioactive) Materials, were met. The results of the special form tests are documented in this test report. This report describes the special form testing activities performed on the two welded ISOTEK-SFC-W-3 capsules. The test units were designated as TU-1 and TU-2. TU-1 was subjected to leak testing, percussion testing, and impact testing. TU-1 was leak tested using the leak rate test specified in 49 CFR 173.469(a)(4)(i). The impact test on TU-1 was conducted according to the requirements in 49 CFR 173.469 (b)(1). The percussion test that was carried out on TU-1 was conducted in accordance with 49 CFR 173.469 (b)(2). TU-2 was subjected to a leak rate test as specified in 173.469(a)(4)(i) and a heat test as specified in 49 CFR 173.469(b)(4). Each test unit was leak tested before and after these respective tests. The leak rate tests performed were helium back-pressure tests and bubble tests, as specified in American National Standards Institute (ANSI) N14.5-2014. The measured leak rates were converted to standard condition leak rates as specified in American Society for Testing and Measurement (ASTM) E 493. The determined standardized leak rates obtained from the test and the calculations for all the test units met the requirements for special form certification. The testing was performed under the direction of the Oak Ridge National Laboratory (ORNL) Package Testing Program (PTP).
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Microhole Test Data
Drilling results from the microhole project at the Sandia High Operating Temperature test facility. The project is seeking to help reduce the cost of exploration and monitoring of geothermal wells and formations by drilling smaller holes. The tests were part of a control algorithm development to optimize the weight-on-bit (WOB) used during drilling with a percussive hammer.
15 GEOTHERMAL ENERGY↗
Microhole drilling technology utilizing a golden section search algorithm
A fundamental issue in microhole drilling is that delivering high weight-on-bit (WOB), high torque rotational horsepower to a conventional drill bit does not scale down to the hole sizes necessary to realize the envisioned cost savings An optimization algorithm called a golden section search (GSS) was used to systematically identify the preferred WOB for a given set of conditions. This research focused on implementing and evaluating two low WOB drilling technologies for microhole drilling: - Laser-assisted mechanical drill, which was tested in the laboratory - Lightly modified commercial off-the-shelf (COTS) percussive hammer, which was tested in a limited field test. Data were collected for microhole GSS using WOB optimization via simulation as well as at the Blue Canyon Dome Site in Socorro, NM. Information on the attached files and folders are as follows: - the .tdms files are LabView data files, which can be opened within Excel using a .tdms add-in or using a Matlab .tdms converter - the .tdms_index files are part of the .tdms file structure - sampling rate, column headers, and length data within the .tdms files follow SOP when utilizing Excel and/or Matlab as described above
15 GEOTHERMAL ENERGY↗
Test of the ITER-like resonant magnetic perturbation configurations for edge-localized mode crash suppression on KSTAR
KSTAR has demonstrated divertor heat flux broadening during edge-localized-mode (ELM)-crash-suppression using ITER-like 3-row resonant magnetic perturbation (RMP) for the first time. To address a couple of critical issues in ITER RMP, robust ELM-crash-suppression methodology has been explored at low q95 and established in KSTAR using low-nRMPs. Taking full advantage of the ITER-like 3-row in-vessel control coils (IVCC) in KSTAR, a set of intentionally misaligned RMP configurations (IMC) was tested to investigate whether or not IMC could be compatible with ELM-crash-suppression, while minimizing electromagnetic loads on RMP coils. As a result, the ITER-like 3-row IMCs were found not only to have been compatible with the ELM-crash-suppression, but also to have broadened the divertor heat fluxesin the vicinity of the outer strike point. In comparison, the 2-row RMPs have rarely affected the near scrape-off-layer (SOL) heat flux despite slightly broadened profile change in the far-SOL. Since the divertor heat flux broadening reflects the dispersal of the peaked near-SOL heat flux, the experimental outcome is quite favorable to the ITER choice of 3-rows, instead of 2-rows. Nonetheless, since the IMC-driven broadening observed in the attached plasmas in KSTAR might appear substantially different in the partially detached plasmas in ITER, additional investigation has been conducted to see if RMP-driven, ELM-crash-suppression could be compatible with detached plasmas. Although no detached plasmas have been identified with ELM-crash-suppression yet, significantly reduced divertor heat flux was confirmed in high density, ELM-crash-suppressed plasmas at q 95 =3.4using n=2 RMPs. These new findings elevate the confidence level about the ITER RMP system, while the remaining uncertainties need to be further clarified using the 3-row IVCCs in KSTAR. As long as mode-locking percussion is minimized along with a quick recovery of wall conditions, the access to the targeted q95(~ 3) for ITER is foreseen to be feasible in KSTAR
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
A Modular Mechanism for Downhole Weight-on-Bit and Torque Reaction in Small Diameter Boreholes
Drilling systems that use downhole rotation must react torque either through the drill-string or near the motor to achieve effective drilling performance. Problems with drill-string loading such as buckling, friction, and twist become more severe as hole diameter decreases. Therefore, for small holes, reacting torque downhole without interfering with the application of weight-on-bit, is preferred. In this paper, we present a novel mechanism that enables effective and controllable downhole weight on bit transmission and torque reaction. This scalable design achieves its unique performance through four key features: (1) mechanical advantage based on geometry, (2) direction dependent behavior using rolling and sliding contact, (3) modular scalability by combining modules in series, and (4) torque reaction and weight on bit that are proportional to applied axial force. As a result, simple mechanical devices can be used to react large torques while allowing controlled force to be transmitted to the drill bit. We outline our design, provide theoretical predictions of performance, and validate the results using full-scale testing. The experimental results include laboratory studies as well as limited field testing using a percussive hammer. These results demonstrate effective torque reaction, axial force transmission, favorable scaling with multiple modules, and predictable performance that is proportional to applied force.
15 GEOTHERMAL ENERGY↗
Completion Report for Well ER-20-12: Corrective Action Units 101 and 102: Central and Western Pahute Mesa
Well ER-20-12 was drilled for the U.S. Department of Energy, Nevada National Security Administration Nevada Field Office in support of the Underground Test Area Activity. The well was drilled from October 2015 to January 2016 as an addition to the Central and Western Pahute Mesa corrective action units 101 and 102 the Phase II drilling program. Well ER-20-12 was identified based on recommendations of the Pahute Mesa Guidance Team as a result of anomalous tritium detections in groundwater samples collected from Well PM-3 in 2011 and 2013. The primary purpose of the well was to provide information on the hydrogeology in the area downgradient of select underground tests on Western Pahute Mesa and define hydraulic properties in the saturated Tertiary volcanic rocks. The main 46.99-centimeter (cm) (18.5-inch [in.]) borehole was drilled to a depth of 765.14 meters (m) (2,510.3 ft) and the hole opened to 66.04 cm (26 in.); followed by the 50.80-cm (20-in.) surface casing, which was installed and sealed with cement; and a piezometer (p4) was set in the Timber Mountain welded-tuff aquifer (TMWTA) between the casing and the open borehole. The borehole was continued with a 46.99-cm (18.5-in.) drill bit to a depth of 1,326.53 m (4,352.16 ft), and an intermediate 24.44-cm (9.625-in.) casing was installed and sealed to 1,188.72 m (3,900.00 ft) A piezometer (p3) was installed across the Calico Hills zeolitic composite unit (CHZCM) (lava-flow aquifer [LFA]) in the annulus of the open borehole. Two additional piezometers were installed and completed between the intermediate casing and the borehole wall, one (p2) in the CHZCM and one (p1) in the Belted Range aquifer (BRA). The piezometers are set to monitor groundwater properties in the completed intervals. The borehole was continued with a 21.59-cm (8.5-in.) drill bit to a total depth of 1,384.80 m (4,543.33 ft), and the main completion 13.97-cm (5.5-in.) casing was installed in the open borehole across the Pre-Belted Range composite unit (PBRCM). Data collected during hole construction include composite drill cutting samples collected every 3.0 m (10 ft), geophysical logs, hydrophysical logs, percussion core samples, water-quality measurements (including tritium), and water-level measurements. The well penetrated 1,384.4 m (4,543.33 ft) of Tertiary volcanic rocks. The stratigraphy and lithology were generally as expected with one noted exception. A thick lava-flow and related ash-flow tuffs were identified as Calico Hills Formation (Th), and no Crater Flat units were noted. Additionally, many of the Thirsty Canyon and Timber Mountain units were thicker than expected. Fluid levels measured in the borehole during drilling are the following: (1) on November 2, 2015, Navarro measured the fluid level in the borehole at a depth of 492.33 m (1,615.25 ft) below ground surface (bgs); (2) Schlumberger and COLOG recorded fluid levels during geophysical logging on November 4 and 5, 2015, at a depth of 492.86 m (1,617 ft) and 492.25 m (1,615 ft) bgs, respectively; and (3) on December 4, 2015, COLOG and Navarro measured fluid level in the 20-in. casing with an open borehole to 1,326.54 m (4,352.16 ft) bgs at 575.77 m (1,889.00 ft) and 574.03 m (1,883.3 ft) bgs, respectively. These and subsequent water-level measurements indicate a potential head difference of greater than 76.2 m (250 ft) for groundwater in aquifers above and below the Upper Paintbrush confining unit (UPCU). As expected, tritium was occasionally measured above the Safe Drinking Water Act limit (20,000 picocuries per liter [pCi/L]). Lab analysis on four bailed samples and taken from the undeveloped well indicate that the tritium activities average approximately 36,545 pCi/L. All Fluid Management Plan (FMP) requirements for Well ER-20-12 were met. Analysis of monitoring samples and FMP confirmatory samples indicate that fluids generated during drilling at ER-20-12 met the FMP criteria for discharge to the lined sump and designated infiltration area. All sanitary and hydrocarbon waste generated was properly handled and disposed of.
54 ENVIRONMENTAL SCIENCES↗
Evaluation of Microhole Drilling Technology for Geothermal Exploration, Assessment, And Monitoring
One of the greatest barriers to geothermal energy expansion is the high cost of drilling during exploration, assessment, and monitoring. Microhole drilling technology—small-diameter 2–4 in. (~5.1–10.2 cm) boreholes—is one potential low-cost alternative for monitoring and evaluating bores. However, delivering high weight-on-bit (WOB), high torque rotational horsepower to a conventional drill bit does not scale down to the hole sizes needed to realize the cost savings. Coiled tube drilling technology is one solution, but these systems are limited by the torque resistance of the coil system, helical buckling in compression, and most of all, WOB management. The evaluation presented herein will: (i) evaluate the technical and economic feasibility of low WOB technologies (specifically, a percussive hammer and a laser-mechanical system), (ii) develop downhole rotational solutions for low WOB drilling, (iii) provide specifications for a low WOB microhole drilling system, (iv) implement WOB control for low WOB drilling, and (v) evaluate and test low WOB drilling technologies.
15 GEOTHERMAL ENERGY↗
Control systems and methods to enable autonomous drilling
A system or method for drilling includes autonomously controlling a rotary or percussive drilling process as it transitions through multiple materials with very different dynamics. The method determines a drilling medium based on real-time measurements and comparison to prior drilling data, and identifies the material type, drilling region, and approximately optimal setpoint based on data from at least one operating condition. The controller uses these setpoints initially to execute an optimal search to maximize performance by minimizing mechanical specific energy.
Buerger, Stephen↗