Abstract: A lost circulation system and a method for reducing losses of drilling fluid in a lost circulation zone of a wellbore. The lost circulation system includes a sheet of lost circulation fabric and particles of a second lost circulation material. The sheet of lost circulation fabric is a material whose structure and composition limit a flow of fluids, particularly drilling fluid, through the sheet. The sheet of lost circulation material has a maximum thickness of 1 millimeter, a length of one foot to one thousand feet, and a width of one inch to twenty inches. The sheet of the lost circulation fabric has holes extending through the sheet.

Abstract: A repairing assembly includes a housing, a packer, and a thermal spray assembly. The housing is attached to a wellbore string disposed within a wellbore with casing. The packer is coupled to the housing. The packer is set on a wall of the wellbore to bound a repair zone defined between the packer and an end of the housing opposite the packer. The housing or the packer includes a fluid channel in fluid communication with the wellbore string or an annulus of the wellbore. The thermal spray assembly is coupled to the housing and sprays a damaged section of the casing with a thermal spray to repair the damaged section. The housing flows an inert gas received from the wellbore string or the annulus of the wellbore and through the fluid channel into the repair zone until an oxygen in the repair zone is substantially removed from the repair zone.

Abstract: A wellbore loss zone remediation method to reduce losses of drilling fluid in a lost circulation zone of a wellbore is described. The wellbore loss zone remediation method includes identifying a lost circulation zone in a wellbore, selecting a lost circulation fabric, selecting a lost circulation material for a slurry, disposing the lost circulation fabric in the wellbore, circulating the slurry in the wellbore, and determining if the lost circulation zone is remediated.

Abstract: A lost circulation system and a method for reducing losses of drilling fluid in a lost circulation zone of a wellbore are described. The lost circulation system includes a sheet of lost circulation material and particles of a lost circulation material. The sheet of lost circulation material has a maximum thickness of 1 millimeter, a length of one foot to one thousand feet, and a width of one inch to twenty inches. The method for reducing losses of drilling fluid in a lost circulation zone of a wellbore includes identifying the lost circulation zone, deploying a sheet of a first lost circulation material in the wellbore at the lost circulation zone, and circulating a slurry containing particles of the lost circulation material through the wellbore.

Abstract: A system including one or more hardware processors for automatic evaluation of a cutting element in a wear testing device. The system includes an access module to access cutting element event analysis results from a sensor array. The system further includes a first model trained to classify a cutting element event of the cutting element according to a supervised machine learning algorithm, and output a predicted event type of the cutting element event. The system further includes a second model trained to classify a cutting element event of the cutting element according to an unsupervised machine learning algorithm, and output a predicted behavior of the cutting element event. The system further includes a controller to determine a toughness and a wear resistance of the cutting element. The system also includes an output module to generate and display a work order on a user interface of a client device.

Abstract: A testing device that includes a wear testing device, a sensor array, and a controller. The wear testing device includes a sample rotation element configured to hold and to rotate a sample; and a cutting element holder configured to hold a cutting element and to engage the cutting element with the sample as the sample rotates. The sensor array includes an acoustic emissions (AE) sensor configured to measure an acoustic signal generated during engagement between the cutting element and the sample; and a load sensor. The controller is communicably connected to the sensor array and configured to determine a toughness and a wear resistance of the cutting element using the acoustic signal, the applied load, and a wear state of the cutting element.

Abstract: A testing device that includes a wear testing device, a sensor array, and a controller. The wear testing device includes a sample rotation element configured to hold and to rotate a sample; and a cutting element holder configured to hold a cutting element and to engage the cutting element with the sample as the sample rotates. The sensor array includes an acoustic emissions (AE) sensor array comprising a plurality of AE sensors, the plurality of AE sensors configured to measure a plurality of acoustic signals generated during engagement between the cutting element and the sample; and a load sensor. The controller is communicably connected to the sensor array and configured to determine a toughness and a wear resistance of the cutting element using the plurality of acoustic signals, the applied load, and a wear state of the cutting element.

Abstract: A drilling tool for drilling a wellbore in a formation, where the drilling tool includes: a drill bit comprising a cutting element, a sensor array, and a controller. The sensor array includes: an acoustic emissions (AE) sensor configured to measure an acoustic signal generated during drilling of the formation by the cutting element and a load sensor configured to measure an applied load by the cutting element on the formation. The controller is communicably connected to the sensor array and configured to determine a toughness of the cutting element using the acoustic signal, the applied load, and a wear state.

Abstract: A system includes sensing modules positioned along a length of a drill string. Each sensing module includes a structure arrangement composed of an outer structure body having a cavity and an inner structure body rotatably supported within the cavity. The structure arrangement is coupled to the drill string such that rotation of the drill string produces a relative rotation between the structure bodies. Ball elements are disposed in a gap between the structure bodies and move along a predetermined path defined in the gap in response to relative rotation between the structure bodies. Movable elements are positioned to physically interact with the ball elements as the ball elements move along the predetermined path. Energy harvesters in the sensor modules generate electrical energy from the mechanical energy produced by physical interaction between the ball elements and movable elements. The sensing modules include sensors to measure parameters in the drill string environment.

Abstract: An instrumented cutter including a polycrystalline diamond table bonded to a substrate with a sensor, for monitoring the condition of the polycrystalline compact diamond table, embedded in the substrate. Further the instrumented cutter includes a wireless transmitter equipped with a power supply to power to the wireless transmitter.

Abstract: An apparatus includes an outer structure body having a cavity and an inner structure body rotatably supported within the cavity. The inner structure body has a central bore. Movable elements are positioned along the inner surface and movably coupled to the outer structure body. Ball elements are positioned along the outer surface and coupled to the inner structure body for movement with the inner structure body. The ball elements are positioned to releasably contact and impart motion to the movable elements in response to relative motion between the inner structure body and the outer structure body. A plurality of triboelectric energy harvesters are positioned to generate electrical charges when motion is imparted to the movable elements by the ball elements.

Abstract: A wellbore fluid monitoring system can implement a method while drilling a wellbore using a drilling assembly that includes a drill string, a rotary table and a bell nipple below the rotary table. Air flowing in a downhole direction through a portion of an annulus within the bell nipple below the rotary table responsive to a decrease in a liquid level in the portion of the annulus is sensed. The annulus is formed by the drill string and an inner wall of the wellbore. In response to sensing the air flowing in the downhole direction, a flow rate of the air flowing in the downhole direction over a period of time is measured. Based on the flow rate and the period of time, a volume of air flowed in the downhole direction over the period of time is determined. A liquid level relative to the rotary table is determined based on the volume of air flowed in the downhole direction over the period of time.

Abstract: Tools and methods are described to measure dimensions of wellbores. Downhole caliper tools include: a downhole collar; an uphole collar; and a caliper sensor assembly disposed between the downhole collar and the uphole collar. The caliper sensor assembly include: an annular sensor module defining a plurality of radially extending tracks; and a caliper including: a plurality of linear slide arms, each linear slide arm at least partially disposed in the annular sensor module in one of the plurality of radially extending tracks and radially moveable relative to the annular sensor module, each linear slide arm extending from a first end within the annular sensor module to a second end outside the annular sensor module, and a cover extending from the downhole collar to the uphole collar. The annular sensor module can measure the radial position of the plurality of linear slide arms relative to the annular sensor module.

Abstract: Tools and methods are described to measure dimensions of wellbores. Downhole caliper tools include a downhole collar and an uphole collar having a running position and a sensing position. The uphole collar is farther from the downhole collar in the running position than in the sensing position. A caliper sensor assembly includes: a sensor module defining tracks extending parallel to an axis of the caliper tool, the sensor module positioned towards an uphole end of the caliper tool relative to the uphole collar; and a caliper disposed between the downhole collar and the uphole collar including: a flexible mesh extending from the downhole collar to the uphole collar. Movement of the uphole collar from the running position to the sensing position axially compresses and radially expands the flexible mesh. The annular sensor module can measure dimensions of the flexible mesh relative to the axis of the caliper tool.

Abstract: A method includes utilizing a charging and communication interface and a sensor system to gather downhole measurements. The method further includes charging and activating the sensor system using the charging and communication interface, installing the sensor system into a nozzle of a drill bit, running the drill bit into a wellbore, conducting measurements using the sensor system, pulling the drill bit out of the wellbore, and contacting the charging and communication interface with the sensor system to retrieve the measurements from the sensor system.

Abstract: A method of forming a composite cutter for a downhole drilling tool is described. The method includes: mixing a polycrystalline diamond powder and a cubic boron nitride powder with a molar ratio between 0.1 and 0.9 to form a catalyst-free composite mixture; placing the catalyst-free composite mixture into a mold configured in a shape of a cutter; exposing the catalyst-free composite mixture to an ultra-high-pressure, high-temperature treatment including a pressure between 11 Gigapascals (GPa) and 20 GPa, and a temperature between 1300 Kelvins (K) and 2600 K to form a solid composite body; and cooling the solid composite body to form the composite cutter.

Abstract: Methods of forming nanoceramic materials and components. The methods may include performing atomic layer deposition to form a plurality of nanoparticles, including forming a thin film coating over core particles, or sintering the nanoparticles in a mold. The nanoparticles can include a first material selected from a rare earth metal-containing oxide, a rare earth metal-containing fluoride, a rare earth metal-containing oxyfluoride or combinations thereof.

Abstract: A system for gathering downhole measurements includes a drill bit, at least one nozzle receptacle located on the drill bit, and a sensor system. The sensor system has a sensor housing, a flow path extending through the sensor housing, wherein the flow path allows fluid to flow through the sensor housing, and an internal cavity provided within the sensor housing separate from the flow path. The internal cavity contains components that include at least one sensor for gathering data about drill bit conditions and downhole conditions, a powering unit, a printed circuit board, and an electrical conductor, wherein the sensor housing is installed in the at least one nozzle receptacle.

Abstract: Described herein are articles, systems and methods where a plasma resistant coating is deposited onto a surface of an article using an atomic layer deposition (ALD) process. The plasma resistant coating has a first layer and a second layer including a solid solution of Y2O3-ZrO2 and uniformly covers features, such as those having an aspect ratio of length to width of about 3:1 to about 300:1.

Abstract: Disclosed are an expansion tool assembly, comprising: an expandable tubular; a guide shoe partially inserted into and connected to the lower end of the expandable tubular; a sealing sleeve arranged in the expandable tubular and connected to the upper end of the guide shoe; an expansion assembly comprising an expansion cone and expansion seat disposed inside the expandable tubular, wherein the lower end of the expansion seat is connected with hooks, which can be rested on the upper end of the sealing sleeve; an upper joint that is connected to the upper end of the expansion seat and can be connected to a drill string. A force transfer path can be established via connection between the expansion seat and sealing sleeve, so that expandable tubular weight is borne on the drill string. Unintentional expansion of the expandable tubular, caused by interaction between expandable tubular and expansion cone, can be avoided.