Abstract: Systems and methods include a computer-implemented method can be used to make drilling tools from new wurtzite boron nitride (w-BN) superhard material. An ultra-high-pressure, high-temperature operation is performed on pure w-BN powder to synthesize w-BN and cubic boron nitride (c-BN) compact having a first size greater than particles of the pure w-BN powder. The ultra-high-pressure, high-temperature operation includes pressurizing the w-BN powder to a pressure of approximately 20 Gigapascal, heating the w-BN powder at a heating rate of 100° C./minute and cooling the w-BN powder at a cooling rate of 50° C./minute. The compact is cut to a second size smaller than the first size using laser cutting tools. The cut compact is bonded metallurgically, mechanically, or both metallurgically and mechanically onto a tool substrate to form the drilling tool.

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 method of fabricating a drill bit is described. The method includes forming a mold with interior surfaces defining a mold cavity within the mold, the mold cavity having a shape corresponding to a shape of a body of the drill bit; forming catalyst-free synthesized polycrystalline diamond compact (PDC) cutting elements using an ultra-high pressure and temperature process; determining positions of the catalyst-free synthesized PDC cutting elements within the mold cavity; placing the catalyst-free synthesized PDC cutting elements at the determined positions within the mold cavity; filling the mold cavity with matrix materials of the body of the drill bit; and bonding the catalyst-free synthesized PDC cutting elements with the matrix materials of the body to form an impregnated drill bit.

Abstract: Methods, systems, and apparatus for carrying out rapid on-site optical chemical analysis in oil feeds are described. In one aspect, a system for manufacture of a tool includes a deposition reactor configured for molecular layer deposition or atomic layer deposition of metal powder to manufacture coated particles, a fabrication unit configured for 3D printing of the tool, and a controller that controls the deposition reactor and the fabrication unit, wherein the fabrication unit and the deposition reactor are integrated for automated fabrication of the tool using the coated particles from the deposition reactor as building material for the 3D printing.

Abstract: Methods for forming a polycrystalline diamond compact (PDC) drill bit from catalyst-free synthesized polycrystalline diamonds are described. The polycrystalline diamonds are deposited within a mold. In some cases, a matrix body material is deposited within the mold, and an infiltration process is performed to bond the polycrystalline diamonds to the matrix body material to form the PDC drill bit. In some cases, a drill bit body is formed within the mold, and forming the drill bit body within the mold includes depositing a layer of matrix body material particles within the mold, depositing an adhesive ink within the mold, and curing the adhesive ink. In some cases, a sintering process is performed after forming the drill bit body to remove at least a portion of the adhesive ink and increase a density of the drill bit body to form the PDC drill bit.

Abstract: Cutters for a downhole drill bit can be formed by providing a catalyst-free synthesized polycrystalline diamond (PCD) having a cross-sectional dimension of at least 8 millimeters; providing a substrate comprising tungsten carbide; and attaching the synthesized PCD to the substrate comprising tungsten carbide to form a PDC cutter.

Abstract: The present disclosure describes methods and systems for downhole well integrity reconstruction in a hydrocarbon reservoir. One method for downhole well integrity reconstruction in a hydrocarbon reservoir includes: positioning, a laser head at a first subterranean location, wherein the laser head is attached to a tubular inside of a wellbore; directing, by the laser head, a laser beam towards a leak on the wellbore; and sealing the leak using the laser beam.

Abstract: Systems, methods, and apparatuses for deploying a lost circulation fabric (LCF) to seal a lost circulation zone during a drilling operation. The LCF may be contained within a lost circulation fabric deployment system (LCFDS) that is coupled to a tubular of a drilling string. The LCFDS may include a controller and sensors to detect the presence of a lost circulation zone and deploy the LCF upon detection of the lost circulation zone. In some implementations, a plurality of LCFDSs may be disposed on the tubular and work in cooperation to deploy a plurality of LCFs to form a seal along the lost circulation zone.

Abstract: A system and a method for forming a composite electrolyte structure are provided. An exemplary composite electrolyte structure includes, at least in part, polymer electrolyte preforms that are bonded into the composite electrolyte structure.

Abstract: Bottom hole assemblies with a combined roller-underreamer assembly can include: a body configured to be attached to a drill pipe; an uphole ring attached to the body; a downhole ring attached to the body between the uphole ring and the downhole end of the body; a sliding ring mounted around the body between the uphole ring and the downhole ring; a set tube slidably mounted around the body between the uphole ring and the sliding ring; a reamer assembly with at least one first articulated arm with extending between the uphole ring and the downhole end of the set tube; and a roller assembly with: at least one second articulated arm extending between the uphole end of the set tube and the sliding ring; and a rolling positioned at a joint of each second articulated arm.

Abstract: A system and a method for forming a composite electrolyte structure are provided. An exemplary composite electrolyte structure includes, at least in part, polymer electrolyte preforms that are bonded into the composite electrolyte structure.

Abstract: The present disclosure describes methods and systems for downhole well integrity reconstruction in a hydrocarbon reservoir. One method for downhole well integrity reconstruction in a hydrocarbon reservoir includes: positioning, a laser head at a first subterranean location, wherein the laser head is attached to a tubular inside of a wellbore; directing, by the laser head, a laser beam towards a leak on the wellbore; and sealing the leak using the laser beam.

Abstract: A method of deploying a flexible cable in a wellbore includes carrying, by a tubular assembly, a cable spool cartridge into the wellbore. The cable spool cartridge is attached to an exterior of the tubular assembly and contains the flexible cable. A first end of the flexible cable is attached to a buoyancy device, and the buoyancy device is releasably attached to the cable spool cartridge. A fluid is flowed by the tubular assembly in a downhole direction through an interior of the tubular assembly and in an uphole direction within an annulus at least partially defined by the exterior of the tubular assembly. The fluid has a greater density than the buoyancy device. The buoyancy device is released by the cable spool cartridge, and the buoyancy device is configured to travel after release in the uphole direction with the fluid and thereby pull the flexible cable from the cable spool cartridge and into the annulus.

Abstract: One or more images of a tubular being run into a well are captured. The one or more images can be captured by an image sensor. The tubular includes a first tubular section and a second tubular section connected together by a connection. An onsite edge gateway local to the image sensor is configured to perform various operations. Based on the captured one or more images, an elevation of the connection relative to a reference elevation of the well is determined. Based on the determined elevation, an operating condition is determined. It is determined whether the operating condition is included in an automation rule. In response to determining that the automation rule includes the operating condition, a signal is transmitted to drive a controllable device.

Abstract: A monitoring system includes an image sensor positioned about a rig, the image sensor directed at a drill string component positioned on the rig, and an onsite gateway communicably coupled to the image sensor and disposed proximate to the rig. The onsite gateway includes one or more processors, and a non-transitory computer-readable storage medium coupled to the one or more processors and storing programming instructions for execution by the one or more processors. The programming instructions instruct the one or more processors to receive an image stream of the drill string component from the image sensor, identify an operating parameter of the drill string component, generate an operating condition of the drill string component, determine that the generated operating condition meets a failure threshold of the drill string component, and send an instruction to drive a controllable device.

Abstract: Bottom hole assemblies for deploying sheets of material in a wellbore include: a body configured for attachment to a drill pipe; a spool ring attached to the body; a spring ring; and rolls of fabric.

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 method of deploying a flexible cable in a wellbore includes carrying, by a tubular assembly, a cable spool cartridge into the wellbore. The cable spool cartridge is attached to an exterior of the tubular assembly and contains the flexible cable. A first end of the flexible cable is attached to a buoyancy device, and the buoyancy device is releasably attached to the cable spool cartridge. A fluid is flowed by the tubular assembly in a downhole direction through an interior of the tubular assembly and in an uphole direction within an annulus at least partially defined by the exterior of the tubular assembly. The fluid has a greater density than the buoyancy device. The buoyancy device is released by the cable spool cartridge, and the buoyancy device is configured to travel after release in the uphole direction with the fluid and thereby pull the flexible cable from the cable spool cartridge and into the annulus.

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: A downhole liner delivery tool includes a housing configured to couple to a tubular work string. The housing includes an interior volume. The tool also includes a liner store enclosed within the interior volume. The liner store is configured to enclose at least a portion of a wellbore liner that includes a flexible membrane. The flexible membrane includes an imbedded epoxy. The tool also includes a hydraulic circulation system arranged in at least a portion of the interior volume and configured to circulate a fluid to expand the wellbore liner from the liner store to an exterior of the housing to contactingly engage a wellbore wall.