Publications

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The U.S. Department of Energy (DOE) has embarked on the Deep Borehole Field Test (DBFT), which will investigate whether conditions suitable for disposal of radioactive waste can be found at a depth of up to 5 km in the earth’s crust. As planned, the DBFT will demonstrate drilling and construction of two boreholes, one for initial scientific characterization, and the other at a larger diameter such as could be appropriate for waste disposal (the DBFT will not involve radioactive waste). A wide range of geoscience activities is planned for the Characterization Borehole, and an engineering demonstration of test package emplacement and retrieval is planned for the larger Field Test Borehole. Characterization activities will focus on measurements and samples that are important for evaluating the long-term isolation capability of the Deep Borehole Disposal (DBD) concept. Engineering demonstration activities will focus on providing data to evaluate the concept’s operational safety and practicality. Procurement of a scientifically acceptable DBFT site and a site management contractor is now underway. The concept of deep borehole disposal (DBD) for radioactive wastes is not new. It was considered by the National Academy of Science (NAS 1957) for liquid waste, studied in the 1980’s in the U.S. (Woodward–Clyde 1983), and has been evaluated by European waste disposal R&D programs in the past few decades (for example, Grundfelt and Crawford 2014; Grundfelt 2010). Deep injection of wastewater including hazardous wastes is ongoing in the U.S. and regulated by the Environmental Protection Agency (EPA 2001). The DBFT is being conducted with a view to use the DBD concept for future disposal of smaller-quantity, DOE-managed wastes from nuclear weapons production (i.e., Cs/Sr capsules and granular solid wastes). However, the concept may also have broader applicability for nations that have a need to dispose of limited amounts of spent fuel from nuclear power reactors. For such nations the cost for disposing of volumetrically limited waste streams could be lower than mined geologic repositories.

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The dynamic stability of deep drillstrings is challenged by an inability to impart controllability with ever-changing conditions introduced by geology, depth, structural dynamic properties and operating conditions. A multi-organizational LDRD project team at Sandia National Laboratories successfully demonstrated advanced technologies for mitigating drillstring vibrations to improve the reliability of drilling systems used for construction of deep, high-value wells. Using computational modeling and dynamic substructuring techniques, the benefit of controllable actuators at discrete locations in the drillstring is determined. Prototype downhole tools were developed and evaluated in laboratory test fixtures simulating the structural dynamic response of a deep drillstring. A laboratory-based drilling applicability demonstration was conducted to demonstrate the benefit available from deployment of an autonomous, downhole tool with self-actuation capabilities in response to the dynamic response of the host drillstring. A concept is presented for a prototype drilling tool based upon the technical advances. The technology described herein is the subject of U.S. Patent Application No. 62219481, entitled "DRILLING SYSTEM VIBRATION SUPPRESSION SYSTEMS AND METHODS", filed September 16, 2015.

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This report presents four concepts for packaging of radioactive waste for disposal in deep boreholes. Two of these are reference-size packages (11 inch outer diameter) and two are smaller (5 inch) for disposal of Cs/Sr capsules. All four have an assumed length of approximately 18.5 feet, which allows the internal length of the waste volume to be 16.4 feet. However, package length and volume can be scaled by changing the length of the middle, tubular section. The materials proposed for use are low-alloy steels, commonly used in the oil-and-gas industry. Threaded connections between packages, and internal threads used to seal the waste cavity, are common oilfield types. Two types of fill ports are proposed: flask-type and internal-flush. All four package design concepts would withstand hydrostatic pressure of 9,600 psi, with factor safety 2.0. The combined loading condition includes axial tension and compression from the weight of a string or stack of packages in the disposal borehole, either during lower and emplacement of a string, or after stacking of multiple packages emplaced singly. Combined loading also includes bending that may occur during emplacement, particularly for a string of packages threaded together. Flask-type packages would be fabricated and heat-treated, if necessary, before loading waste. The fill port would be narrower than the waste cavity inner diameter, so the flask type is suitable for directly loading bulk granular waste, or loading slim waste canisters (e.g., containing Cs/Sr capsules) that fit through the port. The fill port would be sealed with a tapered, threaded plug, with a welded cover plate (welded after loading). Threaded connections between packages and between packages and a drill string, would be standard drill pipe threads. The internal flush packaging concepts would use semi-flush oilfield tubing, which is internally flush but has a slight external upset at the joints. This type of tubing can be obtained with premium, low-profile threaded connections at each end. The internal-flush design would be suitable for loading waste that arrives from the originating site in weld-sealed, cylindrical canisters. Internal, tapered plugs with sealing filet welds would seal the tubing at each end. The taper would be precisely machined onto both the tubing and the plug, producing a metal-metal sealing surface that is compressed as the package is subjected to hydrostatic pressure. The lower plug would be welded in place before loading, while the upper plug would be placed and welded after loading. Conceptual Waste Packaging Options for Deep Borehole Disposal July 30, 2015 iv Threaded connections between packages would allow emplacement singly or in strings screwed together at the disposal site. For emplacement on a drill string the drill pipe would be connected directly into the top package of a string (using an adapter sub to mate with premium semi-flush tubing threads). Alternatively, for wireline emplacement the same package designs could be emplaced singly using a sub with wireline latch, on the upper end. Threaded connections on the bottom of the lowermost package would allow attachment of a crush box, instrumentation, etc.

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Sandia National Laboratories (Sandia) has a long history in developing compact, mobile, very high-speed drilling systems and this technology could be applied to increasing the rate at which boreholes are drilled during a mine accident response. The present study reviews current technical approaches, primarily based on technology developed under other programs, analyzes mine rescue specific requirements to develop a conceptual mine rescue drilling approach, and finally, proposes development of a phased mine rescue drilling system (MRDS) that accomplishes (1) development of rapid drilling MRDS equipment; (2) structuring improved web communication through the Mine Safety & Health Administration (MSHA) web site; (3) development of an improved protocol for employment of existing drilling technology in emergencies; (4) deployment of advanced technologies to complement mine rescue drilling operations during emergency events; and (5) preliminary discussion of potential future technology development of specialized MRDS equipment. This phased approach allows for rapid fielding of a basic system for improved rescue drilling, with the ability to improve the system over time at a reasonable cost.

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Manufactured parts are designed with acceptance tolerances, i.e. deviations from ideal design conditions, due to unavoidable errors in the manufacturing process. It is necessary to measure and evaluate the manufactured part, compared to the nominal design, to determine whether the part meets design specifications. The scope of this research project is dimensional acceptance of machined parts; specifically, parts machined using numerically controlled (NC, or also CNC for Computer Numerically Controlled) machines. In the design/build/accept cycle, the designer will specify both a nominal value, and an acceptable tolerance. As part of the typical design/build/accept business practice, it is required to verify that the part did meet acceptable values prior to acceptance. Manufacturing cost must include not only raw materials and added labor, but also the cost of ensuring conformance to specifications. Ensuring conformance is a substantial portion of the cost of manufacturing. In this project, the costs of measurements were approximately 50% of the cost of the machined part. In production, cost of measurement would be smaller, but still a substantial proportion of manufacturing cost. The results of this research project will point to a science-based approach to reducing the cost of ensuring conformance to specifications. The approach that we take is to determine, a priori, how well a CNC machine can manufacture a particular geometry from stock. Based on the knowledge of the manufacturing process, we are then able to decide features which need further measurements from features which can be accepted 'as is' from the CNC. By calibration of the machine tool, and establishing a machining accuracy ratio, we can validate the ability of CNC to fabricate to a particular level of tolerance. This will eliminate the costs of checking for conformance for relatively large tolerances.