3D Printing Sub-Assembly for In-Situ Wellbore Casing
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Solution Overview
Problem
Current drilling operations in oil and gas extraction require separate casing installation and cementing processes, which are time-consuming and can be challenging, especially in complex well geometries and environments where cementing is difficult.
Innovation Solution
Integration of a 3D printing sub-assembly within the drill string that allows for the simultaneous drilling and 3D printing of casing sections, using a 3D printing head and control unit to print casing materials radially away from the drill string's central axis, enabling in-situ casing creation during drilling operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional separate casing installation and cementing processes are used, then casing can be installed in standard well geometries, but drilling time increases and operational complexity increases
Solution Approach 1:
The patent combines the casing installation process with the drilling operation by integrating a 3D printing sub-assembly into the drill string. This allows the casing to be printed in-situ during drilling, merging two previously separate operations (drilling and casing installation) into a single continuous process, thereby reducing total drilling time and operational complexity
Solution Approach 2:
The casing is printed during the drilling operation itself, performing the casing installation action before the wellbore is completely drilled and before cementing would traditionally be required. This preliminary action eliminates the need for subsequent cementing operations in many cases, further reducing time and complexity
2Reliability
If traditional cementing process is used, then casing can be secured in standard formations, but the process becomes difficult in complex well geometries and environments
Solution Approach 1:
The patent replaces the traditional chemical cementing process with a direct 3D printing deposition process. Instead of relying on cement to secure the casing, the system uses a 3D printing head to deposit material that forms the casing structure directly in-situ, eliminating the chemical cementing step that proves difficult in complex well geometries
Solution Approach 2:
The invention changes the fundamental parameter of casing installation from chemical bonding (cementing) to direct material deposition (3D printing). This parameter change allows the casing to be created with precise control over geometry and material properties, making it feasible in complex well environments where traditional cementing fails
3Adaptability or versatility
If conventional casing installation is used, then standard casing structures can be installed, but customization and repairs are difficult
Solution Approach 1:
The patent introduces dynamic adaptability through computer-controlled 3D printing, allowing the casing structure to be customized in real-time based on wellbore conditions, formation geology, and operational requirements. The printing path and material deposition can be dynamically adjusted to create specialized structures for repairs or complex geometries, whereas conventional methods require pre-fabricated standard components
Solution Approach 2:
The system enables self-service customization by allowing the casing structure to be adapted directly at the wellbore location based on real-time conditions, eliminating the need to transport and install pre-fabricated standard casings. The 3D printing process can respond to on-site requirements for repairs or geometric variations without requiring complex external intervention
Data Source
AI summary
A method includes introducing a drill string including a bottom hole assembly into a wellbore, wherein the bottom hole assembly includes a mounted 3D printing sub-assembly. A wellbore is drilled with the bottom hole assembly, and at least a portion of a casing is printed with the 3D printing sub-assembly while drilling the wellbore. A related system includes a drill string having a length of drill pipe and a bottom hole assembly disposed at a distal end of the length of drill pipe. A 3D printing sub-assembly is mounted on the bottom hole assembly, wherein the printing sub-assembly includes a printer housing and a 3D printing head mounted at the printer housing. A control guides the 3D printing head to print at least a portion of a casing at a location radially away from the central longitudinal axis of the drill string.