Additive Wellbore Casing Liners for Void-Free Cement Placement
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Solution Overview
Problem
Traditional casing operations in wells face issues with inconsistent cement placement, leading to structural integrity problems and increased time and cost due to the difficulty in predicting and tracking cement movement, resulting in voids and potential fractures.
Innovation Solution
Employing additive manufacturing techniques, such as 3D printing, to precisely deposit wellbore lining materials like cement in the annular region between the casing pipe and the wellbore wall, allowing for precise control and integration of structures that modify mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional cement pumping methods are used to fill the annular region, then the cement can be placed in the wellbore, but the cement placement becomes inconsistent and difficult to predict or track, leading to voids and structural integrity problems
Solution Approach 1:
The patent replaces the traditional mechanical cement pumping system with an additive manufacturing (3D printing) system. Instead of pumping cement through pipes and relying on pressure-driven flow, the invention uses a 3D printer to precisely deposit cement layer by layer in the annular region between the wellbore and casing. This substitution of mechanical pumping with additive manufacturing enables precise control over cement placement location, volume, and distribution, eliminating the unpredictability and void formation associated with traditional pumping methods.
Solution Approach 2:
The patent changes the fundamental parameters of cement delivery by transitioning from a continuous pressure-driven flow to a controlled, discrete layer-by-layer deposition process. The additive manufacturing system allows precise control of cement placement parameters including deposition rate, layer thickness, and spatial distribution. This parameter control ensures complete filling of the annular region without voids, directly improving both manufacturing precision and structural integrity.
2Productivity
If traditional cementing operations are performed, then casing can be installed in the wellbore, but the process requires significant time for cement placement and monitoring due to the difficulty in tracking cement movement
Solution Approach 1:
The additive manufacturing system incorporates real-time monitoring and feedback control to track cement deposition as it occurs. The system can monitor the volume of cement deposited, the location of deposition, and the progress of the annular region filling process. This feedback capability eliminates the need for time-consuming post-operation monitoring and quality assurance that is required with traditional pumping methods, where cement movement and placement must be inferred indirectly after the fact.
Solution Approach 2:
By replacing the traditional cementing operation sequence with additive manufacturing, the patent fundamentally changes the operational workflow. The 3D printing process provides inherent visibility and control over cement placement, eliminating the need for separate monitoring and verification steps that are necessary with conventional methods. This substitution directly reduces operational time and increases productivity.
3Ease of manufacture
If traditional cement pumping is used, then cement can be placed in the annular region, but the process is costly due to the need for extensive monitoring and rework to ensure proper placement
Solution Approach 1:
The patent replaces the complex traditional cementing operation with a simpler additive manufacturing process. The 3D printing system provides direct, controlled deposition of cement without the need for complex pumping equipment, pressure management systems, or extensive monitoring infrastructure. This substitution simplifies the manufacturing process and reduces the operational costs associated with equipment, personnel, and time.
Solution Approach 2:
The additive manufacturing system allows for preliminary planning and precise execution of cement placement before the operation begins. The digital model of the annular region can be used to pre-calculate the exact amount and distribution of cement needed, eliminating the need for rework or additional material to correct improper placement. This preliminary action approach reduces waste and operational costs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures consistent cement deposition without voids, enhancing structural integrity and reducing operational time and costs by enabling precise monitoring and control of cement placement.
Implementation Method 1
additive manufacture of a casing liner in an annular region between an exterior of a casing pipe positioned in the wellbore and a wall of the wellbore
Data Source
AI summary
Provided are systems and method for casing a wellbore of a hydrocarbon well. The casing including disposing a casing print head in a wellbore of a hydrocarbon well, and conducting a downhole casing operation including operating the casing print head to eject casing material to form a casing tubular in the wellbore, and operating the casing print head to eject casing liner material into an annular region located between the casing tubular and a wall of the wellbore to form a casing liner in the annular region, the casing tubular and the casing liner forming a casing of the wellbore.