Casing Wear Calculation Using Real-Time Drill String Data

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current casing wear calculations in wellbore drilling are inaccurate due to reliance on wellbore survey data, leading to errors in predicting casing wear, especially in deviated wellbores, which affects well integrity and efficiency.

Innovation Solution

An integrated system and method for predicting casing wear using a combination of corrosion analysis, thermal flow models, stress analysis, and semi-empirical models, along with a model selection mechanism, to provide more accurate assessments by calculating casing shape and tortuosity, and adjusting drilling parameters based on real-time data.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If casing wear calculations are based on wellbore survey data including tortuosity of open hole, then the calculation process is simple, but the accuracy of casing wear prediction is reduced

Engineering Contradiction:

Improvecalculation process simplicityVSAvoidcasing wear prediction accuracy

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent changes the parameters used in casing wear calculations from basic wellbore survey data to a comprehensive set including real-time drill string position, orientation, inclination, azimuth, and torque measurements. This parameter transformation enables accurate three-dimensional modeling of drill string-casing interaction while maintaining computational feasibility through optimized algorithms.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces traditional empirical mechanical calculation methods with a integrated computational model that combines mechanics of materials, fluid dynamics, and real-time sensor data processing. This substitution enables more accurate prediction of casing wear by accounting for complex interactions between drill string, drilling fluid, and wellbore geometry.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If traditional wellbore survey data is used for casing wear calculation, then data collection is straightforward, but the reliability of casing wear prediction is reduced

Engineering Contradiction:

Improvedata collection easeVSAvoidcasing wear prediction reliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent implements real-time feedback mechanisms by continuously monitoring drill string position, orientation, and operational parameters during drilling operations. This feedback is immediately processed to update casing wear predictions, allowing for dynamic adjustment of drilling parameters to minimize wear while maintaining operational efficiency and reliability.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent introduces an integrated computational model as an intermediary that processes raw sensor data from multiple sources (drill string sensors, wellbore survey equipment, drilling fluid flow meters) and transforms them into reliable casing wear predictions. This intermediary layer reconciles data from different measurement systems and compensates for individual sensor limitations.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If accurate casing wear prediction is achieved through multiple models and real-time data, then well integrity is improved, but system complexity increases

Engineering Contradiction:

Improvewell integrityVSAvoidprediction system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent develops a universal predictive platform that performs multiple functions: real-time casing wear prediction, drill string behavior analysis, drilling parameter optimization, and well integrity assessment. This multi-functional system consolidates what would otherwise require separate analytical tools, reducing overall system complexity while maintaining comprehensive monitoring capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges corrosion analysis, thermal flow models, stress analysis, and semi-empirical models into a single integrated predictive framework. By combining these previously separate analytical approaches, the system achieves accurate casing wear prediction while avoiding the complexity of managing multiple independent models and data streams.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11365621B2Casing wear calculation

Publication Date: 2022.06.21 LANDMARK GRAPHICS CORP

AI summary

A method for calculating wellbore casing wear is provided that includes determining a wellbore boundary for an open hole wellbore segment, calculating a casing shape within the open hole wellbore segment based on one or more casing attributes, determining whether or not the casing shape exceeds the wellbore boundary, calculating casing wear based on the boundary of the open hole wellbore segment if the casing shape is determined to exceed the wellbore boundary, otherwise calculating the casing wear parameter based on the casing shape if the casing shape is determined not to exceed the wellbore boundary, and storing the casing wear parameter on a computer readable medium.