Digital Cement Modeling for Longevity Prediction
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Solution Overview
Problem
Existing methods for evaluating cement longevity in oil well drilling and operation lack accuracy in predicting long-term zonal isolation, leading to potential leakage and increased maintenance costs.
Innovation Solution
A method involving computed tomography (CT) scan data acquisition of metal-cement and cement-rock core samples, followed by generation of 3D images and multi-scale borehole digital models using digital rock physics techniques to predict cement longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If laboratory testing of cement specimen under confining pressure is performed to measure material properties, then material properties such as Young's modulus, Poisson's ratio, and compressive strengths can be measured, but it remains unknown whether the measured properties meet the longevity requirement for long term zonal isolation
Solution Approach 1:
The patent creates a digital copy (virtual model) of the cement sheath based on CT scan data, allowing virtual experiments to be performed on this digital replica. This digital twin approach enables prediction of long-term behavior without requiring physical aging tests, resolving the contradiction between measuring current material properties and predicting future performance.
Solution Approach 2:
The patent performs virtual aging tests and degradation simulations in advance on the digital model, predicting how the cement sheath will behave over time before actual long-term field operation begins. This preliminary virtual experimentation provides longevity predictions without waiting for actual long-term physical tests to complete.
2Reliability
If digital rock physics techniques and multi-scale digital modeling are used to predict cement longevity, then prediction accuracy for long term zonal isolation is improved, but the complexity of the modeling process increases
Solution Approach 1:
The patent segments the cement sheath model into multiple scales (micro-scale CT scan data, meso-scale representative volume elements, macro-scale full wellbore model). This hierarchical segmentation allows complex digital rock physics techniques to be applied at appropriate scales, managing computational complexity while maintaining prediction accuracy for cement longevity.
3Loss of information
If CT scan data acquisition and 3D image generation of core samples are performed, then detailed structural information of metal-cement and cement-rock interfaces is obtained, but the time and resources required for data processing increase
Solution Approach 1:
The patent extracts only the essential structural information from CT scan data that is relevant to cement longevity prediction (such as interface quality, porosity distribution, and heterogeneity features). By selectively extracting critical information rather than processing all raw data, the method reduces processing time while maintaining the necessary detail for accurate longevity assessment.
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
This approach allows for more accurate prediction of cement longevity, optimizing field operations by varying cement and rock content, and improving zonal isolation and well maintenance efficiency.
Implementation Method 1
acquiring computed tomography (CT) scan data of a metal-cement core sample and a cement-rock core sample
Data Source
AI summary
A method to perform a field operation with digital cement modeling is disclosed. The method includes acquiring computed tomography (CT) scan data of a metal-cement core sample and a cement-rock core sample that are associated with a borehole setup, generating, based on the CT scan data of the metal-cement core sample and the cement-rock core sample, a three-dimensional (3D) image of a synthesized metal, cement, and rock core sample, generating, by at least upscaling the synthesized metal, cement, and rock core sample, a multi-scale borehole digital model of the borehole setup, and calculating, using the multi-scale borehole digital model of the borehole setup and based on digital rock physics techniques, a predicted cement longevity.