Ultrasonic Casing Cable Welding for Low-Downtime Well Deployment

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Solution Overview

Problem

The high costs and downtime associated with deploying cables and devices within a wellbore during a run-in-hole operation are exacerbated by the need for larger wellbore diameters, which increase drilling expenses and reduce efficiency.

Innovation Solution

The implementation of an ultrasonic welding system that couples fiber optic cables and electro-acoustic transducers to the casing using an ultrasonic spot weld, reducing the outer diameter of the casing and allowing for continuous welding during the run-in-hole operation, thereby minimizing downtime and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If cables and devices are deployed along with casing using traditional methods, then the wellbore can accommodate the equipment, but the outer diameter of the wellbore must increase, leading to higher drilling costs

Engineering Contradiction:

Improvewellbore diameterVSAvoiddrilling costs

Core Design Contradiction:

Volume of moving objectVSQuantity of substance

Solution Approach 1:

The patent applies nesting by placing fiber optic cables and electro-acoustic transducers inside the casing during the run-in-hole operation. The cables are positioned within the casing interior, allowing them to be deployed alongside the casing without increasing the outer diameter requirements. This nested configuration enables simultaneous deployment of multiple well elements through the same borehole path.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent transitions from traditional external attachment methods to internal positioning of cables within the casing. By moving the cables from an external configuration to an internal one, the system reduces the radial space requirements and allows deployment within the existing casing outer diameter, thereby avoiding increased drilling costs associated with larger wellbore diameters.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of operation

If traditional deployment methods are used for cables and devices, then the equipment can be installed, but downtime during run-in-hole operation increases, reducing operational efficiency

Engineering Contradiction:

Improvedeployment capabilityVSAvoiddowntime

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent implements preliminary action by pre-positioning the fiber optic cables and electro-acoustic transducers within the casing before the run-in-hole operation begins. The cables are already arranged in their final positions inside the casing sections, so that when the casing is run into the hole, the cables are deployed simultaneously without requiring separate installation steps or causing operational downtime.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent enables continuous deployment by integrating cable placement into the casing running process itself. As the casing is continuously run into the wellbore, the pre-positioned cables are continuously deployed along with it, eliminating interruptions or downtime that would occur with traditional sequential deployment methods where cables are attached after casing installation.

Inventive Principle:

Principle #20Continuity of useful action

3Volume of moving object

If larger wellbore diameter is used to accommodate cables and devices, then the equipment fits, but drilling expenses increase

Engineering Contradiction:

Improvewellbore capacityVSAvoiddrilling energy costs

Core Design Contradiction:

Volume of moving objectVSUse of energy by moving object

Solution Approach 1:

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent changes the spatial parameter of cable placement from external to internal positioning within the casing. This parameter change allows the system to maintain the same wellbore diameter while accommodating additional equipment, thereby avoiding the increased drilling energy costs that would result from enlarging the wellbore to accommodate externally attached cables and devices.

Inventive Principle:

Principle #35Parameter changes

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 reduces the borehole diameter, lowers drilling costs, and minimizes downtime by enabling fast, efficient, and energy-efficient ultrasonic welding of cables and devices directly to the casing, maintaining wellbore integrity while reducing the need for solvents, adhesives, or mechanical fasteners.

Implementation Method 1

The implementation of an ultrasonic welding system that couples fiber optic cables and electro-acoustic transducers to the casing using an ultrasonic spot weld

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentUS11473372B2Automatic cable and device deployment system

Publication Date: 2022.10.18 HALLIBURTON ENERGY SERVICES INC

AI summary

A method performed during a run-in-hole process for a casing section includes applying pressure to a cable against an outer portion of the casing section. Additionally, the method includes ultrasonic welding the cable to the outer portion of the casing section while the pressure is applied to the cable against the outer portion of the casing section.