# US 2019/0169964 A1 · Additive Manufacture of Casing Liner in a Wellbore

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- Number: US 2019/0169964 A1
- Document ID: US20190169964A1
- Status: Published application
- Kind: A1
- Application number: 16/206,157
- Filed: 2018-11-30
- Published: 2019-06-06
- Earliest claimed: 2017-12-05
- Assignees: Saudi Arabian Oil Company
- Applicants: Saudi Arabian Oil Company
- Inventors: Peter J. Boul; Carl J. Thaemlitz
- Web page: https://patentgrep.com/patent/US20190169964A1

## CPC

- E21B 33/14: for cementing casings into boreholes
- B22F 10/00: Additive manufacturing of workpieces or articles from metallic powder (apparatus or devices therefor B22F12/00)
- B22F 10/85: for controlling or regulating additive manufacturing processes
- B22F 12/00: Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F 12/82: Combination of additive manufacturing apparatus or devices with other processing apparatus or devices
- B28B 1/001: {Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00)}
- B28B 13/022: {Feeding several successive layers, optionally of different materials}
- B28B 13/0275: {Feeding a slurry or a ceramic slip}
- B28B 17/0081: {Process control}
- B29C 64/00: Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C 64/10: Processes of additive manufacturing
- B29C 64/112: using individual droplets, e.g. from jetting heads
- B29C 64/176: Sequentially
- B29C 64/182: in parallel batches
- B29C 64/20: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C 64/205: Means for applying layers
- B29C 64/227: Driving means
- B29C 64/241: for rotary motion
- B29C 64/245: Platforms or substrates (support structures intended to be sacrificed after manufacture B29C64/40)
- B29C 64/25: Housings, e.g. machine housings
- B29C 64/255: Enclosures for the building material, e.g. powder containers
- B29C 64/30: Auxiliary operations or equipment
- B29C 64/307: Handling of material to be used in additive manufacturing
- B29C 64/386: Data acquisition or data processing for additive manufacturing
- B29C 64/393: for controlling or regulating additive manufacturing processes
- B29C 64/40: Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
- B33Y 40/00: Auxiliary operations or equipment, e.g. for material handling
- B33Y 40/10: Pre-treatment
- B33Y 40/20: Post-treatment, e.g. curing, coating or polishing
- B33Y 50/00: Data acquisition or data processing for additive manufacturing
- B33Y 70/00: Materials specially adapted for additive manufacturing
- B33Y 70/10: Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
- B33Y 99/00: Subject matter not provided for in other groups of this subclass
- E21B 41/0078: {Nozzles used in boreholes (drilling by liquid or gas jets E21B7/18; drill bits with nozzles E21B10/60; perforators using direct fluid action E21B43/114; obtaining a slurry of minerals using nozzles E21B43/29)}
- E21B 43/10: Setting of casings, screens, liners {or the like} in wells
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 50/02: for controlling or regulating additive manufacturing processes
- B33Y 80/00: Products made by additive manufacturing
- E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING

## Abstract

Provided are systems and methods for forming a casing liner in a wellbore of a hydrocarbon well. The forming including disposing a casing liner print head in an annular region located between a casing pipe disposed in a wellbore of a hydrocarbon well and a wall of the wellbore, and conducting a downhole lining operation including operating the casing liner print head to eject casing liner material into the annular region to form, in the annular region, a casing liner including elongated voids formed in the casing liner material.

## Claims

### Claim 1

A method of forming a casing liner in a wellbore of a hydrocarbon well, the method comprising:
disposing a casing liner print head in an annular region located between a casing pipe disposed in a wellbore of a hydrocarbon well and a wall of the wellbore; and
conducting a downhole lining operation comprising operating the casing liner print head to eject casing liner material into the annular region to form, in the annular region, a casing liner comprising elongated voids formed in the casing liner material.

### Claim 2 (depends on 1)

The method of claim 1, wherein the downhole lining operation comprises advancing the casing liner print head along a length of the wellbore and ejecting the casing liner material along a length of the annular region to form the casing liner along the length of the annular region.

### Claim 3 (depends on 1)

The method of claim 1, wherein the elongated voids comprise elongated voids extending in a radial direction in the annular region.

### Claim 4 (depends on 1)

The method of claim 1, wherein the elongated voids comprise elongated voids extending in a longitudinal direction in the annular region.

### Claim 5 (depends on 1)

The method of claim 1, wherein the elongated voids are encapsulated within the casing liner material.

### Claim 6 (depends on 1)

The method of claim 1, wherein the elongated voids comprise elliptical shaped voids.

### Claim 7 (depends on 1)

The method claim 1, wherein the lining operation comprises ejecting an integrated structure material to form the elongated voids in the casing liner material.

### Claim 8 (depends on 7)

The system of claim 7, wherein the integrated structure material comprises a gas, liquid or solid.

### Claim 9 (depends on 7)

The system of claim 7, wherein the integrated structure material comprises a polymer.

### Claim 10 (depends on 7)

The method of claim 7, wherein the integrated structure material has a Young's Modulus that is less than a Young's Modulus of the casing liner material.

### Claim 11 (depends on 1)

The method of claim 1, wherein the casing liner material comprises a cementitious material.

### Claim 12 (depends on 11)

The method of claim 11, wherein the casing liner material comprises casing cement.

### Claim 13

A wellbore casing liner printing system comprising:
a casing liner print head configured to be disposed in an annular region located between a casing pipe disposed in a wellbore of a hydrocarbon well and a wall of the wellbore, the casing liner print head configured to eject casing liner material into the annular region to form, in the annular region, a casing liner comprising elongated voids formed in the casing liner material.

### Claim 14 (depends on 13)

The system of claim 13, wherein the casing liner print head is configured to be advanced along a length of the wellbore and to eject the casing liner material along a length of the annular region to form the casing liner along the length of the annular region.

### Claim 15 (depends on 13)

The system of claim 13, wherein the elongated voids comprise elongated voids extending in a radial direction in the annular region.

### Claim 16 (depends on 13)

The system of claim 13, wherein the elongated voids comprise elongated voids extending in a longitudinal direction in the annular region.

### Claim 17 (depends on 13)

The system of claim 13, wherein the elongated voids are encapsulated within the casing liner material.

### Claim 18 (depends on 13)

The system of claim 13, wherein the elongated voids comprise elliptical shaped voids.

### Claim 19 (depends on 13)

The system of claim 13, wherein the casing liner print head is configured to eject an integrated structure material to form the elongated voids in the casing liner material.

### Claim 20 (depends on 19)

The system of claim 19, wherein the integrated structure material comprises a gas, liquid or solid.

### Claim 21 (depends on 19)

The system of claim 19, wherein the integrated structure material comprises a polymer.

### Claim 22 (depends on 19)

The system of claim 19, wherein the integrated structure material has a Young's Modulus that is less than a Young's Modulus of the casing liner material.

### Claim 23 (depends on 13)

The system of claim 13, wherein the casing liner material comprises a cementitious material.

### Claim 24 (depends on 23)

The system of claim 23, wherein the casing liner material comprises casing cement.

### Claim 25

A method of forming a casing liner in a wellbore of a hydrocarbon well, the method comprising:
disposing a casing liner print head in an annular region located between a casing pipe disposed in a wellbore of a hydrocarbon well and a wall of the wellbore; and
conducting a downhole cementing operation comprising operating the casing liner print head to eject casing cement into the annular region to form, in the annular region, a casing liner comprising elongated voids formed in the cementitious material.

### Claim 26 (depends on 1)

The method of claim 1, wherein the downhole cementing operation comprises advancing the casing liner print head along a length of the wellbore and ejecting the casing liner material along a length of the annular region to form the casing liner along the length of the annular region.