# US 2019/0169966 A1 · Additive Manufacture of Wellbore Tubulars

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- Number: US 2019/0169966 A1
- Document ID: US20190169966A1
- Status: Published application
- Kind: A1
- Application number: 16/206,222
- 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/US20190169966A1

## 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 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.

## Claims

### Claim 1

A method of casing a wellbore of a hydrocarbon well, the method comprising:
disposing a casing print head in a wellbore of a hydrocarbon well; and
conducting a downhole casing operation comprising:
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.

### Claim 2 (depends on 1)

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

### Claim 3 (depends on 1)

The method claim 1, wherein the downhole casing operation comprises forming a perforation in the casing.

### Claim 4 (depends on 3)

The method claim 3, wherein forming a perforation in the casing comprises operating the casing print head to form a contiguous void extending across the casing tubular and the casing liner.

### Claim 5 (depends on 4)

The method claim 4, wherein operating the casing print head to form a contiguous void extending across the casing tubular and the casing liner comprises operating the casing print head to deposit a disposable material to define the contiguous void extending across the casing tubular and the casing liner, and the method further comprising:
performing a perforation operation comprising removing the disposable material.

### Claim 6 (depends on 1, 5)

The method of claim 5, wherein the disposable material comprises a dissolvable material, and wherein the perforation operation comprises exposing the dissolvable material to a substance configured to dissolve the dissolvable material. The method of claim 1, wherein the casing material comprises a metal material.

### Claim 8 (depends on 1)

The method of claim 1, wherein the casing material comprises steel.

### Claim 9 (depends on 1)

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

### Claim 10 (depends on 1)

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

### Claim 11

A wellbore casing system comprising:
a casing print head configured to be disposed in a wellbore of a hydrocarbon well, the casing print head configured to:
eject casing material to form a casing tubular in the wellbore; and
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.

### Claim 12 (depends on 11)

The system of claim 11, wherein the casing print head is configured to be advanced along a length of the wellbore and eject the casing material and the liner casing material along a length of the wellbore to form the casing along the length of the wellbore.

### Claim 13 (depends on 11)

The system claim 11, wherein the downhole casing operation comprises forming a perforation in the casing.

### Claim 14 (depends on 13)

The system claim 13, wherein forming a perforation in the casing comprises forming a contiguous void extending across the casing tubular and the casing liner.

### Claim 15 (depends on 14)

The system of claim 14, wherein forming a contiguous void extending across the casing tubular and the casing liner comprises depositing a disposable material to define the contiguous void extending across the casing tubular and the casing liner, wherein the disposable material is removable.

### Claim 16 (depends on 15)

The system of claim 15, wherein the disposable material comprises a dissolvable material.

### Claim 17 (depends on 11)

The system of claim 11, wherein the casing material comprises a metal material.

### Claim 18 (depends on 11)

The system of claim 11, wherein the casing material comprises steel.

### Claim 19 (depends on 11)

The system of claim 11, wherein the casing liner material comprises a cementitious material.

### Claim 20 (depends on 11)

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

### Claim 21

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

### Claim 22 (depends on 21)

The method of claim 21, wherein the downhole lining operation comprises advancing the lining print head along a length of the wellbore and ejecting the tubular material and the lining material along the length of the wellbore to form the casing along the length of the wellbore.

### Claim 23 (depends on 21)

The method of claim 21, wherein the tubular material comprises metal and the lining material comprises a cementitious material.