US 11,851,979 B2
Additive manufacture of wellbore tubulars
Peter J. Boul, Houston, TX (US); and Carl J. Thaemlitz, Cypress, TX (US)
Assigned to Saudi Arabian Oil Company, Dhahran (SA)
Filed by Saudi Arabian Oil Company, Dhahran (SA)
Filed on Feb. 7, 2022, as Appl. No. 17/665,773.
Application 17/665,773 is a division of application No. 16/206,222, filed on Nov. 30, 2018, granted, now 11,293,259.
Claims priority of provisional application 62/594,676, filed on Dec. 5, 2017.
Prior Publication US 2022/0154551 A1, May 19, 2022
This patent is subject to a terminal disclaimer.
Int. Cl. B29C 64/00 (2017.01); E21B 33/14 (2006.01); E21B 43/10 (2006.01); B28B 1/00 (2006.01); B28B 13/02 (2006.01); B28B 17/00 (2006.01); B33Y 70/10 (2020.01); B29C 64/393 (2017.01); B33Y 40/00 (2020.01); B33Y 99/00 (2015.01); B29C 64/20 (2017.01); B22F 12/82 (2021.01); B29C 64/205 (2017.01); B22F 10/00 (2021.01); B29C 64/227 (2017.01); B29C 64/255 (2017.01); B29C 64/245 (2017.01); B29C 64/25 (2017.01); B22F 12/00 (2021.01); B22F 10/85 (2021.01); B33Y 40/10 (2020.01); B29C 64/182 (2017.01); B29C 64/30 (2017.01); B29C 64/307 (2017.01); B33Y 40/20 (2020.01); B29C 64/10 (2017.01); B33Y 70/00 (2020.01); B29C 64/176 (2017.01); B33Y 50/00 (2015.01); B29C 64/386 (2017.01); B29C 64/40 (2017.01); E21B 41/00 (2006.01); B33Y 80/00 (2015.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01); B33Y 50/02 (2015.01)
CPC E21B 33/14 (2013.01) [B22F 10/00 (2021.01); B22F 10/85 (2021.01); B22F 12/00 (2021.01); B22F 12/82 (2021.01); B28B 1/001 (2013.01); B28B 13/022 (2013.01); B28B 13/0275 (2013.01); B28B 17/0081 (2013.01); B29C 64/00 (2017.08); B29C 64/10 (2017.08); B29C 64/176 (2017.08); B29C 64/182 (2017.08); B29C 64/20 (2017.08); B29C 64/205 (2017.08); B29C 64/227 (2017.08); B29C 64/245 (2017.08); B29C 64/25 (2017.08); B29C 64/255 (2017.08); B29C 64/30 (2017.08); B29C 64/307 (2017.08); B29C 64/386 (2017.08); B29C 64/393 (2017.08); B29C 64/40 (2017.08); B33Y 40/00 (2014.12); B33Y 40/10 (2020.01); B33Y 40/20 (2020.01); B33Y 50/00 (2014.12); B33Y 70/00 (2014.12); B33Y 70/10 (2020.01); B33Y 99/00 (2014.12); E21B 41/0078 (2013.01); E21B 43/10 (2013.01); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 50/02 (2014.12); B33Y 80/00 (2014.12)] 4 Claims
OG exemplary drawing
 
1. A system for casing a wellbore of a hydrocarbon well, the system comprising:
a casing print head configured to be disposed in a wellbore of a hydrocarbon well, the casing liner print head comprising a row of nozzles, the row of nozzles comprising a first subset of nozzles configured to eject casing liner material, a second subset of nozzles configured to eject causing material, and a third subset of nozzles configured to eject disposable material; and
a well control system comprising a processor and non-transitory computer readable storage medium comprising program instructions stored thereon that are executable by the processor to cause the following:
conducting a downhole casing operation comprising:
operating the casing print head such that the casing print head rotates about a longitudinal axis of the wellbore and advances along the length of the wellbore, and the second subset of nozzles ejects casing material to form a casing tubular in the wellbore;
operating the casing print head such that the first subset of nozzles ejects cementitious 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 formed of the cementitious casing liner material, such that the casing tubular and the casing liner are simultaneously deposited to form a casing of the wellbore;
forming a perforation in the casing, forming the perforation in the casing comprising operating the casing print head to form a contiguous void extending radially across the casing tubular and the casing liner, wherein operating the casing print head to form a contiguous void extending radially across the casing tubular and the casing liner comprises operating the casing print head such that the third subset of nozzles ejects a disposable material to define the contiguous void extending radially across the casing tubular and the casing liner; and
performing a perforation operation comprising removing the disposable material.