Wellbore casing liner printing
Provided is a wellbore casing liner printing system that includes a casing liner print head adapted 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 and adapted to rotate within the annular region and deposit material into the annular region to form a casing liner in the annular region. The casing liner print head including a first set of printing nozzles arranged in series in a radial direction, and a second set of printing nozzles arranged in series in the radial direction and offset from the first set of printing nozzles. The first set of printing nozzles adapted to eject a first casing liner material into the annular region and the second set of printing nozzles adapted to eject a second casing liner material into the annular region to form the casing liner of the first casing liner material and the second casing liner material.
1. 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 and configured to rotate within the annular region and deposit material into the annular region to form a casing liner in the annular region, the casing liner print head comprising:
a first set of printing nozzles comprising a first row of printing nozzles arranged in series along a first axis extending in a radial direction; and
a second set of printing nozzles comprising a second row of printing nozzles arranged in series along a second axis that is offset from the first axis,
the first set of printing nozzles configured to eject a first casing liner material into the annular region and the second set of printing nozzles configured to eject a second casing liner material into the annular region to form the casing liner of the first casing liner material and the second casing liner material.
2. The system of claim 1 , wherein the casing liner print head is configured to be advanced along a length of the wellbore and to eject the first and second casing liner materials along a length of the annular region to form the casing liner along the length of the annular region.
3. The system of claim 1 , wherein the second axis is parallel to the first axis.
4. The system of claim 1 , wherein the second set of printing nozzles are arranged to trail the first set of printing nozzles during rotation of the casing liner print head about the casing pipe.
5. The system of claim 1 , wherein the casing liner print head comprises a cylindrical collar configured to be disposed about the casing pipe, and wherein the first set of printing nozzles and the second set of printing nozzles extend radially from the cylindrical collar.
6. The system of claim 1 , wherein the first set of printing nozzles are configured to eject the first casing liner material into the annular region in a longitudinal direction parallel to a longitudinal axis of the wellbore, and the second set of printing nozzles are configured to eject the second casing liner material into the annular region in the longitudinal direction.
7. The system of claim 1 , wherein the first casing liner material comprises a cementitious material.
8. The system of claim 7 , wherein the first casing liner material comprises casing cement.
9. The system of claim 7 , wherein the second casing liner material comprises a material other than the cementitious material.
10. The system of claim 7 , wherein the second casing liner material comprises a gas, liquid or solid.
11. The system of claim 7 , wherein the second casing liner material comprises a polymer.
12. The system of claim 1 , wherein the second casing liner material deposited is configured to form a void within the first casing liner material deposited.
13. The system of claim 1 , wherein the second casing liner material has a Young's Modulus that is less than a Young's Modulus of the first casing liner material.
14. 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, the casing liner print head comprising:
a first set of printing nozzles comprising a first row of printing nozzles arranged in series along a first axis extending in a radial direction; and
a second set of printing nozzles comprising a second row of printing nozzles arranged in series along a second axis that is offset from the first axis; and
rotating the casing liner print head within the annular region and depositing material into the annular region to form a casing liner in the annular region, the depositing comprising the first set of printing nozzles ejecting a first casing liner material into the annular region and the second set of printing nozzles ejecting a second casing liner material into the annular region to form the casing liner of the first casing liner material and the second casing liner material.
15. The method of claim 14 , further comprising advancing the casing liner print head along a length of the wellbore and ejecting the first and second casing liner materials along a length of the annular region to form the casing liner along the length of the annular region.
16. The method of claim 14 , wherein the second axis is parallel to the first axis.
17. The method of claim 14 , wherein the second set of printing nozzles trail the first set of printing nozzles during rotation of the casing liner print head about the casing pipe.
18. The method of claim 14 , wherein the casing liner print head comprises a cylindrical collar with the first set of printing nozzles and the second set of printing nozzles extending radially from the cylindrical collar, and wherein disposing a casing liner print head in the annular region located between the casing pipe disposed in the wellbore and the wall of the wellbore comprises disposing the cylindrical collar over the casing pipe.
19. The method of claim 14 , wherein the first set of printing nozzles eject the first casing liner material into the annular region in a longitudinal direction parallel to a longitudinal axis of the wellbore, and the second set of printing nozzles eject the second casing liner material into the annular region in the longitudinal direction.
20. The method of claim 14 , wherein the first casing liner material comprises a cementitious material.
21. The method of claim 20 , wherein the first casing liner material comprises casing cement.
22. The method of claim 20 , wherein the second casing liner material comprises a material other than the cementitious material.
23. The method of claim 20 , wherein the second casing liner material comprises a gas, liquid or solid.
24. The method of claim 20 , wherein the second casing liner material comprises a polymer.
25. The method of claim 14 , wherein the second casing liner material deposited forms a void within the first casing liner material deposited.
26. The method of claim 14 , wherein the second casing liner material has a Young's Modulus that is less than a Young's Modulus of the first casing liner material.
27. A wellbore liner printing system comprising:
a casing liner print head configured to be disposed in an annular region located between a tubular member disposed in a wellbore of a hydrocarbon well and a wall of the wellbore and configured to rotate within the annular region and deposit material into the annular region to form a casing liner in the annular region, the casing liner print head comprising:
a first set of printing nozzles comprising a first row of printing nozzles arranged in series along a first axis extending in a radial direction; and
a second set of printing nozzles comprising a second row of printing nozzles arranged in series along a second axis that is offset from the first axis,
the first set of printing nozzles configured to eject casing cement into the annular region and the second set of printing nozzles configured to eject integrated structure material into the annular region to form the casing liner of the casing cement and voids in the casing cement that are defined by the integrated structure material.
28. The system of claim 27 , wherein the casing liner print head is configured to be advanced along a length of the wellbore and to eject the casing cement and the integrated structure material along a length of the annular region to form the casing liner along the length of the annular region.