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Casing Wear Prediction with Considering Initial Internal Casing Eccentricity

  • Research Article - Petroleum Engineering
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Abstract

Casing components in drilling engineering possess problematic internal eccentricity due to mismachining and circumferential wear in the prophase. Said eccentricity markedly affects the accuracy of casing wear prediction. In this study, casing wear efficiency theory and a novel geometric description are used to establish a wear prediction model for the initial internal casing eccentricity in extended reach drilling (ERD). Composite casing wear analysis is conducted to explore wear in the same groove and across a series of different grooves; then, residual depth (RD) is used to evaluate wear in terms of risk. The model parameters are subjected to sensitivity analysis, and a case study is conducted to validate the model. The results show that slight eccentricity significantly affects the accuracy of casing wear prediction and that worn casing depth increases as drilling footage increases in a manner strongly dependent on composite wear. The RD percentage of the worn casing wall markedly decreased as initial internal casing eccentricity increased, particularly at the most dangerous angle; at footage of 6000 m, the RD of worn casing wall by drill string A and C combination was minimal. Initial internal casing eccentricity should be properly accounted for in ERD processes to ensure drilling safety.

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Abbreviations

a :

is the AR of the rotary drill string, mm

\(a_1 \) :

is the first AR of the rotary drill string, mm

\(a_2 \) :

is the second AR of the rotary drill string, mm

\(a_\mathrm{c}\) :

is the critical AR of the rotary drill string, mm

A :

is the worn casing area, \(\hbox {m}^{2}\)

\(A_1 \) :

is the worn casing area by the first tool joint, \(\hbox {m}^{2}\)

\(A_2 \) :

is the worn casing area by the second tool joint, \(\hbox {m}^{2}\)

\(A_\mathrm{f} \) :

is the total worn casing area, \(\hbox {m}^{2}\)

\(A_\mathrm{i} \) :

is the worn casing area of the jth casing span above the end of the build angle or end of the drop angle, \(\hbox {m}^{2}\)

\(d_\mathrm{cw} \) :

is the worn casing depth, mm

\(d_\mathrm{cw1} \) :

is the worn casing depth by the first tool joint, mm

\(d_\mathrm{cw2} \) :

is the worn casing depth by the second tool joint, mm

\(d_\mathrm{cwf} \) :

is the total worn casing depth, mm

\(d_\mathrm{cwc} \) :

is the critical worn casing depth, mm

\(d_\mathrm{re} \) :

is the RD of the initial internal casing eccentricity, mm

\(D_\mathrm{f} \left( \theta \right) \) :

is the RD of the worn casing wall at an arbitrary phase angle, degrees

\(f_\mathrm{w} \) :

is the casing wear factor, dimensionless

\(F_{i} \) :

is the average axial force corresponding to \(A_i \), N/m

\(L_\mathrm{s} \) :

is the length of a single drill string, m

m :

is the number of drill strings, dimensionless

\(n_j \) :

is the rotary table revolution rate from \(\left( {j-1} \right) L_\mathrm{s} \) to \(jL_\mathrm{s}\), r/min

\(N_j \) :

is the contact force between the drill string and the inner casing wall, N/m (there are many forms of contact force that can be calculated by various means [23])

\(q_j \) :

is the buoyant weight of the jth drill string passing the end of the build or drop angle, N/m

\(R_\mathrm{co} \) :

is the OR of the casing, mm

\(R_\mathrm{ce} \) :

is the IR of the casing, mm

\(\hbox {Rop}_j \) :

is the bit penetration rate from \(\left( {j-1} \right) L_\mathrm{s} \)to \(jL_\mathrm{s} \), m/h

\(R_\mathrm{tj}\) :

is the OR of tool joint, mm

\(R_\mathrm{tj1}\) :

is the first OD of the tool joint, mm

\(R_\mathrm{tj2}\) :

is the second OD of the tool joint, mm

\(R_\mathrm{tj}j\) :

is the OR of jth tool joint, m

w :

is the worn half width, mm

\(w_1 \) :

is the first worn half width, mm

\(w_2 \) :

is the second worn half width, mm

\(w_\mathrm{c}\) :

is the critical worn half width, mm

\(\alpha \) :

is the angle of inclination, degrees

\(\alpha _j \) :

is the angle of inclination from \(\left( {j-1} \right) L_\mathrm{s} \) to \(jL_\mathrm{s} \), degrees

\(\gamma _\mathrm{ls} \) :

is the angle range of the safe zone

\(\gamma _\mathrm{md} \) :

is the angle range of the dangerous zone

\(\Delta A\) :

is the worn area residue for judging whether the composite CWGD is increased or not, \(\hbox {m}^{2}\)

\(\varepsilon \) :

is the inner diameter casing eccentricity caused by circumferential wear of the drill string and defects in manufacturing processes, mm

\(\theta \) :

is phase angle displacement, which starts widdershins from the left X semiaxis, degrees

\(\mu \) :

is the circumferential friction coefficient, dimensionless

\({\mu }'\) :

is the axial friction coefficient, dimensionless

\(\chi _i \) :

is the average radius of curvature corresponding to \(A_i \), m

AR:

apparent radius

CWEM:

casing wear efficiency model

CWGD:

casing wear groove depth

ERD:

extended reach drilling

ERWs:

extended reach wells

IR:

inner radius

N:

CWEM-nonlinear casing wear efficiency model

OD:

outside diameter

OR:

outside radius

RD:

residual depth

SOC:

Shell Oil Company

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Acknowledgements

The authors gratefully acknowledge the financial support from the Natural Science Foundation of China (Grant Number: 51521063). This research was also supported by other projects (Grant Numbers: 2017ZX05009-003 and 2016YFC0303303).

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Authors and Affiliations

  1. MOE Key Laboratory of Petroleum Engineering, China University of Petroleum, Beijing, 102249, China

    Leichuan Tan, Deli Gao & Jinhui Zhou

  2. State Key Laboratory of Petroleum Resources and Engineering, Beijing, 102249, China

    Leichuan Tan, Deli Gao & Jinhui Zhou

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  1. Leichuan Tan
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Correspondence to Leichuan Tan or Deli Gao.

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Tan, L., Gao, D. & Zhou, J. Casing Wear Prediction with Considering Initial Internal Casing Eccentricity. Arab J Sci Eng 43, 2593–2603 (2018). https://doi.org/10.1007/s13369-017-2890-7

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