The failure probability of casing collapse is high in HPHT gas wells because of the cementing complications and the operational environment. In the life of a well, the cement sheath not only provides zonal isolation but also supports casing and increases casing collapse resistance. Due to the high temperature high pressure conditions, the cement sheath plays a more important role in maintaining wellbore integrity. During the production process in HPHT gas wells, the pressure differential inside the casing and the surrounding formation is larger than the conventional wells, this presents a greater challenge to the casing integrity.

Casing eccentricity, cement voids and cement channels usually are cementing complications in HPHT gas wells. Pore-pressure was also considered in this study. In the analysis, the finite element method was used and 2D simulation model was built to study the effect of cementing complications on casing collapse resistance. In the study, two cement systems, brittle cement system and elastic cement system, were used to analyze the effect of the cement property on the casing collapse resistance. In the sensitivity analysis, void location, void size and shape, casing eccentricity, pore pressure, casing internal pressure, horizontal stress, cement Young’s Modulus, cement Poisson ratio, hole diameter, and formation temperature were considered to study their effect on casing collapse resistance.

The results showed that an improvement of collapse resistance of 12% is observed in various conditions in elastic cement system. Casing collapse resistance is very sensitive to void location, cement Poisson’s Ratio, cement Young’s Modulus, and pore-pressure. Casing eccentricity and voids shape have minor effect on the casing collapse resistance. Simultaneous cement channeling and casing eccentricity is the worst case scenario in casing collapse resistance.

This study gives a better understanding of casing collapse failure in HPHT gas wells and helps improve cement and casing design to maintain wellbore integrity that can be expected to last for the life of the well.

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