During their life cycle, high‐pressure gas wells experience circulating working fluid, acid fracturing, blow off, and other development and production conditions. This may lead to the failure of the cement sheath integrity and result in sustained casing pressure (SCP). Therefore, we explored the failure types and mechanisms of the cement sheath using different wellbore operating procedures. In this study, we used the downhole packer as the demarcation point; the integrity of the cement sheath at the upper and lower parts of the packer was tested through a self‐developed wellbore simulation device, which is based on the equivalent theory of cement sheath interface differential pressure. Results showed that the lower part of the single‐layer cement sheath underwent compressive strength failure due to the pressure drop in the wellbore before perforation. Plastic deformation of the cement sheath occurred during acid fracturing. In addition, the cooling effect caused by the acid fracturing led to the bonding failure at the cement sheath's second interface. The double‐layer cement sheath's inner‐layer cement sheath was subjected to tensile failure – attributed to high‐pressure – and the outer‐layer cement sheath maintained its integrity under the pressure changes. Considering the risk factors associated with integrity failure, we propose an engineering optimization plan in the study. The retest results showed that reducing the internal casing pressure and temperature and controlling the annular pressure in the production stage was beneficial in ensuring the integrity of the cement sheath at the lower and upper parts of the packer, respectively. The research results provided an important reference for ensuring the integrity of the cement sheath of high‐pressure gas wells.
19 January 2024 in Construction and Building Materials
The plastic deformation and interface micro annulus of oil-well cement during acid fracturing are key reasons for the failure of the wellbore seal and sustained casing pressure. However, most of the existing research ignores the influence of the wellbore cooling effect during acid fracturing, owing to which, the design conditions in the theoretical analysis may be inconsistent with those of the actual wellbore, and the calculation results may be biased. In this study, a novel elastoplastic mechanical model of the cement sheath was established. This model can analyze the yield state of the cement sheath under the influence of three-dimensional principal stress and consider the effect of the differential temperature stress on the interface debonding of the cement sheath from the beginning to the end of acid fracturing. Moreover, the generation mechanism and development law of the interface micro annulus were clarified. The findings indicated that the influence of the intermediate principal stress cannot be ignored; otherwise, the elastoplastic analysis results of the cement sheath may be conservative. During acid fracturing, the casing–cement sheath interface is influenced by the differential temperature stress, and the interface is debonded; however, a micro annulus is not generated. The debonding of the cement sheath–formation interface and micro annulus occurs only when the cement sheath is completely plastic. After acid fracturing, the interface micro annulus is likely to be generated at the casing–cement sheath interface, and the presence of the differential temperature stress may increase the formation risk of the interface micro annulus. The research results can provide theoretical guidance for the prediction of oil-well cement sheath interface seals under acid-fracturing conditions.