According to the tubing string failure statistics in the oilfield, fatigue crack of tubing joint thread in high temperature high pressure (HTHP) ultradeep gas wells remains a problem because it can cause tubing strength degradation, tubing fracture failure, well workover, and even well abandonment. In order to obtain a better understanding of tubing thread fatigue and quantify the fatigue life of tubing joint thread in HTHP ultradeep wells, experimental study, elastic–plastic mechanical simulation, and multi-axial fatigue calculation are carried out in this paper. Based on the similarity theory, the vibration mechanical testing device of the tubing string is designed, and the multi-axial load of the tubing joint thread in the actual working condition is obtained. Meanwhile, tubing joint BX1 thread model is established with ansys software, and the stress distribution of tubing joint thread is analyzed on the boundary condition acquired from experiments of vibration test of tubing string. Finally, according to the multi-axial fatigue theory, the fatigue life prediction value of the tubing thread made of Super 13Cr110 and Super 15Cr125 is compared and analyzed. The work presented in this paper can provide theoretical method and technological basis for the study on the frequent failure mechanism of tubing joint thread in HTHP ultradeep gas wells.

Casing wear is a serious problem in highly-deviated wells because serious wear will lead to casing deformation, drilling tool sticking and failure of subsequent operations. The purpose of this paper is to predict casing wear depth and evaluate its effect on casing strength degradation in highly-deviated well drilling operation. Special attention has been given to the algorithm to achieve the prediction and evaluation. The effect of tool joint on contact force distribution is considered in contact force model. Then a wear depth prediction model and its solution method are proposed based on crescent-shaped wear morphology and wear-efficiency model. Besides, strength degradation of worn casing is analyzed in bipolar coordinate system and the model is verified by finite element method. Therefore, the technology of casing wear prediction and residual strength evaluation is completed systematically. Then, to apply casing wear prediction and residual strength evaluation technologies to an actual highly-deviated well, casing wear experiment and friction coefficient experiment are carried out to obtain wear coefficient and friction coefficient. Finally, based on the established models as well as experimental results, the distribution of casing wear is predicted and residual strength is evaluated. The method presented in this paper will contribute greatly to casing wear prediction and evaluation in highly-deviated wells.

Summary: Among the casing failures in 46 ultradeep wells in a particular block, 11 ultradeep wells had the same casing failure forms occur during the drilling of cement plugs. The casing failure forms are local bending deformation and local internal pressure damage, which eventually led to a local burst failure of the casing in the 11 typical ultradeep wells. Therefore, a casing strength checking model is established to investigate the primary reasons for the local burst failure of the casing and the local burst failure mechanism of the casing. A case study is performed on casing in typical ultradeep wells with force conditions to evaluate the safety state of the casing and make necessary recommendations to improve its safety. The obtained results indicate that an abnormally high dogleg (AHD), a decrease in the temperature at the bottom of the casing, and an annulus trap space are the characteristics of typical ultradeep wells, and the local burst failure of the casing is caused by the coupled superposition impact of a decrease in the annulus pressure buildup (APB), the casing temperature effect, and the magnification effect of the casing bending stress. The safety factor of the casing can be increased by changing the operation parameters and the material properties of the casing. To address the casing failure problems during the drilling of cement plugs in typical ultradeep wells, the protection and monitoring of the seal quality of the cement sheath should be improved to avoid expansion of the well diameter and formation of the annulus trap space. The casing strength and the injection temperature of the drilling fluid can be increased, and the drilling fluid displacement can be decreased.