Experimental study on the channeling leakage properties of compact-size casing-cement sheath-stratum assembly in deep and ultra-deep wells

• Published in: Process safety and environmental protection 2023-10, Vol.178, p.881-892
• Main Authors: Hou, Duo, Zhang, Zhi, Geng, Yanan, Wu, Zhiqiang, Yang, Huabo
• Format: Article
• Language: English
• Subjects: Annulus pressure; Casing; Cement sheath; Channeling-leakage; Sealing integrity; Stratum rock; Thermal stress; Well integrity
• ISSN: 0957-5820; 1744-3598
• DOI: 10.1016/j.psep.2023.08.016

Within deep and ultra-deep wells, the casing-cement sheath-stratum rock assembly(CCS) bears thermal, mechanical, and chemical multi-field coupling, causing some damage or creating micro-annular gaps at the interface between the casing and the cement sheath as well as the interface between the cement sheath and the stratum. Radial and axial cracks in the cement sheath occur, and even channeling-leakage channels form due to shear failure. These are critical reasons for sustained annular pressure and the risk of wellbore sealing integrity. This paper establishes an evaluation device for channeling-leakage properties of a compact-size CCS assembly. It observes the microstructure and morphology characteristics of cement sheath integrity, tests the channeling-leakage pressure and paths of two cement slurries, and explores the relationships between the channeling-leakage properties of the assembly and the damage to the cementing interfaces as well as the cracking characteristics of cement sheath. Results showed that the proposed method was suitable for evaluating unpredictable security risks of CCS assembly caused by a complex load in deep and ultra-deep wells, such as overload-induced cracking, cementing interface unsealing, and channeling-leakage of the cement sheath. The findings revealed the evolution law from deformation points to cracks and channeling-leakage channels inside the cement sheath under the action of load and proposed technical measures to avoid channeling-leakage of the cement sheath. This research provides a theoretical basis and testing method for evaluating the wellbore sealing integrity and formulating technical safety measures for deep and ultra-deep wells.