Maintaining casing integrity, in terms of downhole zonal isolations and well stability, is extremely important in oil/gas wells. Casing wear occurs not only in directional drilling, but also in vertical drilling with a slight deviation angle. In most hydrocarbon wells, deteriorated casing was reported from the onset of casing wear by the presence of friction force during the rotation of drillpipe. The friction force against the casing wall causes the reduction of casing strength. Furthermore, the rotation of drillpipe combined with corrosive drilling fluids could dramatically degrade the casing strength. We used a finite element analysis to focus on the stress evolution in worn casings. Comparison study between worn casing and perfect casing was conducted. Our study showed that the thermal load significantly increases the stress concentration of the worn casing in the wellbore. Finite element solutions indicated that the radial stress of the worn casing is not affected as much as the hoop stress. Along with the increased burst pressure or the elevated temperature, the unworn portion of the casing also suffers from severe compression stress. This work is important to broadening the understanding of well engineers through addressing the true stress profile of worn casing in cemented wellbore. 1. Introduction Casing wear in the oil and gas industry is recorded on a world basis. Rotation of drillpipe during the drilling process creates significant contact forces that result in the reduction of casing wall thickness. Thickness reduction of the casing wall weakens the burst and collapse resistances of casing, where stress concentration at the worn location is expected. Casing wear will be accelerated in the presence of corrosive fluids. Casing wear is a serious problem that is not limited to directional or extended wells. Because the contact pressure generated on the inner surface of the casing becomes much harder to control during the drill bit penetration into deep formations, worn casing is also found in vertical wells. The strength of the casing depends on the material and geometry of the casing; the calculation of the burst and collapse pressures of casing is given in the Appendix. All criteria indicate that the burst and collapse resistances strengthen with the increase of casing wall thickness. Within the limited information about the stress profile of worn casings, casing wear is analyzed alone in models without including cement sheath and formation. The stress profiles of worn casing developed by using the existing isothermal models [1] are
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