Work

Finite Element Modeling of Casing Connection Integrity in Storage and High-Temperature Wells

Year: 2025

Type: article

Abstract: This paper presents a novel numerical–experimental workflow to evaluate the sealability of casing connections in geothermal and underground gas storage wells, where cyclic thermal and pressure loads challenge conventional qualification methods. The approach combines experimental make-up and cyclic loading tests with finite element analysis by explicitly modeling the connection geometry and the contact conditions. Validation against experimental data shows good agreement in seal ovality, roughness, and wear, confirming the predictive reliability of the model. Results indicate that initial geothermal discharge and seasonal storage cycles generate the highest von Mises stresses, expressed as a percentage of the material’s yield strength (%VMS), mainly under combined tensile and internal pressure loading. After the first make-up, subsequent cycles reduced seal contact pressure and length, increasing leakage risk; however, repeated loading improved tribological behavior, enhancing sealability despite occasional galling. The proposed framework enables accurate prediction of connection integrity under extreme cyclic conditions, offering a novel tool to optimize design and streamline qualification testing.

Source: Processes

DOI: 10.3390/pr13113418

Authors: Jose Manuel Pereiras, Oscar Grijalva Meza, Javier Holzmann Berdasco

Institutions: Universidad de Buenos Aires, Clausthal University of Technology

Language: English

Topic: Drilling and Well Engineering

Subfield: Ocean Engineering

Field: Engineering

Domain: Physical Sciences

SDG: Industry, innovation and infrastructure

Open Access status: gold

Estimated APC paid: $2,896