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Mechanical Expansion of Steel Tubing as a Solution to Leaky Wellbores

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Casing Wear and Wear Factors: New Experimental Study and Analysis.

Omer Alnoor Osman¹, Necar Merah^1,2, Mohammed Abdul Samad^1,2

¹Department of Mechanical Engineering, King Fahd University of Petroleum and Minerals, Dhahran 31261, Saudi Arabia.

Materials (Basel, Switzerland)

|October 14, 2022

Summary

Drilling fluid type significantly impacts casing wear. Oil-based fluids reduce casing wear compared to water-based fluids, with dry conditions causing the most wear.

Keywords:

P110 steel casing wear factor friction oil-based mud water-based mud wear mechanisms

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Area of Science:

Materials Science
Mechanical Engineering
Petroleum Engineering

Background:

Casing wear is a critical factor in drilling operations, affecting equipment longevity and operational costs.
Understanding wear mechanisms under various conditions is essential for optimizing drilling practices.

Purpose of the Study:

To experimentally quantify casing wear under different lubrication conditions and operational parameters.
To investigate the influence of oil-based vs. water-based fluids on casing wear.
To analyze wear mechanisms using surface analysis techniques.

Main Methods:

Experimental wear tests using P110 steel casing samples and actual drill pipe joints (DPJ).
Simulated dry, oil-based, and water-based lubrication conditions.
Varied side loads (1000 N, 1400 N) and DPJ speeds (115, 207 rpm).
Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS) for surface analysis.

Main Results:

Casing wear volume and wear factor were over twice as high with water-based fluids compared to oil-based fluids.
Dry conditions resulted in the highest wear volume and wear factor.
Increased normal load increased wear factor, while increased rotational speed reduced it.
SEM/EDS revealed abrasion and delamination under dry conditions; adhesion and abrasion under oil-based lubrication; particle transfer from oil-based lubricants and contaminants in water-based lubricants.

Conclusions:

Oil-based drilling fluids offer superior protection against casing wear compared to water-based fluids.
Drilling fluid selection and operational parameters (load, speed) are crucial for minimizing casing wear.
Wear mechanisms are dependent on lubrication conditions and operational parameters, influencing material transfer and surface damage.