Numerical Evaluation of Performance and Applicability of Casing Connections Wells Subject to Installation and Service Loads
Well Casings, Threaded Connections, Connection Integrity, Mechanical Contact, Finite Element Method.
In oil and gas wells, tubular components of casing strings are connected through threading. Due to their crucial role in the well structure, these connections are considered critical points that may be directly related to integrity loss events. Threaded casing connections, when subjected to installation and service conditions, are exposed to complex distributions of non-uniform multiaxial stresses, which, combined with thermal gradient, can induce failure in these structural elements. The API/TR 5C3 (2018) establishes equations for analytically calculating the strength of API connections of round, buttress, and extreme-line types with respect to certain failure modes. Due to limitations in the application of these API connections, proprietary design connections, also known as premium connections, have emerged, which offer better structural and sealing performance. Numerical modelling through the finite element method is common in the design and qualification of API and premium connections, as current analytical models are considered limited, and considering the high costs of experimental tests. In view of this, this work seeks to reproduce two-dimensional axisymmetric models of API connections of the types round, buttress and models inspired by premium connections, using the finite element method through the commercial software ABAQUS® CAE. In the parametrized models created using PYTHON scripts, geometric nonlinearities are considered due to the presence of large displacements and/or deformations, allowing for improved adaptability between contact surfaces. Additionally, physical nonlinearities are considered, implemented based on the constitutive model from ASME VIII sec. 2 (2023). The analysis accounts for axial tensile and compressive loads, internal and external pressures, temperature, make-up torque preloads, as well as combinations thereof. Regarding the nonlinearity associated with the mechanical contact model, frictional contact with both tangential and normal behaviour is considered, allowing for finite sliding and separation between threads in the presence of friction. In general, this modelling aims to assess the performance and applicability of casing connections under conditions analogous to installation and service scenarios. This modelling approach is also capable of generating supplementary results related to the integrity analysis of connections subjected to combined loads, aiming to produce strength envelopes.