Residual Collapse Strength of Worn and Corroded Tubes: A Data-Driven and Numerical Modeling based Approach
Well Integrity, Tubular Collapse, Instability, Well Logging, Structural Reliability
This work proposes a methodology for estimating the residual strength of tubes damaged by wear and/or corrosion in oil wells, involving geometric inspection of the elements and their numerical modeling in a probabilistic approach. The objective is to provide a robust assessment of the structural integrity of tubular components in a high-complexity and high-risk environment, such as the Brazilian pre-salt region. Casing and production/injection columns are importante safety barrier elements, playing crucial structural roles and isolating the well and formation to prevent unexpected fluid flow.Wear and corrosion in these tubular components occur during diferente operations throughout their lifecycle, and they are conservatively considered in the design phase to avoid integrity loss situations. However, there is a lot of uncertainty in these predictions. Modern inspection equipment available in the market, such as ultrasonic and electromagnetic logging tools, have allowed for the assessment of the actual state of in-service tubes. Tube radius, thickness, and mass loss are the parameters measured along the well columns. Proper interpretation of this data allows for the identification of tube damage and quantification of the corresponding severities. A methodology is proposed for characterizing the cross-sectional geometry of tubes based on inspection data, in the presence of measurement uncertainties. Bidimensional nonlinear Finite Element Method models are used to estimate the residual colapse strength of the tubes. Additionally, a probabilistic analysis of the residual geometry of damaged tubes is presented, considering random variables related to damage configuration parameters such as maximum depth and position. The results obtained lead to the conclusion that the initial geometric configuration of the damaged tube can result in significant variations in residual strengths for different damage parameters, including depth, radius, position, and distribution. It is worth noting that the analytical models found in the literature only partially consider these factors, not in their entirety. A case study is developed using real ultrasound inspection data to demonstrate the application of the proposed methodology, comparing the results with reference values.