Wellbore Integrity After a Blowout: Stress Evolution Within the Casing-Cement Sheath-Rock Formation System

A robust evaluation of the casing-cement sheath-rock formation system is foundational in ensuring wellbore integrity throughout a well's lifecycle. Analytical theory for a multi-layer, thick-walled cylinder is used to evaluate the aggregate stress distributions within the casing-cement sheath-rock formation system, honoring boundary conditions of radial stress and displacement continuity. These stress distributions are adjusted for scenarios that a well may experience in its lifetime. Each layer of the casing-cement sheath-rock formation system is evaluated separately against various possible mechanical failure mechanisms, all of which can compromise wellbore integrity.

A blowout scenario after a mismanaged loss-of-well-control situation induces high stress loads in the casing-cement sheath-rock formation system, with the wellbore pressure rapidly decreasing during post-blowout discharge, followed by a rapid increase following successful well capping. Casing and cement sheath failures can expose the surrounding rock formation to the pressurized fluid inside the wellbore, risking hydrocarbons broaching the surface, or the seafloor. The aggregate stress distribution model is applied on a case study performed using parameters from the MC 252–1 “Macondo Well” blowout from April 20, 2010 in the deepwater Gulf of Mexico. The stress evolution suggests stability against mechanical failure mechanisms within the casing (collapse/burst and tensile/compressive), cement-sheath (inner or outer debonding, and shear cracking), and rock-formation layers (longitudinal or transverse tensile fracture initiation, along with shear-slippage along pre-existing faults in the near-well vicinity), throughout the blowout aftermath. Nevertheless, tendencies towards radial cracking and disking (tensile) failures were indicated for the cement-sheath layer as the system reaches radial stress and displacement continuity, after cement setting.