Analysis of Casing Fatigue Failure During Multistage Fracturing Operations

Tubular fatigue failures have been commonly reported in geothermal and heavy oil wells with cyclic steam injection operations. Recently, possible fatigue failures in casing connections during multistage fracturing operations have also been reported in the literature. These occurrences raised the question of whether casing fatigue is a real problem, even for shale plays. This paper describes fatigue modeling and analysis of the casing connections during fracturing operations to provide additional information about this issue. The varying casing temperature and temperature-dependent casing loads were obtained using numerical simulations of cyclic hydraulic fracturing operations, such as end of cementing → shut-in → plug and perforation → stimulation (stage 1) → shut-in → plug and perforation → stimulation (stage 2) etc. These simulations were accomplished using commercial software, including a thermal flow simulator and stress analyzer. The previously simulated casing loads were then used to calculate localized stress amplitude, strain amplitude, and maximum stress. Finally, the localized strain and stress values were used as input parameters of fatigue models to estimate the lifetime (cycles) of selected casing sections. The fatigue model was implemented in a computer program and integrated with the thermal flow and stress analysis commercial software, and a field case (shale oil/gas well) was studied with the integrated fatigue simulation. The predicted casing connection fatigue behavior closely correlates with failure field data, and the casing failure location was analyzed and explained in terms of environmental and cyclic stress/strain conditions. The corrosion fatigue appears important for the acidic environment during hydraulic fracturing. The field case study indicates that the fatigue analysis, coupled with numerical thermal-flow analysis and multistring stress analysis, can provide more insight into the failure of casing connections during fracturing operations. Consequently, it is valuable to include fatigue analysis during the wellbore tubular design when multistage fracturing and/or refracturing operations are involved.