Casing damage is a common problem encountered during oil and gas field development due to the complex stress state of the casing. Despite the large number of studies focusing on this problem, the mechanism of non-uniform in-situ stress-induced casing damage in a low-permeability reservoir is still unclear. In this study, casing damage due to non-uniform in-situ stress variations was investigated, and then the tectonic stress coefficients in the study area were determined by an in-situ stress inversion technique, which led to the derivation of formulas for calculating the maximum and minimum horizontal in-situ stresses. Subsequently, finite element numerical simulations were performed to assess the stress distribution during the formation of the casing cement sheath in a G155 block, a typical low-permeability reservoir. The results indicate that casing damage is caused not only by non-uniform in-situ stresses but also by various additional creep-induced loads. Subsequent finite element investigations into casing behavior under mudstone creep conditions indicated that immersion of mudstone in water instigated further shearing and deformation of the casing, culminating in premature well failure prior to water inundation. Notably, Von Mises stress levels exhibited a positive correlation with injection production ratios, with values exceeding critical thresholds leading to distinct modes of mechanical failure including shear-induced deformations, longitudinal tensile stress, and localized yielding near water wells. Maintenance of an optimal injection production ratio is identified as a key strategy for prolonging casing longevity in the region. To this end, recommendations include augmenting the casing wall thickness or enhancing the steel pressure specifications to mitigate casing damage progression, thereby extending the operational lifespan. This research serves as a pivotal theoretical framework for informing future development strategies aimed at mitigating and preempting casing failures in a low-permeability reservoir.
