Research on Thread Seal Failure Mechanism of Casing Hanger in Shale Gas Wells and Prevention Measures

Abstract

The strength and sealing failure of the connecting thread of the casing head mandrel hanger causes huge economic losses. One of the major challenges is the thread seal failure mechanism of the casing hanger in the wellhead during pressure testing in shale gas wells. In order to analyze the failure causes of connecting threads and put forward improvement measures, a typical case of a well accompanied by a hanger seal failure is analyzed in this paper, and a series of material tests are carried out. The microstructure and mechanical properties of casing materials and hanger materials could meet the field requirements. It is concluded that both the hanger material and casing material are characterized with significant ductile fracture. A three-dimensional model of the hanger and casing system is established, and the mechanical behavior is calculated for the connecting thread under different working conditions. The results showed that the connection degree of the hanger–casing is insufficient at the torque recommended by the manufacturer because of the difference in wall thickness between the box thread of the hanger and the box thread of the joint according to the connection degree of the coupling casing. It is seen that the high contact pressure ring of zone three on the sealing surface plays an effective sealing role under the manufacturer’s recommended torque (20,465 N·m). Finally, when the torque is increased by 25%, the maximum contact pressure between the pin thread of the casing and the box thread of the hanger can fully meet the internal pressure from the wellbore pressure test and the internal pressure strength required for subsequent operations.