Casing recovery in offshore well abandonment is challenging due to the cementation force between the casing and the cement sheath. To improve the well abandonment operation efficiency and success rate, in this paper, a newly developed metal casing recovery method for the well abandonment process and a revolutionary tool were first proposed. The proposed design of a high-pressure fluid-controlled device is discussed in detail regarding its working mechanism and structural composition. After describing the configuration of the eccentric roller mechanism and operational principle of the hydraulic rubblizer, static modeling for a mechanical part is analyzed by considering the nonlinear constitutive model of cement materials behavior, and elastic deformation of the casing. Moreover, both the linear and nonlinear behaviors of the extrusion process acting on casing and cement are analyzed and incorporated. Experimental results showed that the pulling-out force of casing is decreased by up to 61.1% under 35 MPa working pressure compared with the absence of the tool. As a result, the total well abandonment time is reduced by at least 50% compared with conventional operations. The results of this study are expected to serve as a theoretical basis for optimizing the structural and hydraulic parameters of hydraulic rubblizer.
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Zhang et al. (2024) studied this question.
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