An advanced stiff-string model used during casing wear simulation to evaluate the drillstring contact position at any given casing depth can reflect the actual downhole scenario more precisely. The model yields a more representative wall thickness reduction percentage along the casing string by estimating multiple groove positions at each cross section. The simulated casing wear severity is subsequently incorporated into tubular design calculations by amending critical dimensions for each stress criteria to represent the worn tubular operating limits. The integration process reduces the safety margin for the modeled loading conditions that the casing string is expected to withstand during the well's life cycle.

This paper highlights the different methodologies applied during casing wear simulation and discusses how to integrate the results into the casing design and stress analysis workflow to predict the critical failure mode for the investigated tubular string.

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