With the goal to increase time and cost efficiencies across multiple segments while maintaining safety and environmental stewardship, a new threaded and coupled connection addressing a set of operating challenges was developed through collaboration between an operator and a casing and connection manufacturer. This paper focuses on the collaborative method used to develop a connection from concept to field deployment.

In the Permian Basin, the operator routinely used a premium connection that allowed for adequate clearance inside and below an intermediate drilling liner. Through its features, this premium connection exceeded the application requirements, resulting in the operator and casing and connection manufacturer identifying the necessity for a new connection capable of withstanding the anticipated loads during casing installation, completion, and production, while offering an adequate radial clearance for cementing and improved running efficiencies.

To determine the required performance of the new connection, installation, completion and production inputs were analyzed for validation of the connections performance properties. This included a string design analysis to ensure the connection would be fit for the most demanding scenario expected, a comprehensive torque, drag, and fatigue analysis to determine casing installation loads, and a cementing analysis to understand the effect of the new connections outer diameter on cement placement and equivalent circulating density. The paper presents a detailed discussion of this analysis and its result.

Main design inputs were defined, and a prototype was selected to undergo a systematic validation program, that included full scale testing in a lab and on a rig, as well as a three well pilot field trial to ensure optimum performance.

Through collaboration, a new connection was developed with inputs from the end-user while considering specific requirements generated by their well design and anticipated loads during the well life. We show the process, from the design stage and validation, together with important parameters, leading to successful field deployment. This approach is currently replicated across other plays with different requirements to address field-wide challenges.

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