Research on the Evolution of Wellbore Pressure During Managed Pressure Casing Running

With the continuous advancement of deep and ultra-deep well drilling technologies, formations with complex pressure windows are becoming increasingly common. During casing running operations, it is necessary to ensure both leak prevention in loss-prone formations and pressure stabilization in high-pressure formations, demanding increasingly higher accuracy in wellbore pressure calculation. This study establishes a wellbore pressure calculation model for managed pressure casing (MPC) running in deep wells, specifically addressing the scenario where a multi-density gradient drilling fluid column exists in the annulus after tripping out. The model’s novelty lies in integrating transient surge pressure calculation with a dynamic fluid column structure model that tracks the displacement of multi-density drilling fluid layers during casing running. The governing equations based on one-dimensional unsteady flow theory are solved using the method of characteristics with adaptive time stepping and a grid independence study confirming the discretization scheme. Quantitative analysis reveals that casing running speed is the dominant factor affecting surge pressure; when the speed increases from 0.5 m/s to 1.5 m/s, the surge pressure increases from approximately 1.2 MPa to 3.5 MPa at a 2000 m depth. Drilling fluid properties also significantly influence surge pressure: increasing the density from 2.0 g/cm3 to 2.22 g/cm3 results in a surge pressure increase of approximately 0.6 MPa; increasing the yield value from 2.85 Pa to 15 Pa leads to an increase of about 1.1 MPa; the surge pressure shows a clear increasing trend with both the consistency coefficient and flow behavior index. Casing running depth affects the buffering effect of the bottomhole flow channel; when the casing is run to 7000 m, the surge pressure is approximately 0.5 MPa higher than at 2000 m. Taking a typical deep well (8578 m) with a negative pressure window of −0.008 g/cm3 as an example, three casing running speed plans were designed and evaluated. Plan 1 was selected with running speeds ranging from 0.16 m/s in the upper section to 0.115 m/s in the lower section, maintaining the equivalent circulating density (ECD) within the safe density window throughout the entire operation. Field application of this plan proceeded smoothly without any occurrences of lost circulation or overflow. This provides a practical basis for MPC running technology in deep wells with narrow or negative pressure windows.