Casing damage in oil and water wells: Causes and prevention
Jiang-Feng Liu, Xin-Yue Zhang*, Li-Yuan Yu*, Xiao-Liang Wang, Yun-Hu Lu, Zi-Hao Zhang, Zhi-Jie Jian
Deep Resources Engineering. 2026, 3(1): 100200. 
doi.org10.1016j.deepre.2025.100200.pdf
Abstract: Casing damage represents a persistent and multifaceted challenge in oil and gas development, often manifesting as structural deformation, rupture, or seal failure. These issues not only compromise well integrity and production continuity but also pose environmental risks through potential hydrocarbon leakage. Despite extensive operational experience, the mechanisms underlying casing damage at various development stages remain poorly understood. This study presents a systematic investigation into the types and causes of casing damage arising during drilling, cementing, perforation, and water injection operations. It identifies the complex interplay among stress variations, thermal fluctuations, corrosive fluids, and mechanical disturbances as key contributors to casing failure. What distinguishes this work is its integrative analysis of stage-specific damage mechanisms, including cement slurry discontinuity, rock slippage due to injection-induced stress changes, and corrosion from high-salinity fluids. The study proposes targeted preventive and remedial strategies tailored to distinct damage types and operational contexts—such as enhanced casing materials, optimized perforation techniques, and dynamic injection control. For wells already affected, adaptive repair methods like plastic deformation shaping and precision sealing are examined for their effectiveness. By bridging engineering practice with a mechanistic understanding of casing failure, this research provides actionable insights for mitigating casing damage. Furthermore, it presents a forward-looking vision in which artificial intelligence and data-driven diagnostics facilitate predictive maintenance and intelligent field management, thereby improving oilfield safety, longevity, and productivity.
Highlights:
• Summarized the types of casing damage existing throughout the whole process of oilfield development.
• Analyzed the factors that may cause casing damage in different stages of oilfield development.
• Analyzed the preventive measures for casing damage in oil and water wells at different stages.
• Provided countermeasures for oil and water wells with existing casing damage.
Keywords: Casing damage in oil and water wells; Causes of casing damage; Preventive measures; Treatment measures
Cite: Liu, J.F.; Zhang, X.Y.; Yu, L.Y.; Wang, X.L.; Lu, Y.H.; Zhang, Z.H.; Jian, Z.J., Casing damage in oil and water wells: Causes and prevention, Deep Resources Engineering 2026, 3 (1): 100200. https://doi.org/10.1016/j.deepre.2025.100200
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