MASTER

Well Drilling

Casing Design

Casing Design
Why Run Casing? Types of Casing Strings Classification of Casing Wellheads Burst, Collapse and Tension Example Effect of Axial Tension on Collapse Strength Example
2

Read Applied Drilling Engineering, Ch.7

Casing Design
What is casing? Why run casing? Casing Cement

1. To prevent the hole from caving in 2. Onshore - to prevent contamination of fresh water sands 3. To prevent water migration to producing formation
4

Casing Design -

Why run casing, contd

4. To confine production to the wellbore 5. To control pressures during drilling 6. To provide an acceptable environment for subsurface equipment in producing wells 7. To enhance the probability of drilling to total depth (TD)
e.g., you need 14 ppg to control a lower zone, but an upper zone will fracture at 12 lb/gal. What do you do?
5

Functions of Casing Individually

Drive pipe
Provides a means of nippling up diverters Provides a mud return path Prevents erosion of ground below rig

Conductor pipe
Same as Drive pipe Supports the weight of subsequent casing strings Isolates very weak formations

Surface casing

Intermediate or protective casing Provides a means of

nippling up BOP Provides a casing seat strong enough to safely close in a well after a kick. Provides protection of fresh water sands Provides wellbore stabilization Usually set in the first abnormally pressured zone Provides isolation of potentially troublesome zones Provides integrity to withstand the high mud weights necessary to reach TD or next csg seat
7

Functions of Casing Individually

Functions of Casing Individually

Production casing
Provides zonal isolation (prevents migration of water to producing zones, isolates different production zones) Confines production to wellbore Provides the environment to install subsurface completion equipment

Liners
Drilling liners
Same as Intermediate or protective casing

Production liners
Same as production casing

Tieback liners
Tie back drilling or production liner to the surface. Converts liner to full string of casing

Types of Strings of Casing

Diameter 1. Drive pipe or structural pile
{Gulf Coast and offshore only} 150-300 below mudline.

Example 30

16-60

2. Conductor string. 100 - 1,600

(BML)

16-48

20

3. Surface pipe. 2,000 - 4,000

(BML)

8 5/8-20

13 3/8
9

Types of Strings of Casing

Diameter Example 9 5/8 7

4. Intermediate String 5. Production String (Csg.) 6. Liner(s) 7. Tubing String(s)

7 5/8-13 3/8 4 1/2-9 5/8

10

Example Hole and String Sizes (in)

Hole Size
36 26
Structural casing Conductor string

Pipe Size
30 20

17 1/2 12 1/4 8 3/4

Surface pipe

13 3/8 9 5/8 7
11

IntermediateString Production Liner

Example Hole and String Sizes (in)

Hole Size
36 26
Structural casing Conductor string

Pipe Size
30 20

17 1/2 12 1/4 8 3/4

Surface pipe

13 3/8 9 5/8 7
12

IntermediateString Production Liner

Example Hole and String Sizes (in)

Structural casing Conductor string 250 1,000 Mudline

4,000 Surface pipe IntermediateString Production Liner

13

Classification of CSG.
1. Outside diameter of pipe 2. Wall thickness 3. Grade of material
(e.g. 9 5/8) (e.g. 1/2)

(e.g. N-80)
LCSG)

4. Type to threads and couplings (e.g. API

5. Length of each joint (RANGE) (e.g. Range 3) 6. Nominal weight

(Avg. wt/ft incl. Wt. Coupling) (e.g. 47 lb/ft)
14


15

Length of Casing Joints

RANGE RANGE RANGE

1 2 3

16-25 ft 25-34 ft > 34 ft.

16

Casing Threads and Couplings

API round threads - short API round thread - long Buttress Extreme line Other See Halliburton Book...
17

{ CSG } { LCSG } { BCSG } { XCSG }

Rounded Threads * 8 per inch ~ Square Threads * Longer * Stronger Integral Joint * Smaller ID, OD * Costs more * Strong
18

19

23 lb/ft 26 lb/ft

N-80

20

API Design Factors (typical)

Required 10,000 psi 100,000 lbf 10,000 psi Collapse 1.125 Tension Burst 1.8 1.1 Design 11,250 psi 180,000 lbf 11,000 psi
21

Abnormal

Normal Pore Pressure 0.433 - 0.465 psi/ft

Abnormal Pore Pressure gp > normal

22

Design from bottom

23

Press. Gauge Wing Valve

X-mas Tree

Choke Box Master Valves

Wellhead
Hang Csg. Strings Provide Seals Control Production from Well

24

Wellhead

25

Wellhead

26

Casing Design
Tension Depth Burst Collapse Collapse STRESS
Burst: Burst Collapse: Tension: Assume full reservoir pressure all along the wellbore. Hydrostatic pressure increases with depth Tensile stress due to weight of string is highest at top
27

Tension

Casing Design - Tension

28

Tensile force balance on pipe body

Ften = yield * A s
29

Tensile force balance on pipe body Example 7.1:

Compute the bodyyield strength for 20in., K-55 casing with a nominal wall thickness of 0.635 in. and a nominal weight per foot of 133 lbf/ft.

Ften = yield * A s
30

Tensile force balance on pipe body

K55

Solution:
This pipe has a minimum yield strength of 55,000 psi and an ID of:
Ften = yield * A s

d = 20 .00 2 ( 0 .635 ) = 18 .730 in .

31

Tensile force balance on pipe body

Thus, the cross-sectional area of steel is
As =

( 20 2 18 . 73 2 ) = 38 . 63 sq .in .

and a minimum pipe-body yield is predicted by Eq. 7.1 at an axial force of:

Ften = yield * A s
Ften = 55,000 (38.63) = 2,125,000 lbf
32

Pipe Body Yield Strength

2 2 Py = (D d )Yp 4

where
Py = pipe body yield strength, lbf Yp = specified minimum yield strength, psi D = outside diameter of pipe, in d = inside diameter of pipe, in
33

Casing Design - Burst (from internal pressure)

4 Internal Yield Pressure for pipe 4 Internal Yield Pressure for couplings 4 Internal pressure leak resistance

Internal Pressure

34

Internal Yield Pressure for Pipe (Burst)

2 Yp t P = 0.875 D
where
P = internal yield pressure, psi Yp = minimum yield strength, psi t = nominal wall thickness, in D = O.D. of pipe, in

FT FP

FP = DLP FT = 2tLYP DLP = 2tLYP

2Y p t P= D
35

Example
For 7, 26 #/ft P-110 pipe
2 Yp t P = 0.875 D

(7 - 6.276) = 0.875 * 2 * 110,000 * 2*7 = 9,955

P = 9 ,960 psi

(to the nearest 10 psi)

agrees with Halliburton Tables.
36

Casing Design - Burst

Example Design a 7 Csg. String to 10,000 ft. Pore pressure gradient = 0.5 psi/ft Design factor, Ni=1.1 Design for burst only.
37

Burst Example
1. Calculate probable reservoir pressure.
p res psi = 0 .5 * 10 ,000 ft = 5,000 psi ft

2. Calculate required pipe internal yield pressure rating

p i = p res * N i = 5 ,000 * 1 . 1 = 5 ,500 psi
Ni = API Design Factor for BURST = 1.1
38

Example
3. Select the appropriate csg. grade and wt. from the Halliburton Cementing tables:
Burst Pressure required = 5,500 psi 7, J-55, 26 lb/ft has BURST Rating of 4,980 psi 7, N-80, 23 lb/ft has BURST Rating of 6,340 psi 7, N-80, 26 lb/ft has BURST Rating of 7,249 psi Use N-80 Csg., 23 lb/ft
39

40

23 lb/ft 26 lb/ft

N-80
41

Casing Design - Collapse

42

Collapse Pressure
The following factors are important: 4 The collapse pressure resistance of a pipe depends on the axial stress 4 There are different types of collapse failure

43

Collapse Pressure
There are four different types of collapse pressure, each with its own equation for calculating the collapse resistance:
4 Yield strength collapse

4 Plastic collapse 4 Transition collapse 4 Elastic collapse

44

Casing Design - Collapse

If Axial Tension is Zero:
Yield Strength Plastic Transition Elastic

J-55 N-80 P-110

14.81 13.38 12.44

25.01 22.47 20.41

37.31 31.02 26.22

(D / t)
45

Casing Design
Collapse pressure - with axial stress 1.
YPA
1/ 2 2 S A SA = YP 1 0.75 Y Y 0.5 P P

YPA = yield strength of axial stress equivalent grade, psi YP = minimum yield strength of pipe, psi SA = Axial stress, psi (tension is positive)
46

Casing Design - Collapse

2. Calculate D/t to determine proper equation to use for calculating the collapse pressure

Yield Strength Collapse :

P YP

= 2 Yp

D 1 t 2 D t

Plastic Collapse:

A Pp = Yp B C D t
47

Casing Design - Collapse, contd

Transition Collapse:
F PT = Y p G D t
46 . 95 X 10 D t
6 2

Elastic Collapse:

PE =

D 1 t

48

Example 2
Determine the collapse strength of 5 1/2 O.D., 14.00 #/ft J-55 casing under zero axial load. 1. Calculate the D/t ratio:
D 5.500 = = 22.54 1 t (5.500 5.012) 2 From Halliburton book
49

Casing Design - Collapse

If Axial Tension is Zero:
Yield Strength Plastic Transition Elastic

J-55 N-80 P-110

14.81 13.38 12.44

25.01 22.47 20.41

37.31 31.02 26.22

(D / t)
50

Example 2
2. Check the mode of collapse
D = 22.54 t

Table (above) shows that, for J-55 pipe, with 14.81 < D/t < 25.01 the mode of failure is plastic collapse.

51

Casing Design - Collapse

Calculate D/t to determine proper equation use for calculating the collapse pressure to

Plastic Collapse:

A Pp = Yp B C D t
52

Example 2
The plastic collapse is calculated from:
A B C Pp = Yp D/t 2.991 = 55,000 0 .0541 1,206 22.54
Pp = 3,117 psi

Halliburton Tables rounds off to 3,120 psi

53

Example 3
Determine the collapse strength for a 5 1/2 O.D., 14.00 #/ft, J-55 casing under axial load of 100,000 lbs The axial tension will reduce the collapse pressure as follows:
Y PA = 1 0 . 75 SA Y p
2

SA 0 .5 Y p

YP

FA 100,000 SA = = = 24,820 psi Area 5.5 2 5.012 2 4

54

Example 3 contd

Y PA

2 S S = 1 0 . 75 A 0 . 5 A Y P Y Y p p

The axial tension will reduce the collapse pressure rating to:
YPA
2 24,820 24,820 = 1 0.75 0 .5 55,000 55,000 55,000

= 38,216 psi

Here the axial load decreased the J-55 rating to an equivalent J-38.2 rating
55

Example 3 - contd
A B C Pp = YPA D/t 2 .945 2 = 38,216 4 .557 x10 700 .43 = 2,551 22 .54
P p 2 , 550 psi

compared to 3,117 psi with no axial stress!

56

Example 3 - contd
The Halliburton Cementing Tables list the collapse resistance of 5 -in, 14.00 lb/ft J-55 casing at 3,120 psi. The axial tension in this case would derate the collapse strength to about 2,550 psi. We shall be using API Tables to correct for the effect of axial tension on collapse strength of casing.
57

Combined Loading

58

59

60

61

Linear Interpolation

y = mx + c P = mS + C P1 = mS 1 + C P 2 = mS 2 + C

(i) (ii) (iii)

62

Linear Interpolation

(iii) (ii)

P2 P1 = m(S2 S1 )

P2 P 1 m= S2 S1

(i) (ii)

P2 P 1 P P (S S1 ) 1 = m( S S1 ) = S2 S1
63

Linear Interpolation

S S1 P = P1 + S S (P2 P1 ) 1 2

With design factor:

S S1 1 (P1 P2 ) Pcc = P1 D.F. S2 S1
64

 = dogleg severity, deg/100 ft = angle build rate, deg/100 ft

Build Radius =

18,000

65

Length of arc, L = RR L = (R + r) - R R

R+r

dn L = r = 2 dn L dn = = = L 2 L 2(12 ) 100 180

30 * 10 = E = 2,400

dn 180

= 218dn
(7.14a)
66

= 218 dn

F = 218 dn A s

Figure 7.14 - Incremental stress caused by bending of casing in a directional well The area of steel, As, can be expressed conveniently as the weight per foot of pipe divided by the density of steel. For common field units, Eq. 7.14a becomes Fab = 64 d n w.............................(7.14b)
where Fab , , d n , and w have units of lbf, degrees/100 ft, in., and lbf/ft, respectively.
67

Example
= 5 deg/100 ft
d n , = 7 in w = 35 lbf / ft

Fab = 64 d n w.............................(7.14b)

Fab = 64 * 5 * 7 * 35 = 74,400 lbf Fab = 74,400 lbf

68

Casing Design Example

Example Problem API Design Factors Worst Possible Conditions Effect of Axial Tension on Collapse Strength Iteration and Interpolation Design for Burst, Collapse and Tension

69

Casing Design Example

Design a 9 5/8-in., 8,000-ft combination casing string for a well where the mud wt. will be 12.5 ppg and the formation pore pressure is expected to be 6,000 psi. Only the grades and weights shown are available (N-80, all weights). Use API design factors. Design for worst possible conditions.
70

Casing Design - Solution

Before solving this problem is it necessary to understand what we mean by Design Factors and worst possible conditions.

API Design Factors Design factors are essentially safety factors that allow us to design safe, reliable casing strings. Each operator may have his own set of design factors, based on his experience, and the condition of the pipe.
71

Casing Design
In PETE 661, well use the design factors recommended by the API unless otherwise specified.

These are the API design Factors: Tension and Joint Strength: NT = 1.8 Collapse (from external pressure): Nc= 1.125 Burst (from internal pressure): Ni = 1.1
72

Casing Design
What this means is that, for example, if we need to design a string where the maximum tensile force is expected to be 100,000 lbf, we select pipe that can handle 100,000 * 1.8 = 180,000 lbf in tension. Note that the Halliburton Cementing Tables list actual pipe strengths, without safety factors built in.
73

Casing Design
Unless otherwise specified in a particular problem, we shall also assume the following: Worst Possible Conditions 1. For Collapse design, assume that the casing is empty on the inside (p = 0 psig) 2. For Burst design, assume no backup fluid on the outside of the casing (p = 0 psig)
74

Casing Design
Worst Possible Conditions, contd
3. For Tension design, assume no buoyancy effect 4. For Collapse design, assume no buoyancy effect The casing string must be designed to stand up to the expected conditions in burst, collapse and tension. Above conditions are quite conservative. They are also simplified for easier understanding of the basic concepts.
75

Casing Design - Solution

Burst Requirements (based on the expected pore
pressure) Depth Pressure

PB = pore pressure * Design Factor = 6,000 psi *1.1 PB = 6,600 psi

The whole casing string must be capable of withstanding this internal pressure without failing in burst.
76

Casing Design - Solution

Collapse Requirements For collapse design, we start at the bottom of the string and work our way up. Our design criteria will be based on hydrostatic pressure resulting from the 12.5 ppg mud that will be in the hole when the casing string is run, prior to cementing.

77

Casing Design

Collapse Requirements, contd

= 0.052 * 12.5 * 8,000 * 1.125 Pc = 5,850 psi req' d at the bottom.

Depth Pressure

Pc = 0.052 * mud weight * depth * design factor

Further up the hole the collapse requirements are less severe

78

Casing Design
Reqd: Burst: 6,600 psi Collapse: 5,850 psi

79

Casing Design
Note that two of the weights of N-80 casing meet the burst requirements, but only the 53.5 #/ft pipe can handle the collapse requirement at the bottom of the hole (5,850 psi). The 53.5 #/ft pipe could probably run all the way to the surface (would still have to check tension), but there may be a lower cost alternative.
80

Casing Design
To what depth might we be able to run N-80, 47 #/ft? The maximum annular pressure that this pipe may be exposed to, is:
Depth Pressure

Collapse pressure of pipe 4,760 Pc = = = 4,231 psi design factor 1.125

81

Casing Design
First Iteration At what depth do we see this pressure (4,231 psig) in a column of 12.5 #/gal mud?
Pc = 0 . 052 * 12 . 5 * h 1 Pc 4 , 231 h1 = = = 6 ,509 ft 0 . 052 * 12 . 5 0 . 052 * 12 .5
82

Casing Design
This is the depth to which the pipe could be run if there were no axial stress in the pipe But at 6,509 we have (8,000 - 6,509) = 1,491 of 53.5 #/ft pipe below us. The weight of this pipe will reduce the collapse resistance of the 47.0 #/ft pipe!
83

6,509 8,000

Casing Design
Weight, W1 = 53.5 #/ft * 1,491 ft = 79,769 lbf This weight results in an axial stress in the 47 #/ft pipe

weight 79 ,769 lbf of S1 = = = 5,877 psi 2 end area 13.572 in

84

Casing Design
The API tables show that the above stress will reduce the collapse resistance from 4,760 to somewhere between 4,680 psi (with 5,000 psi stress) and 4,600 psi (with 10,000 psi stress)

85

Casing Design
Interpolation between these values shows that the collapse resistance at 5,877 psi axial stress is:
S S1 Pc1 = P1 (P1 P2 ) S S 1 2

(5,877 5,000) Pc1 = 4,680 * ( 4,680 4,600 ) = 4,666 psi (10,000 5,000) 4,666 Pcc1 = = 4,148 psi 1.125
86

With the design factor,

Casing Design
This (4,148 psig) is the pressure at a depth
4,148 h2 = = 6,382 ft 0.052 * 12 .5

Which differs considerably from the initial depth of 6,509 ft, so a second iteration is required.
87

88

89

Casing Design
Second Iteration Now consider running the 47 #/ft pipe to the new depth of 6,382 ft.
W 2 = ( 8,000 6,382 ) * 53 . 5 = 86 ,563 lbf 86 ,563 lbf = 6,378 psi S2 = 2 13 . 572 in
90

Casing Design
Interpolating again,
S S1 1 (P1 P2 ) Pc1 = P1 D.F. S 2 S1

1 6,378 5000 pcc2 = * (4,680 4,600) = 4,140 psi 4,680 1.125 5000

This is the pressure at a depth of

4,140 h3 = = 6,369 ft 0 .052 * 12 .5
91

Casing Design
This is within 13 ft of the assumed value. If more accuracy is desired (generally not needed), proceed with the: Third Iteration
h 3 = 6,369 ' W 3 = ( 8,000 6,369 ) * 53 . 5 = 87 ,259 lbf 87 ,259 S3 = = 6,429 psi 13 . 572

Pcc3 = ?
92

Casing Design
Third Iteration, contd
1 6,429 5,000 thus Pcc3 = * (4,680 4,600) 4,680 1.125 5,000 = 4,140 psi = Pcc 2

93

Casing Design
Third Iteration, contd This is the answer we are looking for, i.e., we can run 47 #/ft N-80 pipe to a depth of 6,369 ft, and 53.5 #/ft pipe between 6,369 and 8,000 ft. Perhaps this string will run all the way to the surface (check tension), or perhaps an even more economical string would include some 43.5 #/ft pipe?
94

Casing Design
At some depth the 43.5 #/ft pipe would be able to handle the collapse requirements, but we have already determined that it will not meet burst requirements.

NO!
95

N-80 43.5 #/ft? Depth = 5,057? 5,066? 5,210? N-80 47.0 #/ft Depth = 6,369 6,369 6,382 6,509 8,000
96

N-80 53.5 #/ft

Tension Check
The weight on the top joint of casing would be (6,369 ft * 47.0# / ft ) + (1,631 ft * 53.5# / ft )
= 386,602 lbs actual weight

With a design factor of 1.8 for tension, a pipe strength of

1.8 * 386,602 = 695,080 lbf is required
97

Tension Check
The Halliburton cementing tables give a yield strength of 1,086,000 lbf for the pipe body and a joint strength of 905,000 lbf for LT & C.

47.0 # / ft is OK to surface

98

Casing Design Review

We have 4 different weights of casing available to us in this case: 1. Two of the four weights are unacceptable to us everywhere in the string because they do not satisfy the burst requirements. 2. Only the N-80, 53.5 #/ft pipe is capable of withstanding the collapse requirements at the bottom of the string
99

Casing Design Review

3. Since the 53.5 #/ft pipe is the most expensive, we want to use as little of it as possible, so we want to use as much 47.0 #/ft pipe as possible. 4. Dont forget to check to make sure the tension requirements are met; both for pipe body, and for threads and couplings (T&C).
100

Casing Design Review

The collapse resistance of N-80, 47 #/ft will determine to what depth it can be run. Two factors will reduce this depth: Design Factor Axial Stress (tension) Halliburton collapse resistance: 4,760 psi Apply design factor:4,760 = 4,231 psi 1.125
101

Casing Design Review

To determine the effect of axial stress requires an iterative process: 1. Determine the depth capability without axial stress
4,231 depth = = 6,509 ft 0.052 * 12.5

2. Determine axial stress at this point

102

Casing Design Review

3. Determine corresponding collapse resistance 4. Determine depth where this pressure exists 5. Compare with previous depth estimate 6. Repeat steps 2-6 using the new depth estimate 7. When depths agree, accept answer (typically 2-4 iterations) (agreement to within 30 ft will be satisfactory)
103