PEGN 361A Basic Tubular Manufacturing and Types Failure Criteria State of Stress in a Tubular

Appreciation to Maverick Tubulars and Lone Star Steel

Tubulars
Definition of casing and tubing
Geometry
Casing is 4.5 to 20 Tubing is < 4.5

Use
Casing has no production fluid flow Tubing has production fluid flow

Casing, Tubing, Drill Pipe, Line Pipe

Standards
API ISO

WPF
Nominal
Plain end Average

OD, WPF, Grade, Connection Range

1 16 to 25 2 25 to 34 3 >34

Actual

Grade
Minimum yield point API
H, J, K, M, N, L, C90, C95, T95, P, and Q HCP, HCQ, H2S, LS, USS, etc.

Tolerances
OD 0.75% thickness no less than 87.5%

Non API

Drift
Special drift
6 8-5/8 12 > 8-5/8

Connection
API
LTC, STC, BTC, XL

Non-API
Grant Prideco Hydril

Manufacturing Processes
Seamless Electric Resistance Weld

API Seamless
Seamless pipe is made from solid bars One piece at a time Bars are heated and pierced Pipe is tested and threaded

API Seamless Tubular Manufacturing

Rotary Hearth Furnace

Cold Billets Charged

Hot Billets Removed

Mannesmann Piercing Mill

API Seamless Tubular Manufacturing

Elongator: Elongates the tube and produces desired wall thickness

Rotary Sizer: Produces final OD size

Reducing Mill: Reduces the OD of the tube

API ERW Method of Manufacturing

ERW pipe is made from steel coils Coils are cut to exact width Cut coils are cold formed continuously into tube Edges of strip heated to 2600 degrees Heated edges are fused together Pipe is tested and threaded

Close Up of Particular Tube Making Operations

Weld Line

Contacts Pipe Heated Strip Edges Apex Vee

Weld Point

Steel Tubular Making

Advantages of ERW Oil Country Tubulars

Uniform wall thickness from end to end and around the pipe circumference.
Same amount of metal under the thread root around the complete perimeter. Line-up of pipe ends is assured. No unexpected thin wall areas. Uniform strength along length and throughout pipe cross-section. Consistent expansion around the perimeter during mandrel expansion or hydroforming.

Excellent surface quality (ID & OD) that performs well in painting or coating operations.

Eccentric Cross Section Cross Section Of Seamless Product

.500 Wall
0.62 Eccentricity

.500 Wall

.562 Wall

.438 Wall

Center of O.D. Circle and concentric dotted I.D. Circle (Similar to ERW I.D.)

Center of solid I.D. Circle (Extreme I.D. possible with Seamless)

Hot Mill Gauge Control Example

API Allowable 12.5%

+.005% +12.5%

+1%
+1/2%

-1/2%

-1%

-12.5%

North American Pipe Market, 2004 Market Share

(Preston Pipe Report)

Product Oil Country Tubulars

Welded 52.2

Seamless 47.8

Line Pipe

87

13

Tubular Types
Conductor Surface Intermediate
Casing Liner Tieback

Production
Casing Liner Tieback

Tubing

Madson Deep Casing Plan

Conductor
Returns mud to elevated pits Supports weight of other casing strings Keeps hole from washing out under the rig

Surface Casing
Protects fresh water Anchors the first blow-out prevention equipment Protects hole from potentially poor shallow formations

Intermediate Casing, Liner, or Tieback

Protects holes from abnormally pressured zones
Low High
Transition zone

Protects holes from poor formations

Salts Sloughing shales

A liner is a casing string that terminates below the surface A tieback is a casing string that connects a liner to the surface

Production Casing, Liner, or Tieback

Acts as the conduit for production fluid tubing The production tubing fits inside the production string

Design Steps
Decide on objectives Identify lifetime loads Satisfy management guidelines
risk versus cost

Create criteria Make computations Select casing

Decide on Objectives
Surface and bottom hole locations Size and number of tubulars Potential for drilling beyond planned total depth Setting depths Failure consequences Economics Optimum balance between risk and cost

Pipe Loads
Load means anything acting upon pipe such as a force, tension, compression, bending, pressure, or weight
Force is mass times acceleration Tension is when two marks on a pipe diverge upon application of a load Compression is when two marks on a pipe converge upon application of a load Bending is when a section of pipe has compression on one side and tension on the other side Pressure is a force acting over an area. In this case, it is applied to a fluid Weight is mass time gravitational acceleration

Pipe Load Examples

Gravity Friction Contact
Objects pushing on pipe Ledges Bottom of the hole Bridges

Weight of other strings

Liners Wellhead hangoff

Weight of surface equipment

BOPE Wellhead

Torsion Dynamic
Jarring Drilling

Formation
Salt flows

Applied by rig
Pick up Slack off

Pressures
Internal External Changing fluid densities Evacuation

Temperature changes

Identify Service Life Loads

Loads
Burst Collapse Tensile

Buckling Yielding
Free sections Cemented sections

Backups
Burst Collapse Tensile

Thermal
Stimulation EOR

Cementing procedures
Cement to surface

Kick scenarios
Gas to surface Water to surface Bubble

Margin of overpull Doglegs Salt zones Casing wear Corrosion

H2S and CO2

Lost circulation

Wellhead loads BOPE loads

Design Factors
Management and engineering risk factor (safety or ignorance factor?). Varies depending on company and individual. Typical values are:
Collapse Burst Pipe body tensile 1.5. Joint strength tensile 1.1. 1.1.

1.8.

Determine your own design factors.

Criteria
Basic design equation is:

Sc DF L B
Where

Sc is minimum casing strength DF is the design factor L is the load B is the backup

Casing Collapse 1

Casing Collapse 2

Casing Collapse 3

Casing Collapse 4

Casing Collapse 5

Casing Collapse 6

Failure
Comprehensive stress analysis Material Loading
History Magnitude Duration
Slowly Rapidly Transient Transient with reversals

Stress distribution
Even Cracks Concentrations

Safety Factor

Failure Types

Excessive displacement/deflection Plastic deformation (yielding) Fracture Corrosion

Typical Stress Strain Diagram

Steel Constants

E = 29, 000, 000 psi G = 11, 000, 000 psi

= 0.3 = 6.7 x 10
6

1 o F

lbm lbm = 0.28 3 = 484 3 ft in

Stresses in Pipe

xy

yz

yx

Axial

al i t en g n Ta

zx

xz

x
Ra dia l

zy

Stress Equations
Lames radial stress 2 2 Ai D Ao d r = Pi 1 Po 1 Acs Acs b b Lames tangential stress 2 2 Ai Ao D d t = Pi 1 + Po 1+ Acs b Acs b Axial stress

a =

Treal + bending Acs

Effective Tension

Teff = Treal Pi Ai + Po Ao at the point of investigation

Bending Stress
OD 2 ID 2 3, 385 ( OD ) C Teff 2 2 OD + ID = Teff tanh 0.2 4 4 OD ID

FLUB

Fbeam = 17,135 ( OD ) C ( OD 2 ID 2 ) FLUB Fbeam or whichever is larger b = Acs Acs

 Radial strain

Strain Equations r ( t + z ) + T r = E

Tangential strain

t =

t ( r + z )
E

+ T

z =
Axial strain

z ( t + r )
E

+ T

Failure Criteria

Failure Criteria

Stress Strain Envelope

Von Mises Failure Criteria

Von Mises Stress is non-existent Von Mises equivalent stress is:

vm =

( r t ) + ( r a ) + ( t a )
2 2

2 + 6 ( r2 + t2 + a )

Helps determine if failure is likely If the Von Mises equivalent stress is greater than the yield strength, then the pipe is, by definition, in danger of failure

Stress Analysis
Determine the stresses:
Radial Tangential Axial Bending Von Mises w/o bending Von Mises w/ bending
Pressure is 3,850 psi Pressure is 1,100 psi Outside Mud Weight is 10.2 ppg from 2,200 ft to surface

Surface Casing is 8-5/8" 24 ppf K55 STC @ 2,395 ft

T = 200 deg F C = 10 deg/100 ft @ DOI

Is the pipe at the depth of investigation in danger of failure?

Casing is 5.5" 23 ppf N80 LTC from surface to 1,050' 5.5" 20 ppf P110 LTC from 1,050' to 6,500' 5.5" 23 ppf P110 LTC from 6,500' to 9,110' 5.5" 26 ppf P110 LTC from 9,110' to TD Outside Mud Weight is 13.2 ppg from 6,400 ft to 2,200 ft

Inside Mud Weight is 9.5 ppg Depth of investigation is 7,500' Outside Mud Weight is 15.4 ppg from 6,400 ft to TD Float Collar is at 10,423 ft Inside Mud Weight is 15.4 ppg Total Depth is 10,503 ft in 7-7/8" hole