Casing Design

RUNNING AND CEMENTING

CASING
Reasons for Running Casing
Provide a means of controlling well pressures.
Permit circulation.
Prevent collapse of hole.
Prevent fluid migration.
Isolate troublesome zones.
Facilitate control of a production well.
2

Types of Casing and

Common Size
Conductor
Surface Casing
Intermediate String
Production String
Liner

20:24
13-3/8
9-5/8
9-5/8:7
7:5"

Conductor Casing
Characteristics:
Casing is usually large: 20 in. to 30 in.
diameter.
The hole may be severely eroded.
4

Conductor Casing
The setting depth of the conductor can
vary from as little as 20 ft to as much as
a few hundred feet.
The most common pipe and hole sizes
are a 16 in. pipe in a 20 in. hole and 20
in. pipe in a 26 in. hole.
5

Conductor Casing
Conductor Casing is set to :
Prevent washing out under rig.
Provide elevation for flow line.
Provide support for part of the wellhead.
A BOP is usually not attached to conductor
6
casings.

Conductor Casing
Recommended Cements
Accelerated neat.
Thixotropic cement.
Typical slurries used for conductor casings
consist of Class A, C, G, or H with 2% calcium
chloride as accelerator.
Lost-circulation additives may be added without
significant effect on slurry-thickening time or
compressive strength.
Where lost circulation is severe, a thixotropic
7
cement can be used.

Conductor Casing
Often cemented through drill pipe with
sealing sleeve.
When cementing down casing, plugs may not
be used, cement is simply displaced.
Large diameter casing plugs (30 in., 26 in.,
and 20 in.) are wooden body plugs.
If bumped on baffle or float, be careful in
pressuring up to prevent bypassing plug.
Excess cement is usually determined by
experience in the area.
8

Surface casing
Surface casing is usually the second
string of pipe set in the well.
when a conductor casing is not set
because, the surface pipe becomes the
first string set.

Surface casing
Surface casing is set to:
Protect fresh water sands.
Case unconsolidated formations.
Provide primary pressure control (BOP
usually nippled up on surface casing).
Support future casings.
Case off potential loss circulations zones.
10

Surface casing

Characteristics
Casing sizes normally range from 13-3/8in. on
shallow wells to 20 in. on deep, multistring wells.
Hole may be severely eroded.
Shallow strings can be pumped out easily.
Drilling muds often viscous with little water loss
control.
Casing may stick easily in unconsolidated
formations.
Loss of circulation may be a problem.
Guide shoe, or float shoe, float collar and
centralizers are commonly used.
11

Surface casing
Surface casings are set from a few hundred feet
to several thousand feet.
The depth depends on the proposed total well
depth, the competency of shallow formation
encountered, and state regulations regarding
protection of fresh water reservoirs.
Recommended Cements
Shallow surface casings are cemented in the
same manner as conductor casings.
Completion cements with accelerated
12
thickening times.

Surface casing
There is a cost advantage by using a
high-yield completion slurry to cement
the entire string.
Sometimes, when the well is shallow or a
significant load will be placed on the
wellhead, a densified filler slurry can
cement the entire casing.
Economically, omitting the tail-in slurry
will not save much.
13

Surface casing
Filler cements (high water ratio)
followed by neat or high strength tail in.
Usually accelerated.
LCM often used.
High strength cements often used on
deep well surface casings to support
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future strings.

Summary Of Surface Casing

Large diameter strings often cemented through
drill pipe with sealing sleeve.
Use both bottom and top plugs because of mud
contamination.
Centralize the bottom joints and thread lock to
prevent backing off while drilling.
Regulator rules usually require a WOC time of
8 hours or 500 psi minimum compressive
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strength.

Summary Of Surface Casing

A float collar placed two joints above the
guide shoe helps prevent mud from
contaminating the cement around the
shoe joint.
Centralizers are the final consideration of
equipment on the casing.
Centralizers center the Csg in the hole.
16

Intermediate Casing
The intermediate casing strings extend
from the surface to formations able to
hold the expected mud weights at greater
depths.
This depth can vary several thousand feet
in a single stage job.
When a second intermediate string is set,
the casing is run to just below the weak
zone to a firm formation and cemented at
17
that point.

Intermediate Casing
Purpose
Separates hole into workable drilling
segments and cases off loss circulation zones,
water flows, etc.
isolates salt sections.
protects open hole from increases in mud
weight.
prevents flow from high pressure zones if
mud weight must be reduced.
Basic pressure control casing.
BOP always installed.
Supports subsequent casings.
18

Intermediate Casing
Characteristics

The pipe and hole size are largely determined

by the number of casing strings to be run
below the intermediate string.
Casing sizes range from 6-5/8 in. to 20 in. Most
common are 9-5/8 in., 10-3/4 in.
Some sections may erode severely, particularly salt
sections.
Strings may be very heavy and set on bottom.
Both extremely weak zones and high pressure
zones are covered by intermediate strings.
19

Intermediate Casing
Cement volume is dictated by wellbore
condition.
Guide shoe, or float shoe, and float collar
are commonly used.
Cement volumes usually largest in well.
Often cemented in stages.
Prolonged drilling may be done through this
casing and damage is common.
Completion may be made in intermediate
casing.
20

Intermediate Casing
Recommended Cements
Because of the large volume of cement, and the
type of formations to be covered, both filler and
composition cements are used to cement most
intermediate casing.
Sometimes, as many as three combinations of
slurries are needed.
Formation-fracture gradients, lost-circulation
zones, formation temperatures, possible future
producing zones, and well depth determine the
21
number and types of slurries to use.

Intermediate Casing
For a single stage cementing job, the
slurry requirements are similar to those
for a long surface job.
The filler slurry needs to be light enough
not to break down weaker formations.
The completion slurry needs to have
enough strength to hold the pipe and
provide a good seal between the pipe and
formation.
22

Intermediate Casing
The bottom of the pipe is cemented (usually
1000 to 3000 ft) in a single stage intermediate
job.
because of cost, or because the uncemented
section of casing may be reclaimed from the
well later and re-used. In this case, only a highstrength completion slurry with a retarder is
needed.
Retarders insure sufficient pumping time to get
the slurries in place and impart some frictionreduction.
23

Intermediate Casing
Unlike the conductor and surface casings,
additives such a friction reducers, fluid-loss
additives, and retarders are required for
intermediate slurries.
Where the annulus is small, friction reducers
lower pump pressures and reduce the chance of
losing fluids in a lost-circulation zone.
Fluid-loss additives prevent slurry loss into lostcirculation zones and dehydration in the
annulus due to permeable zones and will give
better bonding results.
24

Summary Of Intermediate Casing

Use a bottom and top plug to minimize cement
contamination. As in other strings of casing, the bottom plug
wipes the mud film off the casing and ahead of the cement.
Heads that contain both plugs, or heads that are loaded with
plugs are attached to casing.
Pipe extends from surface to the bottom of the hole.
Stage tools are occasionally used when cementing long
strings of pipe where breaking down a weak formation
becomes a concern.
The number of slurries used may be determined by possible
production, weak zones and wellbore temperatures.
Use scratchers, centralizers and flushes.
25

Production Casing
The production casing is the last full string of
pipe set in the well.
It extends from below the deepest producing
formation to the surfaceProduction tubing, downhole pumps, and other
equipment needed to produce oil and gas are
housed in this casing.
The production-casing cement must give a
pressure-tight seal between the formations and
the production casing.
It is essential to isolate the reservoir from fluids
both within the producing zone itself and from
other zones.
26

Production Casing
Purpose
Complete well for production.
Effect zonal isolation.
Protect pay zones from unwanted fluids.
Provide pressure control.
Cover worn or damaged intermediate
casing.
27

Production Casing
Since the production casing may extend from the
total depth of the well to the surface, the setting
depth can vary from a few thousand feet to as much
as 14000 feet.
Below 14000 ft, liners may be set because of cost
savings and less pipe weight.
The size of the casing depends upon the number of
strings of production tubing to be run into the well
and the size of production equipment used.
28

Production Casing
Characteristics
Common size 4-1/2in., 5-1l2 in., and 7 in.
casing.
Drilling mud usually of good condition.
Usually not circulated. Generally cemented
back to intermediate casing.
Good cement job is vital to successful
completion.
29

Production Casing
Recommended Cement
Filler cements with high strength tail-in.
All potential pay zones are usually
covered by low water ratio cements.
Densified cements are commonly used for
high competency and pressure control.
Fluid loss control.
30

Types of Liners
Liners are classified as:
production,
intermediate liners,
protective or drilling (which could be
considered the same as an intermediate
liner),
scab, or stub liners.
31

Liner String
The liner string consists of:
The cementing head with a drill pipe wiper
dart in place.
A drill pipe swivel if movement is considered.
Drill pipe.
Liner-setting mechanism.
Latch-in liner wiper plug.
A mechanical set or hydraulic set liner hanger.
Floating equipment.
32

Liner hangers are set mechanically or hydraulically.

The float shoe and float collars are spaced two to
five joints apart.
The liner plug landing collar is located some
distance above the float collar.
Most liner hangers are equipped with a tie-back
receptacle should the need arise to run a tie-back
string to surface or to run a scab liner.
The tie-back sleeve is usually a minimum of six feet
in length and fluted for easier entry.
Production liners are many times equipped with a
polished bore receptacle to serve as a seal assembly
placement facility when production string is run 33
in
the well.

Purpose of Intermediate Liner

Extension of intermediate casing.
Cases hole for changes in mud weights.
Requires less casing in hole.
Permits running tie-back casing at future
date to complete well with new casing.
34

Characteristics
Liners often long and heavy.
Muds and cements usually above 12.0 ppg.
Most often set to control high pressure gas.
Casing may not be rotated or reciprocated.
Effective mud displacement is impaired.
Thickening times require careful control to
have adequate pumping time on bottom and
prevent over-retardation at top.
35

Common Cements
API Class C, G or H cements with
filtration control and dispersants.
High density.
Some high water ratio cements for
weight control may be required.

36

Cementing Procedure
Cementing head and plugs furnished by
supplier of liner hanger.
Liner hanger is set before cementing.
Setting tool with sealing cups is kept in
liner.
Cement is placed, often circulated above
liner top.
Liner setting tool is pulled from hole.
Sometimes, excess cement is reversed
37
out through drill pipe.

Production Liners
The purpose, cements characteristic and
cementing procedures used on production
liners are described below:
Purposes
Completion casing.
Require less casing in well.
Permit completing with larger tubing for
high flow capacities.
38

Production Liners
Purposes (cont)
Common Cements
API Class G or H cement.
Some high water ratio cements may be
used for weight control.
Slurries contain dispersants and fluid loss
additives.
High density cement and high strength
cements most commonly used slurries for
39
most deep liners.

Production Liners
Characteristics
Often covers long intervals.
Usually small annular clearance.
Casing is usually not rotated or
reciprocated during cementing.
Pumping rates often restricted to prevent
fracturing.
Effective mud displacement from annulus
is impaired.
40

Production Liners
Cementing Procedure (Same as intermediate
liners)
Liner hanger is set before cementing. Setting tool
with sealing cups is kept in liner.
Cement is placed, often circulated above liner tops.
Liner setting tool is pulled from hole.
Sometimes, excess cement is reversed out
through drill pipe.
41

Reciprocation vs. Rotation

Liner reciprocation, as does liner rotation,
aids in mud displacement and fillup.
When reciprocating the liner, you use a
hanger with a longer barrel.
The slips are set so that the liner can be
moved some 5-15 feet without movement
of the slip cage in the pipe.
When liner reciprocation is employed
during the cementing process, the liner
tool is released after cementing.
42

Reciprocation vs. Rotation

Liner rotation is more sophisticated than liner
reciprocation.
Many liner hanger companies offer hangers that
permit both rotation and reciprocation.
When rotating, a power swivel is used that has
plug release features.
The liner rotation is normally done on liners up
to 2000 feet in length and having clearances of
1 to 1-1/2 inches.
Liner rotation is not quite as popular in hard
rock areas as in soft rock country due to tighter
clearances, crooked holes, long shale sections,
43
etc.

Reciprocation vs. Rotation

The consequences of liner movement could
cause hole problems such as:
centralizers could become entangled with the
hanger.
pressure surges and lost circulation during
displacement.
The knocking off of debris in the annulus
forming a bridge and causing the cement to be
squeezed off.
The liner sticking off bottom resulting in the
liner being set in compression.
44
the drill string could part or twist off.

Reciprocation vs. Rotation

Movement does provide good
cementing jobs.
Liner movement can eliminate costly
trips to perform remedial work, e.g.
expensive and unnecessary squeeze
jobs.
Some operators go to the expense of
under-reaming the hole prior to
running the liner to make sure that
45
larger clearances are available.

Production Liners
Once the production liner is set, it may
be desirable to run a tie-back casing
which extends the production casing to
the surface for maximum pressure
control.
When set and cemented, the tie-back
string serves as the production casing.
The purpose, characteristics, cements,
and procedures used in tie-back
46
cementing follow:

Purposes
Extend production casing to surface for
maximum pressure control.
Serve as new production casing.
Cover worn or damaged intermediate
casing.
Case off exposed liner tops.

47

Characteristics
Primarily used on deep wells.
Often very long strings are set and
cementing pressures are extremely
high.
Conventional floats cannot be used.

48

Common Cements
API Class C,G or H.
High water ratio cements to control
hydrostatic pressures.
Cements with silica flour for strength,
stability, and casing support if
temperatures warrant.

49

Cementing Procedures
Three different techniques commonly
used:
Cemented through side ports in polished
bore receptacles.
Cemented by reverse circulation.
Cemented by use of stage tool above tie50
back receptacle.

Scab Liners
A scab liner is usually run to repair
damaged intermediate casing.
It may not extend back into the
intermediate casing but only over that
area where the casing is damaged.
Scab liners are usually short sections and
hung before cementing.
They are not set into a receptacle.
51

Problem Areas When Setting Liners

Inability to break circulation.
The logical solution is to bring the liner
out of the hole and locate the cause of
the difficulty.
The liner sticks while being moved or
reciprocated.
Continue as before but without further
52
reciprocation.

Problem Areas When Setting Liners

The liner hanger sets when the drill pipe wiper
plug picks up the liner wiper plug.
Continue as before but eliminate further attempt to
reciprocate.
Cannot release from liner hanger after setting it.
The only logical solution is to retrieve the liner
from the hole at a slow rate and fill the annulus
with mud as the cement falls to bottom. Upon
removal of the liner, drill out and renew the liner
hanger and liner string.
53

Problem Areas When Setting Liners

Squeezing the overlap is not successful. Run
a liner top isolation packer with a scab liner
and a tie-back seal mandrel.

The plug does not bump the liner to the

bottom. Hydraulically set the slips, leave
the liner on bottom, and release from the
liner hanger.
54

Hole Conditions
Sloughing
In many cases, this is the purpose
of setting an intermediate casing and it can
create several cement problemssuch as
bridging the annulus, sticking the casing, and
increasing the annulus hydrostatic pressure.
Drill Pipe Drag
Where the drag is occurring, and exactly why it
exists, could be important. This condition may
indicate the need for centralized casing or the
use of fluid loss control cements.
55

Hole Conditions
Low Pressure Zone:
One of the most persistent problems is
incompetent formations that will not
support effective columns of cements.
Mud Condition:
A well-conditioned mud greatly
increases the mud removal capability
of the flushes and cement slurry.
56

Hole Conditions
Fluid Movement
Zone isolation fails any time fluid
movement is allowed to move during the
time a cement slurry is between the fluid
and set state. If the cement moves
during the hardening, the cement will
not set.
Formation Movement
Are you located in an active fault zone?
The most common formation movement
57
occurs with salt intrusions.

General Considerations
Tally all pipe, count, number and rabbit
(gauge) all joints of casing on the rack.
Check all casing threads for cleanliness and
damage. Additionally, check the threads on all
crossover equipment for proper thread type
and cleanliness.
Identify all joints by weight and thread type,
and place them in proper order for running
into the hole.
Landing joint(s) should be spaced out so the
cementing head can be installed from the
stabbing board or rig floor after casing is
landed.
58

Physical Properties
Length Ranges
a. Casing comes in three range lengths:
RI 10 to 25 feet
RII 25 to 34 feet
RIII > 34 feet
b. There are different 'grades' of casing
which indicate the strength of the sheet.
59
These are color coded:

Grades
H40
J55
K55
C75
N80
C95
P105
P110
V150

Yield Strength
40000
55000
55000
75000
80000
95000
105000
110000
150000

Colour coding
No colour black
One band bright green
Two bands bright green
Light blue
Red
Yellow band
White
White
60

Couplings
API couplings
STC- Short round thread casing
LTC- Long round thread casing
BTC- Butress thread casing
XL- Extreme line casing

Non-API couplings
Hydril super EU, TS
Valorec
Vam

61

STRENGTH PROPERTIES
Yield strength
Collapse strength
Burst strength

62

Yield strength (Tensile Loading )

Tensile loading is applied to casing as
a result of its own weight and is at a
maximum underneath the casing
hanger at the surface.
Buoyancy reduces the tensile loading
on casing.
Tensile loading on the casing is
increased as a result of running it in
directional hole.
63

Yield strength (Tensile Loading)

A critical factor is the outside diameter of
the casing which, if reduced, reduces the
tensile loading on the casing.
It is for this reason that smaller sizes of
casing are selected to be run on the build
up sections of directional hole, particularly
if rapid changes of angle are expected.
API defines it as the tensile stress required
to produce a total elongation of 0.5 % of
the gauge length
64

Yield strength (Tensile Loading )

65

Collapse Loading
The maximum external pressure required
to collapse a specimen of casing.
If the casing is emptied of fluid completely
the worst collapse situation exists. With no
internal hydrostatic pressure of the mud,
the full formation pressure is exerted on
the casing at the shoe.
At the surface the collapse pressure is
clearly zero since only atmospheric
pressure is acting on the casing. The
collapse design line may now be drawn.
66

Collapse Loading
Where exceptional circumstances
occur such as casing run in salt
formations or in earthquake areas,
extra collapse resistance is required
and must be designed for.
Types
Elastic collapse
Plastic collapse
Transition collapse
67

Burst Loading (or Internal Yield)

strength
The maximum value of internal pressure
required to cause the steel of casing to yield.
Burst loading is the net internal pressure load
exerted on the casing.
The worst case of burst loading usually occurs
when a gas kick is taken and the well is shut in.
The net burst load is the difference between the
pressure inside the casing and the pressure
outside.
The point of maximum burst loading in this case
is therefore at the top of the casing string
where there is a high gas pressure.
68

Casing Design
Casing design is required to ensure that casing
run in the well will withstand the various loads
applied to it.
The principle loadings casing is subjected to are:
Burst
Collapse
Tensile
The worst case loading is considered in each
case.
Safety Factors
Burst pressure 1- 1.1
Collapse pressure 0.85- 1.125
Tensile force 1.6- 1.8
69

Burst Loading
Burst loading is the net internal pressure load
exerted on the casing.
The worst case of burst loading usually occurs
when a gas kick is taken and the well is shut in.
The net burst load is the difference between the
pressure inside the casing and the pressure
outside.
The point of maximum burst loading in this
case is therefore at the top of the casing string
where there is a high gas pressure.
70

Collapse Loading

If the casing is emptied of fluid completely the worst

collapse situation exists. With no internal hydrostatic
pressure of the mud, the full formation pressure is
exerted on the casing at the shoe.
At the surface the collapse pressure is clearly zero since
only atmospheric pressure is acting on the casing. The
collapse design line may now be drawn.
Where exceptional circumstances occur such as casing
run in salt formations or in earthquake areas, extra
collapse resistance is required and must be designed for.
71

Tensile Loading
Tensile loading is applied to casing as a result of its own
weight and is at a maximum underneath the casing
hanger at the surface.
Buoyancy reduces the tensile loading on casing.
Tensile loading on the casing is increased as a result of
running it in directional hole.
A critical factor is the outside diameter of the casing
which, if reduced, reduces the tensile loading on the
casing.
It is for this reason that smaller sizes of casing are
selected to be run on the build up sections of directional
hole, particularly if rapid changes of angle are expected.
72

Biaxial Loading
Collapse and burst loading on casing are both
affected by tensile loading.
Tensile loading tends to reduce the collapse
resistance of casing. This is a particular problem
in deep wells with long casing strings.
Tensile loading has the reverse effect on burst
resistance.
Burst resistance is increased due to the tensile
loading.
Temperature effects must also be considered as
the elongation of the casing can effect all
loadings.
The Drilling Engineer will make use of standard
tables and equations to allow for the effect of
73
tension and temperature.

Casing Design Chart

We have seen how the casing design chart is
constructed by considering burst and collapse
loadings on the casing at the surface and the casing
shoe.
The engineer now has the task of selecting the
correct weights and grades to be used in the string.
More than one weight and grade of casing is used
for economical reasons (less steel required with
thinner wall casing) and to reduce tensile loading.
A set of casing tables with the following information
74
is used.

Casing Design Chart

Using the casing design chart, the engineer selects a
casing weight and grade which has a burst resistance
greater than the burst design line. He must also
check to see that the same casing weight and grade
has a collapse resistance greater than the collapse
design line.
In this way, several different weights and grades of
casing will be used in a casing string.
A check must always be made to make sure that the
75
tensile yield strength of the casing is not exceeded.

Graphical Method for Casing

Design
Collapse Line
Pc = Pout - Pin,
P = 0.052* (ppg)*D (ft) psi
Calculate Psurface, Pshoe (empty
casing).
Draw collapse line

76

Graphical Method for Casing

Design
Burst Line
Burst pressure = Internal pressure
External pressure
Internal pressure = Pf (TD CSD)*G
External pressure = CSD* Gm
Where
Pf, formation pressure at total depth
TD, total depth, CSD, casing setting depth
G, formation fluid gradient (0.1 psi/ft)
Gm, mud gradient (0.465 psi/ft)

77

Graphical Method for Casing Design

Tensile force
Tensile force = weight of casing in air
Buoyancy force78

Refer to
Examples in
the text
79

Running Casing
Condition hole.
Bakerlock shoe and first two or three joints.
Check float equipment.
Remove wear bushing.
While running casing, check calculated displacement
to trip tank.
Keep pipe moving to avoid sticking and circulate.
Rig up cement head and plugs.
Pump water or chemical spacer to remove mud cake.
Drop bottom plug.
Load top plug (if not already in cement head).
80

Conclusion
It can clearly be seen that loading casing string
of different weights and grades can be a
logistical nightmare!
For this reason, the number of casing weight
and grade changes is restricted to ensure that
the casing is picked up and run into the hole in
the correct order.
81