Master of Petroleum Well

Engineering
Advanced Drilling Practices
CASING DESIGN
April 2005
Assoc. Prof. Sampaio
[email protected]

1
 Casing Design
Why Run Casing?
Types of Casing Strings

Classification of Casing

Wellheads

Burst, Collapse and Tension

Examples
Effect
of Axial Tension on Collapse
Strength
Examples
2
 Casing Design - Introduction
Casing
What is casing?

Why run 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,
3
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 to do?

4
Functions of Casing Individually
Drive pipe Conductor pipe
Provides a means Same as Drive pipe
of nippling up Supports the
diverters weight of next
Provides a mud casing strings
return path Isolates very weak
Prevents erosion of formations
ground below rig

5
Functions of Casing Individually
Surface casing Intermediate casing
Provides a means of Usually set in the first
nippling up BOP abnormally pressured
Provides a casing seat zone
strong enough to Provides isolation of
safely close in a well potentially
after a kick troublesome zones
Provides protection of Provides integrity to
fresh water sands withstand the high
Provides wellbore mud weights
stabilization necessary to reach TD
or the next csg. seat
6
Functions of Casing Individually contd

Production casing Liners

Provides zonal Drilling liners
isolation (prevents Same as Intermediate
migration of water to casing
producing zones and Production liners
isolates different Same as production
production zones) casing
Confines production to Tieback liners
wellbore Tie back drilling or
production liner to the
Provides the surface. Converts liner
environment to install to full string of casing
subsurface completion
equipment

7
 Types of Strings of Casing
Diameter Example
1. Drive Pipe or Structural
Pile (Gulf Coast and
16-60 30
offshore only)
150-300 BML
2. Conductor String
16-48 20
100 - 1,600 BML
3. Surface Pipe
85/8-20 133/8
2,000 - 4,000 BML

8
 Types of Strings of Casing contd

Diameter Example
4. Intermediate
75/8-133/8 95/8
String

5. Production String 4-95/8 7

6. Liner(s)

7. Tubing String(s)

9
Example Hole and String Sizes (in)
Hole Size Pipe Size

36 Structural casing 30

26 Conductor string 20

17 Surface pipe 133/8

12 Intermediate String 95/8

83/8 Production Liner 7

10
 Classification of CSG.
Outside diameter of pipe (e.g. 95/8)
Wall thickness (e.g. )
Grade of material (e.g. N-80)
Type to threads and couplings (e.g. API
LCSG)
Length of each joint (e.g. Range III)
Nominal weight (e.g. 47 lb/ft)

11
Most Common Minimum Yield Ultimate Tensile
Grades Strength (KPSI) Strength (KPSI)
H-40 40 60
J-55 55 75
K-55 55 95
C-75 75 95
L-80 80 95
N-80 80 100
C-90 90 100
C-95 95 105
P-110 110 125
V-150 150 160

12
Length of Casing Joints

LENGTH
RANGE
(ft)

I 16 - 25

II 25 - 34

III > 34

13
 Casing Threads and Couplings

API round threads short ( CSG )

API round thread - long ( LCSG )
Buttress ( BCSG )
Extreme line ( XCSG )
Other

See Halliburton Book...

14
Casing Threads and Couplings contd

Rounded Threads Square Threads Integral Joint

8 threads per inch Longer Smaller ID, OD
4 to 20 Stronger Costs more
4 to 20 Strong
5 to 103/4
15
16
17
 Wellhead & Christmas Tree
Wellhead
Hang Casing Strings
Provide Seals

Christmas Tree
Control Production
from Well

18
Wellhead & Christmas Tree contd

19
 Casing Performance - Uniaxial
Loadings
Axial Tension (couplings & body)

Burst Pressure

Collapse Pressure

Bending

Buckling

20
 Casing Performance - Uniaxial

Tension Strength/Failure

21
 Tension Strength
Tension Strength
Couplings: API
Tables for various
couplings
Body (perm. deform.)

Ften =
4
(d 2
n )
d 2 yield

Ften = pipe body yield strength

dn = nominal diameter
d = internal diameter
yield= yield stress

22
 Tension Strength Example 1

Compute the body-yield strength for a

7, N-80, 23 lb/ft casing.
Solution:
From API Table (1 & 2)

d n = 7 in
d = 6.366 in
yield = 80,000 psi

Ften =
4
(7 2
)
6.366 2 80,000 = 532 kips
23
 Tension Strength Formula

Uses Nominal Diameter

API minimum Thickness 87.5% of
original (nominal) thickness
Yield Strength

Rupture much larger

May deform plastically

24
 Casing Performance - Uniaxial

Burst (Internal Pressure)

Yield the body P
Yield the coupling

Leak the coupling

25
 Burst (Internal Pressure)

Barlow (API allows 87.5% of thickness)

Thin Wall Assumption

2(0.875 t )
Pbr = yield
dn

Pbr = pipe body burst pressure

dn = nominal diameter
yield= yield stress

26
 Burst (Internal Pressure) Example 2

Compute the body burstpressure for a

7, N-80, 23 lb/ft casing.
Solution:
From API Table

d n = 7 in
7 6.366
d = 6.366 in t = = 0.317 in
2
yield = 80,000 psi
2(0.875 0.317 )
Pbr = 80,000 = 6340 psi
7
27
Collapse (External Pressure)

28
 Collapse (External Pressure) contd

The following factors are important:

The collapse pressure resistance of a pipe
depends on the axial stress (biaxial stress)
There are different regimes of collapse
failure (depends on ratio dn/t)
Yield Strength Collapse (thick wall)
Plastic Collapse

Transition Collapse

Elastic Collapse

(Empirical Formulation from API)

29
 Collapse (External Pressure) contd

Yield Strength Collapse Pressure

(d n t ) 1
( pcr )yield = 2( yield )e 2
(d n t )
Pcr = pipe body collapse pressure
dn = nominal diameter
t = wall thickness
(yield)e= yield stress (effective for biaxial stress)

30
 Collapse (External Pressure) contd

Plastic Collapse Pressure

F1
( pcr ) plastic = ( yield )e F2 F3
(d n t )
Pcr = pipe body collapse pressure
dn = nominal diameter
t = wall thickness
(yield)e= yield stress (effective for biaxial stress)
F1, F2, F3, F4, F5, Material (and stress) dependent coefficients

31
 Collapse (External Pressure) contd

Transition Collapse Pressure

F4
( pcr )trans = ( yield )e F5
(d n t )
Pcr = pipe body collapse pressure
dn = nominal diameter
t = wall thickness
(yield)e= yield stress (effective for biaxial stress)
F1, F2, F3, F4, F5, Material (and stress) dependent coefficients

32
 Collapse (External Pressure) contd

Elastic Collapse Pressure

46.95 10 6
( pcr )elast =
(d n t )(d n t 1) 2

Pcr = pipe body collapse pressure

dn = nominal diameter
t = wall thickness

33
 Collapse (External Pressure) contd

F1, F2, F3, F4, F5

These values are for
the uniaxial stress
Different values for
effective yield stress
For Biaxial calculate
the effective Yield
Stress and
interpolate the Fs

(Fs depend on Yield Stress)

34
 Collapse (External Pressure) contd

Upper Limit for Yield Strength Collapse

(F1 2) + 8 F2 +
2
F 3 + (F1 2 )

dn ( )
yield e

t F

2 F2 + 3
( )
yield e

35
 Collapse (External Pressure) contd

Upper Limit for Plastic Collapse

dn ( yield ) e (F1 F4 )

t F3 + ( yield ) e (F2 F5 )

36
 Collapse (External Pressure) contd

Upper Limit for Transition Collapse

d n 2 + F2 F1

t 3 F2 F1

37
 Collapse (External Pressure) contd
Boundaries for Axial Stress = 0

38
 Collapse (External Pressure) Example 3

Calculate the Collapse pressure rating for a 7 in,

N-80, 23 lb/ft casing.

Solution:
Solution 7 in, N-80, 23 lb/ft t = 0.317 in

Grade F1 F2 F3 F4 F5

N-80 3.071 0.0667 1,955 1.988 0.0434

dn 7
= = 22.08 Plastic collapse for N-80
t 0.317

39
Collapse (External Pressure) Example 3

F1
( pcr ) plastic = ( yield ) F2 F3
( dn t )
e

3.071
( pcr ) plastic = 80,000 0.0667 1,955 = 3,836 psi
22.08

40
 Triaxial Collapse
Effect of Axial Stress in the Collapse
Resistance Effective Yield Stress
Von Mises Criteria (Distortion Energy)
Material fails (ductile yield failure) when
total distortion energy equals uniaxial test
energy

( z r ) + ( r t ) + ( t z ) 2
2 2 2 2
yield

41
 Triaxial Collapse contd

Triaxial

z + pi z + pi
2

( )
yield e = 2
yield 3 + 3 z pi
2 2
Biaxial
z
( )
yield e = 2
yield 0.75 z
2

2
(yield)e = effective yield stress
yield = uniaxial stress t
z = axial stress
pi = internal pressure (pi >> po)

42
 Triaxial Collapse contd

Linear Interpolation for Fs

Fs depend on Yield Stress

For A < e < B interpolate using (linear)

e A
Fe = FA + (FB FA )
B A

43
 Fs Formulas (API Bull. 5C3)

F1 = 2.8762 + 0.10679 10 5 Y + 0.21301 10 10 Y2 0.53132 10 16 Y3

F2 = 0.026233 + 0.50609 10 6 Y
F3 = 465.93 + 0.030867 Y 0.10483 10 7 Y2 + 0.36989 10 13 Y3
3
3( F2 / F1 )
46.95 10 6

2 + ( F / F1
)
F4 = 2
2
3( F2 / F1 ) 3( F2 / F1 )
Y ( F2 / F1 ) 1
2 + ( F2 / F1 ) 2 + ( F2 / F1
)
F5 = F4 ( F2 / F1 )

44
 Triaxial Collapse Example 4

For the casing of Example 3, calculate the

corrected critical collapse pressure if a
section of 2000 ft, 7 in, N-80, 23 lbm/ft
casing is suspended below it (assume
linear weight of 23 lbf/ft and empty
borehole - no buoyancy effect). What is
the corrected collapse pressure if the
internal pressure is 1000 psi?

45
 Triaxial Collapse Example 4

Solution:
Weight of Casing Below Point in Question

F = 2000 ft 23 lbf/ft = 46,000 lbf

Cross Section Area

(7 2 6.366 2 )
Ac = = 6.6555 in 2
4
Axial Stress

46,000 lbf
z = 2
= 6,912 psi
6.6555 in

46
 Triaxial Collapse Example 4

Effective Yield Stress (biaxial)

z
( )
yield e = 2
yield 0.75 z
2

2

( )
yield e
2 6,912
= 80,000 0.75 6,912 = 76,320 psi
2

(an equivalent N-76.32)

47
 Triaxial Collapse Example 4

Interpolated Fs
Grade F1 F2 F3 F4 F5
C-75 3.054 0.0642 1,806 1.990 0.0418
N-76.32 3.058 0.0649 1,845 1.992 0.0422
N-80 3.071 0.0667 1,955 1.998 0.0434

API Fs Formulas (MsExcel Spreadsheet)

y ield 76320
F1 F2 F3 F4 F5
3.058 0.0649 1845 1.992 0.0422

48
 Triaxial Collapse Example 4
dn 7
Collapse Regime = = 22.08
t 0.317

Yield Regime U-Limit:

(F1 2) + 8 F2 +
2 F 3 + (F1 2 )

dn ( yield ) e

t F
2 F2 + 3
( yield ) e

1,845
(3.058 2) + 8 0.0649 +
2
+ (3.058 2)
76,320
= 13.54 < 22.08
1,845
2 0.0649 +
76,320
49
 Triaxial Collapse Example 4

Plastic Regime U-Limit:

dn ( yield ) e (F1 F4 )

t F3 + ( yield ) e (F2 F5 )

76,320 (3.058 1.992 )

22.08 = 22.79
1,845 + 76,320 (0.0649 0.0422 )

Collapse occurs in the Plastic Regime

50
 Triaxial Collapse Example 4

Plastic Collapse Strength

F
( p ) = ( ) F F 1

(d n t )
cr plastic yield e 2 3

3.058
( pcr ) plastic = 76,320 0.0649 1,845 = 3,772 psi
22.08

(compare with 3,830 psi for the unstressed

casing)

51
 Triaxial Collapse Example 4

Effect of Internal Pressure

Critical pressure expressions are for pressure
differential. However, the effective yield stress
should account or the internal pressure, since
the yield will start at the internal wall.

The triaxial expression must be used:

z + pi z + pi
2

( )
yield e = 2
yield 3 + 3 z pi
2 2

52
 Triaxial Collapse Example 4

6.912 + 1 6.912 + 1
2

( )
yield e = 80 3
2
2
+ 3 6.912 1
2

( ) yield e = 75.800 ksi = 75,800 psi

y ield 75800
F1 F2 F3 F4 F5
3.056 0.0646 1830 1.991 0.0421

3.056
( pcr ) plastic = 75,800 0.0646 1,830 = 3, 764 psi
22.08

( pext )max = 3, 764 + 1, 000 = 4, 764 psi

53
Pressure Collapse Table

54
 Casing Design Criteria
Biaxial Method or Uniaxial Method
Burst
Conductor
Surface and Intermediate Casing
Production Casing
Collapse

Tension

55
 Casing Design Criteria contd

Burst Conductor:
External pressure is zero
The maximum internal pressure is the
formation fracture pressure at the depth of the
conductor set depth. If the fracture pressure is
unknown, assume pff=1 psi/ft
F.S.=1.1
Neglect the gas density inside the conductor

56
Burst of Conductor

57
 Casing Design Criteria contd

Burst of Surface & Intermediate Csg.:

External pressure: hydrostatic pressure of the heaviest mud
used to drill the hole and set the casing
Internal pressure: based on pore pressure at the final depth
of the next casing. If the pore pressure at the bottom of the
next casing is not known, assume the following:

p p = 0.564 psi/ft Depth next casing < 8000 ft

p p = 0.650 psi/ft Depth next casing 8000 ft
Assume that a fraction f (usually not less than 40%) of the
length is evacuated by gas and (1-f) fraction of the length
remains filled with drilling fluid.
Neglect the gas density inside the conductor.
F.S.=1.1
Worse scenario at the top of string

58
Burst of Surf. & Interm. Csg.

59
 Casing Design Criteria contd
Burst of Production Casing:
External pressure: hydrostatic pressure due to formation saltwater (SGsw
= 1.1542)
Internal pressure: based on pore pressure at the final depth Dc
(production depth). If the pore pressure at the bottom of the casing is not
known assume the following:

p p = 0.564 psi/ft Depth casing < 8000 ft

p p = 0.650 psi/ft Depth casing 8000 ft
Assumed the whole internal casing filled with gas (gas lift production)
Pressure inside the casing determined as follows:
DC D

Mg
( DC D )
pi = pb e RT
pb e 40000

F.S.=1.1 is used
Worse scenario at the top of string

60
Burst of Production Casing

61
 Casing Design Criteria contd

Collapse:
Collapse due to fluid in the annulus between the
casing and the borehole
Considered the heaviest drilling fluid used to drill
the hole and set the casing
Assume casing empty
No buoyancy
F.S.=1.0 (neglect the strengthening effect of
cement; most of the casing will not be empty)
Worse scenario at the bottom of string

62
Collapse of Casing

63
 Casing Design Criteria contd

Tension:
Corresponds to the weight of the
casing weight measured in the air
(no buoyancy effect)
F.S.:
1.6 for couplings
1.8 for casing body
Worse scenario at the bottom of string

64
 Casing Design Example
Evaluate the burst and collapse pressure
loadings and design an appropriate surface
casing using the biaxial method. Check for
axial load.
Setting depth of the casing string: 4000 ft
Mud density as setting the string: 10.0 lb/gal
Setting depth of the next csg. string: 11000 ft
Mud density of the next phase: 10.5 lb/gal
Casing size and coupling: 103/4 Buttress
threads, minimum grade K-55
Assume f = 40%.

65
 Casing Design Example contd

Burst Loading (this is a surface csg.)

External Pressure:

po(psi) = 0.052 x 10 lb/gal x D(ft)

po = 0.52 x D

66
 Casing Design Example contd

Internal Pressure:
pp=0.650 psi/ft (Dnc>8,000 ft)
pp = 11,000 x 0.650 = 7,150 psi
(1-0,4)xDnc = 6,600 ft
p6600= 7,150-0.052x10.5x6,600=3,546 psi

pi= 3,546 psi

67
 Casing Design Example contd

Burst Pressure contd:

F.S. = 1.1

pab = (pi-po)

pab= 3,546 0.52D

68
 Casing Design Example contd

Collapse Loading

External Pressure:
po = 0.52 x D
Internal pressure = 0 psi

F.S. = 1.0

pac = 0.52 x D
69
 Casing Design Example contd
Design for Burst
Start at bottom (minimum burst pressure)

pab,4000 = 3,546 0.52 x 4000 = 1,466 psi

Cheapest casing: (p.320-321)

K-55, 40.50 lb/ft, Burst Strength 3,130 psi

Minimum depth that can go:

pab,D = 3,546 0.52 x D = 3130 psi / 1.1
Dmin = 1347 ft

70
 Casing Design Example contd

Continue with next cheapest Casing

K-55, 45.50 lb/ft, Burst Strength 3,580 psi

Minimum depth that can go:

pab,D = 3,546 0.52 x D = 3,580 psi / 1.1
Dmin = 561 ft

71
 Casing Design Example contd

Continue with next cheapest Casing

K-55, 51.00 lb/ft, Burst Strength 4,030 psi

Minimum depth that can go:

pab,D = 3,546 0.52 x D = 4,030 psi / 1.1
Dmin = -226 ft (above surface)

72
 Casing Design Example contd
Burst Diagram

0 ft
103/4 K-55 51.00 lb/ft
561 ft
103/4 K-55 45.50 lb/ft

1347 ft

103/4 K-55 40.50 lb/ft

4000 ft 73
 Casing Design Example contd
Design for Collapse (uniaxial)
Start at top (minimum collapse pressure)
pac = 0.52 x D

Cheapest casing:
K-55, 40.50 lb/ft, Collapse Strength 1,580 psi

Maximum depth that can go:

pac,D = 0.52 x D = 1,580 psi / 1.0
Dmax = 3,038 ft

74
 Casing Design Example contd

Continue with next cheapest Casing

K-55, 45.50 lb/ft, Collapse Strength 2,090 psi

Maximum depth that can go:

pac,D = 0.52 x D = 2,090 psi / 1.0
Dmax = 4.019 ft

75
 Casing Design Example contd
Collapse Diagram

0 ft

103/4 K-55 40.50 lb/ft

3038 ft

103/4 K-55 45.50 lb/ft

4000 ft 76
 Casing Design Example contd
Combine Two Diagrams

0 ft
103/4 K-55 51.00 lb/ft
561 ft
103/4 K-55 45.50 lb/ft

1347 ft
burst
+ = 103/4 K-55 40.50 lb/ft

collapse
3038 ft
103/4 K-55 45.50 lb/ft

4000 ft
77
 Casing Design Example contd

Collapse Adjustment (Biaxial)

Start at bottom (Iterative Process)
No need to check at bottom of 45.50 lb/ft
Bottom of 103/4 K-55 40.50 lb/ft - 3,038 ft

d n 10.75
= = 30.71
t 0.350

A=
4
(10.75 2
10.050 2
) = 11.44 in 2

W = 45.50 lb/ft (4000 ft 3038 ft) = 43, 771 lbf

43, 771 lbf
z = 2
= 3,828 psi
11.44 in
78
 Casing Design Example contd

Effective Yield Stress (biaxial)

3,828
( yield )e = 55, 0002 0.75 3,8282
2
= 52,986 psi

y ield 52986
F1 F2 F3 F4 F5
2.985 0.0530 1146 1.994 0.0354

79
Casing Design Example contd
Yield Regime U-Limit

1,146
( 2.985 2 ) + 8 0.0530 + + ( 2.985 2 )
2

52,987
= 14.98 < 30.71
1,146
2 0.0530 +
52,987

Not Yield Regime

80
 Casing Design Example contd
Plastic Regime U-Limit

52,987 (2.985 1.994 )

= 25.26 < 30.71
1,146 + 52,987 (0.0530 0.0354)

Not Plastic Regime

81
Casing Design Example contd
Transition Regime U-Limit

2 + 0.0530 2.985
= 37.84 < 30.71
3 0.0530 2.985

Collapse occurs in the Transition Regime

82
 Casing Design Example contd

Transition Collapse Pressure

1.994
( pcr )trans = 52,986 0.0354 = 1,562 psi
30.71

Maximum depth that can go:

pac,D = 0.52 x D = 1,562 psi / 1.0
Dmax = 3,004 ft

83
 Casing Design Example contd
2nd Iteration
Bottom of 103/4 K-55 40.50 lb/ft - 3,001 ft

W = 45.50 lb/ft (4000 ft 3009 ft) = 45,318 lbf

45,318 lbf
z = 2
= 3,963 psi
11.44 in

84
 Casing Design Example contd

Effective Yield Stress (biaxial)

3,963
( )
yield e = 55, 000 2
0.75 3,9632

2
= 52,911 psi

y ield 52911
F1 F2 F3 F4 F5
2.984 0.0530 1143 1.994 0.0354

85
 Casing Design Example contd
Plastic Regime U-Limit

52,911 ( 2.985 1.994 )

= 25.26 < 30.71
1,144 + 52,911 ( 0.0530 0.0354 )

Not Plastic Regime

86
 Casing Design Example contd
Transition Regime U-Limit

2 + 0.0530 2.985
= 37.86 > 30.71
3 0.0530 2.985

Collapse occurs in the Transition Regime

87
 Casing Design Example contd
Transition Collapse Pressure

1.994
( pcr )trans = 52,911 0.0354 = 1,561 psi
30.71

Maximum depth that can go:

pac,D = 0.52 x D = 1,561 psi / 1.0
Dmax = 3,002 ft

Close Enough!

88
 Casing Design Example contd
Final Diagram

0 ft
1 103/4 K-55 51.00 lb/ft
561 ft
2
103/4 K-55 45.50 lb/ft

1347 ft
3

103/4 K-55 40.50 lb/ft

3006 ft
3038 ft 4
103/4 K-55 45.50 lb/ft

4000 ft
89
 Casing Design Example contd

Check for Tension

Critical section: Top of section 3
Axial Load

W=45.50x(4000-3006)+40.50x(3006-1347)=112,417 lbf

103/4 K-55 40.50 lb/ft

Body Strength: 629 kips/1.8 = 349 kips
Coupling Strength: 819 kips/1.6 = 512 kips

90
 Csg. Design & Pore Pressure

pressure

Abnormal
P: >0.4365 psi/ft
depth

Normal
P: 0.433-0.4365 psi/ft
91
 Casing Set Depth
Need for:
Pore Pressure
Gradient
Formation
Fracture
Gradient

92