Faculty of Engineering

Petroleum Engineering Department

Drilling Engineering II
Fourth Stage

Lecture # 17
Casing Design

Pshtiwan Jaf 1
[email protected]
 Graphical Method for Casing Design
Solution:
C. 9 5/8" Casing
Collapse:
At surface = 0 psi
73
At shoe = × 10400 = 5272 𝑝𝑠𝑖
144

The collapse line is drawn between 0 at surface and 5272 psi at 10400 as shown in
the figure.
From table 10.6, the collapse resistances of the available grades as adjusted for a
safety factor of 0.85 as in below table.
2
 Graphical Method for Casing Design
Solution:
C. 9 5/8" Casing
Collapse:

Collapse Resistance (psi)

Grade Wt (Ib/ft) Coupling
SF = 1 SF = 0.85
C75 43.5 BTS 3750 4412
L80 47 BTS 4750 5588
C95 53.5 BDS 7330 8624

The collapse resistance values are plotted as vertical lines as shown in the figure

3
 Graphical Method for Casing Design
Solution:
C. 9 5/8" Casing
Selection based on collapse only:

Depth (ft) Grade Weight (Ib/ft)

0 - 8700 C75 43.5

0 – 10400 L80 47
0 – 10400 C95 53.5

4
 Graphical Method for Casing Design
Solution:
C. 9 5/8" Casing
Burst
𝑃𝑓 𝑎𝑡 𝑛𝑒𝑥𝑡 𝑇𝐷 = 13900 × 0.57 = 7923 𝑝𝑠𝑖
At shoe
𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 𝑃𝑓 − 𝑇𝐷 − 𝐶𝑆𝐷 𝐺
= 7923 − 13900 − 10400 0.1 = 7573 𝑝𝑠𝑖

𝐸𝑥𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 𝐶𝑆𝐷 × 𝐺𝑚

= 10400 × 0.465 = 4836 𝑝𝑠𝑖

𝐵𝑢𝑟𝑠𝑡 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 7573 − 4836 = 2737 𝑝𝑠𝑖

5
 Graphical Method for Casing Design
Solution:
C. 9 5/8" Casing
Burst:
At surface
Burst pressure= 𝑃𝑓 − (𝑇𝐷 × 𝐺)

𝐵𝑢𝑟𝑠𝑡 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 7923 − (13900 × 0.1) = 6533 𝑝𝑠𝑖

The burst line can now be drawn between 6533 psi at surface and 2737 psi at
10400 as shown in the figure.

From table 10.6, the burst resistances of the available grades as adjusted for a
safety factor of 1.1 as in below table. 6
 Graphical Method for Casing Design
Solution:
C. 9 5/8" Casing
Burst:

Burst Resistance (psi)

Grade Wt (Ib/ft) Coupling
SF = 1 SF = 1.1
C75 43.5 BTS 5930 5391
L80 47 BTS 6870 6245
C95 53.5 BDS 9410 8855

The burst resistance values are plotted as vertical lines as shown in the figure

7
 Graphical Method for Casing Design
Solution:
C. 9 5/8" Casing
Selection based on burst only:

Depth (ft) Grade Weight (Ib/ft)

3200 - 10400 C75 43.5

800 – 10400 L80 47
0 – 10400 C95 53.5

8
 Graphical Method for Casing Design
Solution:
C. 9 5/8" Casing
Selection based on collapse & burst:

Wt of section in
Depth (ft) Grade & Wt
air (x 1000 Ib)
0 – 800 C95, 53.5 42.8
800 – 3200 L80, 47 112.8
3200 – 8700 C75, 43.5 239.25
8700 - 10400 L80, 47 79.9

9
 Graphical Method for Casing Design
Solution:
C. 9 5/8" Casing
Tension:
The suitability of selected grades in tension will be investigated by considering the total
tensile forces resulting from:
a) Casing buoyant weight
73
𝐵𝐹 = 1 − = 0.851
489.5

b) Bending Force
𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝐹𝑜𝑟𝑐𝑒 = 63 𝜃 𝐷 𝑊𝑛 = 63 × 3 × 9.625 × 𝑊𝑛 = 1819.125 𝑊𝑛

c) Shock Load
𝐹𝑠 = 3200 𝑊𝑛 10
 Graphical Method for Casing Design
Solution:
C. 9 5/8" Casing
Tension:
Starting from bottom to top, the SF in tension for each section could be calculated as in
below table;

Section Section Bending Shock

Carried Buoyant Total Tensil Yield Strenght SF in
Depth (ft) Grade & Wt Length Buoyant Force Load
Wt (Ib) Load (Ib) (Ib) Tension
(ft) Wt (Ib) (Ib) (Ib)
8700 - 10400 L80, 47 1700 67995 67995 85499 150400 303894 1086000 3.57
3200 - 8700 C75, 43.5 5500 203602 271597 79132 139200 489929 942000 1.92
800 - 3200 L80, 47 2400 95993 367590 85499 150400 603489 1086000 1.80
0 - 800 C95, 53.5 800 36423 404013 97323 171200 672536 1458000 2.17

11
 Graphical Method for Casing Design
Solution:
C. 9 5/8" Casing
Pressure Testing:
𝑇𝑒𝑠𝑡𝑖𝑛𝑔 𝑃 = 0.6 × 𝑏𝑢𝑟𝑠𝑡 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑜𝑓 𝑙𝑜𝑤𝑒𝑠𝑡 𝑔𝑟𝑎𝑑𝑒 (𝐶75, 43.5)
= 0.6 × 5930 = 3558
During pressure testing an extra tensile force is generated and selected grades with
marginal SF should be checked.
At 800 ft, grade L80, 47# has the lowest SF of 1.8, hence this grade should be checked.
Then:
𝜋
𝑇𝑜𝑡𝑎𝑙 𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑓𝑜𝑟𝑐𝑒 𝑑𝑢𝑟𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟 𝑡𝑒𝑠𝑡𝑖𝑛𝑔 = 𝑊𝑎𝑖𝑟 × 𝐵𝐹 + ( 𝐼𝐷2 × 𝑡𝑒𝑠𝑡𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒)
𝜋 4
= 367590 + 8.681 2 × 3558 = 578179 𝐼𝑏
4

1086000
𝑆𝐹 = = 1.88 > 1.8
578179 12
 Graphical Method for Casing Design
Solution:
C. 9 5/8" Casing
Biaxial effects
The weakest grade should be checked (C75, 43.5#), This grade carrying a total buoyant load of
271597 Ib as shown in the previous table.

𝑊𝑒𝑖𝑔ℎ𝑡 𝑐𝑎𝑟𝑟𝑖𝑒𝑑 271597

𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑟𝑎𝑡𝑖𝑜 = = = 0.288
𝑌𝑖𝑒𝑙𝑑 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 942000
From table 10.8, it can be seen that for a tensile ratio of 0.264, the collapse resistance reduces to
82% of its original value, hence:

𝐶𝑜𝑙𝑙𝑎𝑝𝑠𝑒 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑢𝑛𝑑𝑒𝑟 𝑏𝑖𝑎𝑥𝑖𝑎𝑙 𝑙𝑜𝑎𝑑𝑖𝑛𝑔 = 0.82 × 3750 = 3075 psi

𝑐𝑜𝑙𝑙𝑎𝑝𝑠𝑒 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑢𝑛𝑑𝑒𝑟 𝑏𝑖𝑎𝑥𝑖𝑎𝑙 𝑙𝑜𝑎𝑑𝑖𝑛𝑔 3075

𝑆𝐹 𝑖𝑛 𝑐𝑜𝑙𝑙𝑎𝑝𝑠𝑒 = = = 1.9 > 0.85
𝑐𝑜𝑙𝑙𝑎𝑝𝑠𝑒 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑎𝑡 3200 𝑓𝑡 73 × 3200
144 13
 Graphical Method for Casing Design
Solution:
C. 9 5/8" Casing
Final Selection:
Hence selection based on Collapse, Burst, Tension (Buoyant, Bending & Shock
loads), Pressure Testing and Biaxial Loads is as below:

Grades & SF in SF in SF in pressure SF in biaxial

Depths (ft) SF in burst
Weights collapse tension testing loading
0 – 800 C95, 53.5# 18.1 1.44 2.17 2.4 15
800 – 3200 L80, 47# 2.9 1.1 1.80 1.88 9.2
3200 – 8700 C75, 43.5# 0.85 1.11 1.92 1.94 1.9
8700 – 10400 L80, 47# 0.9 2.05 3.57 3.9 1.04

14
 Graphical Method for Casing Design
Solution:
D. 7" Casing
Collapse:
At surface = 0 psi
87
At shoe = × 13900 = 8398 𝑝𝑠𝑖
144

The collapse line is drawn between 0 at surface and 8398 psi at 13900 as shown in
the figure.
From table 10.7, the collapse resistances of the available grades as adjusted for a
safety factor of 0.85 as in below table.
15
 Graphical Method for Casing Design
Solution:
D. 7" Casing
Collapse:

Collapse Resistance (psi)

Grade Wt (Ib/ft) Coupling
SF = 1 SF = 0.85
K55 26 BTS 4320 5082
L80 29 BTS 7020 8259
C95 29 BDS 7820 9200

The collapse resistance values are plotted as vertical lines as shown in the figure

16
 Graphical Method for Casing Design
Solution:
D. 7" Casing
Selection based on collapse only:
Collapse
0 1000 2000 3000 4000 5000 6000 7000 8000 9000
0

2000

4000 Depth (ft) Grade Weight (Ib/ft)

6000

8000 0 – 8400 K55 26

10000
0 – 13700 L80 29
12000

14000
0 – 13900 C95 29
16000

17
 Graphical Method for Casing Design
Solution:
D. 7" Casing
Burst
𝑃𝑓 𝑎𝑡 𝑛𝑒𝑥𝑡 𝑇𝐷 = 13900 × 0.57 = 7923 𝑝𝑠𝑖
At shoe
𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 𝑃𝑓 − 𝑇𝐷 − 𝐶𝑆𝐷 𝐺
= 7923 − 13900 − 13900 0.1 = 7923 𝑝𝑠𝑖

𝐸𝑥𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 𝐶𝑆𝐷 × 𝐺𝑚

= 13900 × 0.465 = 6463 𝑝𝑠𝑖

𝐵𝑢𝑟𝑠𝑡 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 7923 − 6463 = 1460 𝑝𝑠𝑖

18
 Graphical Method for Casing Design
Solution:
D. 7" Casing
Burst:
At surface
Burst pressure= 𝑃𝑓 − (𝑇𝐷 × 𝐺)

𝐵𝑢𝑟𝑠𝑡 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 7923 − (13900 × 0.1) = 6533 𝑝𝑠𝑖

The worst condition in practice, hydrocarbon production is carried out through a
tubing sealed in a packer as shown in the figure. Thus, under ideal conditions only
the casing shoe will be subjected to burst effects.

19
 Graphical Method for Casing Design
Solution:
D. 7" Casing
Burst:
However, a situation may arise in practice when the production tubing leaks gas to
the 7 inch casing. In this case, the surface pressure (6533 psi) is now acting on the
column of packer fluid between the casing and the tubing.

Hence, burst calculations for production casing should be modified as follows:

At surface
Burst pressure= 𝑃𝑓 − (𝑇𝐷 × 𝐺)
𝐵𝑢𝑟𝑠𝑡 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 7923 − (13900 × 0.1) = 6533 𝑝𝑠𝑖 20
 Graphical Method for Casing Design
Solution:
D. 7" Casing
Burst
At shoe
𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 + ℎ𝑦𝑑𝑟𝑜𝑠𝑡𝑎𝑡𝑖𝑐 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑜𝑓 𝑝𝑎𝑐𝑘𝑒𝑟 𝑓𝑙𝑢𝑖𝑑
87 × 13900
= 6533 + = 14931 𝑝𝑠𝑖
144

𝐸𝑥𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 𝐶𝑆𝐷 × 𝐺𝑚

= 13900 × 0.465 = 6463 𝑝𝑠𝑖

𝐵𝑢𝑟𝑠𝑡 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 14931 − 6463 = 8467 𝑝𝑠𝑖

21
 Graphical Method for Casing Design
Solution:
D. 7" Casing
Burst:
The burst line can now be drawn between 6533 psi at surface and 8467 psi at
13900 as shown in the figure.

From table 10.7, the burst resistances of the available grades as adjusted for a
safety factor of 1.1 as in below table.

22
 Graphical Method for Casing Design
Solution:
D. 7" Casing
Burst:

Burst Resistance (psi)

Grade Wt (Ib/ft) Coupling
SF = 1 SF = 1.1
K55 26 BTS 4980 4527
L80 29 BTS 8160 7418
C95 29 BDS 9690 8809

The burst resistance values are plotted as vertical lines as shown in the figure

23
 Graphical Method for Casing Design
Solution:
D. 7" Casing
Selection based on burst only:

Burst
0 1000 2000 3000 4000 5000 6000 7000 8000 9000
0

2000
Depth (ft) Grade Weight (Ib/ft)
4000

6000
0 – 6100 L80 29
8000

10000
0 – 13900 C95 29
12000

14000

16000

24
 Graphical Method for Casing Design
Solution:
D. 7" Casing
Selection based on collapse & burst:
Collapse & Burst
0 1000 2000 3000 4000 5000 6000 7000 8000 9000
0

2000

4000 Wt of section in
Depth (ft) Grade & Wt
6000 air (x 1000 Ib)
8000
0 – 6100 L80, 29 176.9
10000

12000 6100 – 13900 C95, 29 226.2

14000

16000

25
 Graphical Method for Casing Design
Solution:
D. 7" Casing
Tension:
The suitability of selected grades in tension will be investigated by considering the total
tensile forces resulting from:
a) Casing buoyant weight
87
𝐵𝐹 = 1 − = 0.822
489.5

b) Shock Load
𝐹𝑠 = 3200 𝑊𝑛

26
 Graphical Method for Casing Design
Solution:
D. 7" Casing
Tension:
Starting from bottom to top, the SF in tension for each section could be calculated as in
below table;

Section Section Shock

Carried Buoyant Total Tensil Yield Strenght SF in
Depth (ft) Grade & Wt Length Buoyant Load
Wt (Ib) Load (Ib) (Ib) Tension
(ft) Wt (Ib) (Ib)
6100 - 13900 C95, 29 7800 185936 185936 92800 278736 803000 2.88
0 - 6100 L80, 29 6100 145412 331348 92800 424148 676000 1.59

27
 Graphical Method for Casing Design
Solution:
D. 7" Casing
Tension:
• Since a minimum safety factor of 1.8 is to be used in tension, the L80, 29 lb/ft
may be used if it is designed to carry a maximum weight, W, given by:
676000
1.8 = ⇒ 𝑊 = 375556 𝐼𝑏
𝑊
• Hence, useable weight of section of L80 = [Total weight which can be carried)-
(weight of lower casing grades)

Weight of section of L80, 29 Ib/ft = 375556 – 278736 = 96820 lb

And length of usable section of L80, 29 Ib/ft = 96820/29 = 3339 ft
Remaining top length = 6100 – 3339 = 2761 ft
28
 Graphical Method for Casing Design
Solution:
D. 7" Casing
Tension:
• A heavy casing must be used for top 2761 ft, try C95, 29 Ib/ft:

Section Section Shock

Carried Buoyant Total Tensil Yield Strenght SF in
Depth (ft) Grade & Wt Length Buoyant Load
Wt (Ib) Load (Ib) (Ib) Tension
(ft) Wt (Ib) (Ib)
6100 - 13900 C95, 29 7800 185936 185936 92800 278736 803000 2.88
2761 - 6100 L80, 29 3339 79595 265531 92800 358331 676000 1.89
0 - 2761 C95, 29 2761 65817 331348 92800 424148 803000 1.89

29
 Graphical Method for Casing Design
Solution:
D. 7" Casing
Pressure Testing:
𝑇𝑒𝑠𝑡𝑖𝑛𝑔 𝑃 = 0.6 × 𝑏𝑢𝑟𝑠𝑡 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑜𝑓 𝑙𝑜𝑤𝑒𝑠𝑡 𝑔𝑟𝑎𝑑𝑒 (𝐿80, 29)
= 0.6 × 8160 = 4896
During pressure testing an extra tensile force is generated and selected grades with
marginal SF should be checked.
At 2761 ft, grade L80, 29# has the lowest SF of 1.89, hence this grade should be checked.
Then
𝜋
𝑇𝑜𝑡𝑎𝑙 𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑓𝑜𝑟𝑐𝑒 𝑑𝑢𝑟𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟 𝑡𝑒𝑠𝑡𝑖𝑛𝑔 = 𝑊𝑎𝑖𝑟 × 𝐵𝐹 + ( 𝐼𝐷2 × 𝑡𝑒𝑠𝑡𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒)
𝜋 4
= 79595 + 6.184 2 × 4896 = 226647 𝐼𝑏
4

676000
𝑆𝐹 = = 2.98 > 1.8
226647 30
 Graphical Method for Casing Design
Solution:
D. 7" Casing
Biaxial effects
The weakest grade should be checked (L80, 29#), This grade carrying a total buoyant load of
265531 Ib as shown in the previous table.

𝑊𝑒𝑖𝑔ℎ𝑡 𝑐𝑎𝑟𝑟𝑖𝑒𝑑 265531

𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑟𝑎𝑡𝑖𝑜 = = = 0.39
𝑌𝑖𝑒𝑙𝑑 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 676000
From table 10.8, it can be seen that for a tensile ratio of 0.39, the collapse resistance reduces to
76.3% of its original value, hence:

𝐶𝑜𝑙𝑙𝑎𝑝𝑠𝑒 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑢𝑛𝑑𝑒𝑟 𝑏𝑖𝑎𝑥𝑖𝑎𝑙 𝑙𝑜𝑎𝑑𝑖𝑛𝑔 = 0.763 × 7020 = 5356 psi

𝑐𝑜𝑙𝑙𝑎𝑝𝑠𝑒 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑢𝑛𝑑𝑒𝑟 𝑏𝑖𝑎𝑥𝑖𝑎𝑙 𝑙𝑜𝑎𝑑𝑖𝑛𝑔 5356

𝑆𝐹 𝑖𝑛 𝑐𝑜𝑙𝑙𝑎𝑝𝑠𝑒 = = = 1.45 > 0.85
𝑐𝑜𝑙𝑙𝑎𝑝𝑠𝑒 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑎𝑡 3200 𝑓𝑡 87 × 6100
144 31
 Graphical Method for Casing Design
Solution:
D. 7" Casing
Final Selection:
Hence selection based on Collapse, Burst, Tension (Buoyant & Shock loads),
Pressure Testing and Biaxial Loads is as below:

Grades & SF in SF in SF in pressure SF in biaxial

Depths (ft) SF in burst
Weights collapse tension testing loading
0 – 2761 C95, 29# 4.69 1.40 1.89 3.77 3.51
2761 – 6100 L80, 29# 1.90 1.11 1.89 2.98 1.45
6100 – 13900 C95, 29# 0.93 1.14 2.88 2.41 0.82

32
 Graphical Method for Casing Design
Solution: Final Selection
Casing Size Setting Section Grade & Wt in air String wt Total Wt in
(inch) depth (ft) length (ft) Wt (Ib/ft) (Ib) (Ib) air (Ib)
20 350 0 – 350 K55, 94# 32900 32900
0 – 2400 L80, 72# 172800
13 3/8 6200 2400 – 4200 K55, 68# 122400 439200
4200 – 6200 L80, 72# 144000
0 – 800 C95, 53.5# 42800
800 – 3200 L80, 47# 112800 1349950
9 5/8 10400 474750
3200 – 8700 C75, 43.5# 239250
8700 – 10400 L80, 47# 79900
0 – 2761 C95, 29# 80069
7 13900 2761 – 6100 L80, 29# 96831 403100
6100 - 13900 C95, 29# 226200 33
 Graphical Method for Casing Design
Solution:
A. 20" Casing
Tension:
• The conductor pipe must be checked for tension loading since it carries the
weight of other strings.

• The procedure is to determine the total buoyant weight of string carried and then
compare this with the yield strength of the conductor pipe. A minimum Safety
factor of 1.1 should be obtained.

• For this example, the mud weight of 65 pcf will be considered, i.e., the worst case
is taken into account. 34
 Graphical Method for Casing Design
Solution:
A. 20" Casing
Tension:
65
𝐵𝐹 = 1 − = 0.868
489.5

𝑇𝑜𝑡𝑎𝑙 𝑏𝑢𝑜𝑦𝑎𝑛𝑡 𝑤𝑡 𝑐𝑎𝑟𝑟𝑖𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑡𝑜𝑝 𝑗𝑜𝑖𝑛𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟 𝑝𝑖𝑝𝑒

= 1349950 × 0.868 = 1171757 𝐼𝑏

1479000
𝑆𝐹 = = 1.26 > 1.1
1171575

35
 Graphical Method for Casing Design
Solution:

That is it!

36