Casing Design

Casing Design

Why Run Casing? Types of Casing Strings

Classification of Casing
Burst, Collapse and Tension Example
Effect of Axial Tension on Collapse Strength
Example

4
Casing Design

What is casing?
–Casings are tubular goods run in a wellbore after
drilling the hole. They have various sizes to suit the
different hole sizes used in each section of the drilling
operation. Normally, casing will be cemented in a
wellbore.
–Typically, casing is terminated on surface at the casing
hanger. Liners do not reach surface but are suspended
within the string of previous casing

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CASING DESIGN

• Why is Casing Design/Selection Important?

– Casing is used for protection during all phases of
drilling & production.
– Casing must be designed to withstand many
severe operating conditions.
– The casing design must meet all potential
completion requirements

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 Casing Design

Why run casing?

1.To prevent the hole from caving in (keep it open due
to sloughing or swelling)
2.To protect fresh water zones from contamination.
3.To prevent water migration to producing formation.
4.To isolate porous formations with different
pressure regimes
5.To provide a production conduit & confine
production to the wellbore.

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Casing Design - Why run casing, cont’d

6. To provide a foundation for the wellhead/BOP

7. To control pressures during drilling
8. To provide an acceptable environment for
subsurface equipment in producing wells
9. 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?

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 Casing seat selection

• For the casing setting depth determination, pore pressure and

fracture gradient are normally described in PPG
• The first step of casing seat design is to apply the safety
margin to the PP-FG plot.
• Usually a 0.5 ppg for safety for both pore pressure and
fracture gradient are applied.
• You need to add the safety factor into formation pressure and
subtract it from the fracture gradient.
Step 1 : Substract
safety margin
from FG and add
same to PP

8
 Bottoms Up Design
• This is the standard method for casing seat
selection.
• From Point A (the highest mud weight required
at the total depth), draw a vertical line upward
to Point B.
• A protective 7 5/8-in. casing string must be set
at 12,000 ft, corresponding to Point B, to
enable safe drilling on the section AB.
• To determine the setting depth of the next
casing, draw a horizontal line BC and then a
vertical line CD.
• In such a manner, Point D is determined for
setting the 9 5/8-in. casing at 9,500 ft.
• The procedure is repeated for other casing
strings, usually until a specified surface casing
depth is reached.
 Top Down Design

• From the setting depth of the 16-in.

surface casing (here assumed to be at
2,000 ft), draw a vertical line from the
fracture gradient dotted line, Point A, to
the pore pressure dashed line, Point B.
• This establishes the setting point of the
11¾-in. casing at about 8000 ft.
• Draw a horizontal line from Point B to the
intersection with the dotted frac gradient
line at Point C; then, draw a vertical line to
point D at the pore pressure curve
intersection. This establishes the 9 5/8-in.
casing setting depth at about 10,500 ft.
• This process is repeated for the casing at
TD.
 PP-FG Plot for Well Data

• Add and subtract safety margin of 0.5 ppg

from PP and FG respectively.
• BOTTOMS UP DESIGN
• WATER DEPTH 5724 ft
• TOS @8270 FT, BOS @16430 FT
• 36” @ 6060 FT ( 270 FT BML)
• 28” @ 6490 FT (700 FT BML)
• TOS @ 9270 ft, I set 22” after drilling into salt
for better well integrity.
• After setting 22” @ 9140 ft, Bottoms Up
method allows next casing to be set at 21830
ft, could have skipped 13-5/8” altogether.
• Reason is rubble zone below BOS at 16430 ft.
As such, for well integrity reasons, 13-5/8”
set before coming out of salt at 16017 ft.
 Observations: Top Down / Bottoms Up

• When compared both methods do not necessarily give the same

casing setting depths.
• They do not necessarily give the same number of strings.
• In the top-down design, the bottomhole pressure is missed by a slight
amount that requires a short 6-in. liner section.
• This slight error can be fixed by resetting the surface casing depth.
• The top-down method is more like actually drilling a well, in which the
casing is set when necessary to protect the previous casing shoe.
• This analysis can help anticipate the need for additional strings, given
that the pore pressure and fracture gradient curves have some
uncertainty associated with them.
CASING SCHEMATIC
Functions
1. Conductor (20”-30”) to protect loose,
near surface formations and enables
Conductor circulation of drilling fluid

2. Surface casing (13-3/8”- 20”) to

provide blowout protection and prevent
loss circulation
Surface
3. Intermediate casing (9-5/8” - 16”) to
casing isolate unstable hole section and loss
Tieback string circulation, low pressure and
production zones (often set in the
transition between normal to abnormal
Intermediate zone)

casing 4. Production (4-1/2”-9-5/8”) to isolate

production zone and contains
formation pressure in the event of
tubing leaks
Production 5. Liner (4-1/2” - 13-3/8”) to improve
casing hydraulic performance during deep
drilling and to allow the use of larger
tubing above the liner top
6. Tieback string to provide additional
Production pressure integrity from the liner top to
liner the wellhead

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 PHYSICAL PROPERTIES

• Casing is defined by its physical properties :

• Pipe Grade refers to the pipe's yield strength by a

letter and a 2 or 3 digit number e.g. N80.
• The letter selected defines the metallurgy and
production method (K is seamed, J is seamless, L is
seamless and heat treated)
• The Numerical Code indicates the minimum yield
strength in psi (N80 has a minimum yield strength of
80,000 psi).
• The Yield strength is used to determine the minimum
value of pipe Burst and Collapse resistance and the
tensile strength.
CASING GRADES
 Casing Designations

• When ordering casing, we should specify the

following:
• Grade: refers to the yield strength and metallurgy of the tubular [N80,
K55, H40]

• Weight: refers to weight per unit length of tubular [47.0 lb/ft, 29.0 lb/ft]

• Size: refers to the outside diameter of tubular [13 3/8”, 9 5/8”]

• Connection: the coupling used to connect the tubulars [Buttress, VAM,

LT&C]

• Range: refers to average length of tubular joint [API: R1 = 16 to 25

ft, R2 = 25 – 34 ft and R3=35 – 45 ft]
Casing Threads and Couplings

API round threads - short { CSG }

API round thread - long { LCSG }
Buttress { BCSG }
Extreme line { XCSG }
Other …
See Halliburton Book...
 API BULLETINS

• All Oilwell Tubular Goods (OCTG) are governed by the

American Petroleum Institute's Committee on
Standardization of tubular goods.
API Publications Relating to Casing and Tubing
Specification/RP/BUL Title
• Spec 5B Specification for Threading, Gauging & Thread
Inspection of Casing, Tubing and Drill pipe
• Spec 5L Specification for Line Pipe
• Spec 5CT Specification for Casing & Tubing
• RP 5CI Rec. Practice for Care and Use of Casing & Tubing
• Bul 5A2 Bulletin on Thread Compounds
• Bul 5C2 Bulletin on Performance Properties of Casing and
Tubing
• Bul 5C3 Bulletin on Formulas and Calculations for Casing,
Tubing, Drill pipe and Line Pipe Properties
• Bul 5C4 Bulletin on Round Thread Casing Joint Strength with
Combined Internal Pressure and Bending.
 CASING DESIGN

• Casing strings types & functions

• Setting depth determination
– Classification of Casing – weight,
grade, connection. Size, Cement Top
• MAASP, Casing pressure test
• Burst, Collapse and Tension
• Effect of Axial Tension on Collapse
Strength
 CASING DESIGN

General Design Criteria

The final selection of casing (weight & grade) is
based on an assessment of the loadings to which a
casing may be subjected.

Four primary factors to be considered in the final

selection:
–Collapse
–Burst
–Tension
–Compression
 CASING DESIGN

Secondary considerations
in casing design:
– Traxial stress
– Buckling
– Wear
– Internal and external
corrosion
– Loading during pressure
testing
– Loading during
reciprocation
 CASING DESIGN

Sources of Tubular Loads

 Tension  Burst and Collapse

✓ String Weight ✓ Fluid pressure
✓ Friction ✓ Fluid expansion
 Compression  Bending
✓ Buoyancy ✓ Buckling
✓ Setting weight ✓ Hole deviation
✓ Reservoir compaction ✓ Doglegs
CASING
DESIGN
(Process)
DETAILED CASING PROGRAM
 CASING DESIGN

Required Design

10,000 psi Collapse 1.0 10,000 psi

100,000 lbf Tension 1.4 140,000 lbf

10,000 psi Burst 1.1 11,000 psi

Casing Design-Burst Failure
 Internal Yield Pressure for Pipes & Couplings
The casing will experience a net burst loading if the
internal radial load exceeds the external radial load.
 Casing Design-Burst

Example 1

Design a 7” Csg. String to 8,000 ft.

Pore pressure gradient = 0.6 psi/ft

Design factor, Ni=1.1

Design for burst only.

 Burst Example

1. Calculate probable reservoir pressure.

psi
p res = 0.6 *8,000 ft = 4,800 psi
ft
2. Calculate required pipe internal yield
pressure rating

pi = pres * Ni = 4,800 *1.1 = 5,280 psi

 Example

3. Select the appropriate casing grade and wt. from

the Halliburton tables:
Burst Pressure required = 5,280 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

Can use N-80 Csg., 23 lb/ft

Halliburton
Tables
23 lb/ft
26 lb/ft

N-80
Casing Design - Collapse Failure
• The casing will
experience a net collapse
loading if the external
radial load exceeds the
internal radial load.
• The greatest collapse
load on the casing will
occur if the casing is
evacuated (empty) for
any reason.
 Casing Design - Collapse Failure

• 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 mud density that will
be in the hole when the casing
string is run, prior to cementing.
Casing Design - Collapse Example

• Example 2 (Extension of Example 1)

• Design a 7” Csg. String to 8,000 ft.

• Mud Density= 12.5 ppg

• Design factor Ci=1.0
• Gas gradient = 0.07 psi/ft
• Design for collapse only.
 Collapse Example

psi
p = 0.052 *8,000 ft *12.5 ppg *1.0 = 5,200 psi
ft
2. Calculate pipe internal pressure

pi = .07 psi / ft *8000 ft = 560 psi

3. Required minimum collapse rating of

pipe is 4640 psi
 Casing Design – Solution

• We can make the following preliminary

selections for the bottom section of casing:
• – Burst: 5,280 psi Collapse: 4,640 psi
 Casing Design - Tension
The axial loads on the casing can be either tensile or
compressive, depending on the operating conditions.
Casing Design - Tension Example

• Example 3 (Extension of Example 1&2)

• Investigate running a 7”, 26 lb/ft string

to 8,000 ft.
• Design factor Ci=1.4
• Design for Tension only.
 Tension Example

The weight on the top joint of casing would

be:
𝑊𝑖 = 26𝑙𝑏/𝑓𝑡 ∗ 8000 ft = 2,08,000𝑙𝑏𝑠

With a design factor of 1.4 for tension, we

require a pipe strength of:

W = 1.4* 2,08,000 lbs = 2,91,200 lbs

 Tension Example

• The casing mechanical property tables

indicates that 7“ (N-80, 26 lb/ft) casing has a
yield strength of 604,000 lbf for pipe body and
a thread and coupling strength of 519,000 lbf.
• Recall that we require a minimum of 291,200
lbf in order to be adequate to run 26 lb/ft to
surface.
• Therefore 26 lb/ ft is OK to surface.
 PP-FG Plot for Well Data

20313.1 20183.8 13055.0 12.44 12.94

MD TVD Pres PP 0.5 ppg 20702.0 20545.3 13263.0 12.41 12.91
20811.1 20646.9 13309.5 12.40 12.90
ft ft psi ppg SM 20816.1 20651.5 13311.4 12.40 12.90
5724.00 5724.00 2619.30 8.80 9.30 20826.1 20660.8 13316.0 12.39 12.89
7783.50 7783.00 3844.80 9.50 10.00 21473.0 21264.6 13371.1 12.09 12.59
• BOTTOMS UP DESIGN 9843 9842 5271.38 10.3 10.80 21657.1 21436.2 13595.0 12.20 12.70
• WATER DEPTH 5724 ft 11202 11200 6173.44 10.6 11.10 22383.0 22109.5 14096.9 12.26 12.76
13302 13300 7676.76 11.1 11.60 22403.0 22128.1 14104.4 12.26 12.76
• TOS @8270 FT, BOS @16430 FT 14583 14580 8870.47 11.7 12.20 22595.0 22305.3 14180.8 12.23 12.73
• 36” @ 6060 FT ( 270 FT BML) 160120 16017 9994.61 12 12.50 22623.0 22331.1 14192.2 12.22 12.72
16159.00 16156.41 10091.07 12.01 12.51 22730.0 22429.7 14585.0 12.50 13.00
• 28” @ 6490 FT (700 FT BML) 23740.0 23360.1 16272.6 13.40 13.90
16176.99 16174.45 10097.94 12.01 12.51
23913.1 23519.2 16334.5 13.36 13.86
16233.95 16231.40 10125.77 12.00 12.50
24104.0 23694.3 16410.2 13.32 13.82
16302.98 16300.43 10156.70 11.98 12.48 24175.0 23759.2 16559.8 13.40 13.90
16315.98 16313.44 10162.30 11.98 12.48 25701.0 25132.9 18320.0 14.02 14.52
16825.97 16823.42 10595.56 12.11 12.61 25705.0 25136.6 18320.0 14.02 14.52
16967.98 16965.43 10762.98 12.20 12.70 Depth TVD LOT fit-tvd-bml LOT-SM
17557.0 17554.4 11172.8 12.24 12.74 9147 9147 13.6 3351 13.10
18337.1 18331.1 11939.2 12.53 13.03 16017 16017 14.2 10221 13.70
18869.1 18848.0 12044.8 12.29 12.79 21830 21600 15.3 15804 14.80
25850 25600 15.6 19804 15.10
Subsea WH System
• The subsea wellhead system is a
pressure-containing vessel that provides a
means to hang off and seal off casing
used in drilling the well.
• The wellhead also provides a profile to
latch the subsea blowout preventer (BOP)
stack and drilling riser back to the floating
drilling rig.
• The subsea wellhead system is located on
the ocean floor, and must be installed
remotely with running tools and drillpipe.
WH Main Function

• Structural
−External forces
−Internal forces
−Support for
inner casings
• Barrier
• BOP Interface
WH system

Wellhead Lock
ring

Conductor Housing

Landing shoulder

Weld 30”

Weld 20”

A rigid lockdown of the high- and

low-pressure housings to enhance
fatigue life effects on the
wellheads and surface casing(s)
4
designs.
Example WH &
Extension joint
Weld
TENARIS ER™ 16" TO 24 1/2"
Tenaris BlueDock® Connector 18" TO 26"
 Casing Info for Example Well

• Casing size 11-7/8”

• Casing size : 22”
• Weight : 71.8 ppf
• Weight : 224 ppf
• Burst rating : 10720 psi
• Burst rating : 6360 psi
• Collapse rating: 7190 psi
• Collapse rating: 3870 psi
• Tensile rating : 2581 klbf
• Tensile rating : 5278 klbf

• Casing size 13-3/8”

• Weight : 88.2 ppf
• Burst rating : 10030 psi
• Collapse rating: 3580 psi
• Tensile rating : 2596 klbf
Burst Design for 22” Casing

• Design a 22” Csg. String to 9140 ft.

• Pore pressure gradient = 0.546 psi/ft

• Design factor, Ni=1.1

• Design for burst.

Burst Design for 22” Casing

1. Calculate probable reservoir pressure.

pres = 0.456 psi/ft* 9140 ft = 4250 psi

2. Calculate required pipe internal yield

pressure rating

pi = pres * Ni = 4,250 *1.1 = 4675 psi

Burst Design for 22” Casing

3. Use appropriate casing grade and wt. given

Burst Pressure required = 4675 psi
22"-224 ppf, X-80, S-90MT has BURST Rating of 6360 psi

Can use X-80 Csg., 224 lb/ft for this well

Collapse Design for 22” Casing

• Design a 22” Casing string to 9140 ft.

• Mud Density= 11.0 ppg

• Design factor Ci=1.0
• Gas gradient = 0.07 psi/ft
• Design for collapse only.
Collapse for 22” Casing

psi
p = 0.052 *9140 ft *10.5 ppg *1.0 = 4990 psi
ft
2. Calculate pipe internal pressure
pi = .07 psi / ft *9140 ft = 640 psi
3. Required minimum collapse rating of pipe is 4990-640
psi = 4350 psi
4. 22"-224 ppf, X-80, S-90MT has Collapse Rating of
3870 psi
5. Will this mean, collapse criteria is failed?
Collapse Design for 22”

psi
p = 0.052 *9140 ft *10.5 ppg *1.0 = 4990 psi
ft
2. Calculate pipe internal pressure
pi = .07 psi / ft *2150 ft + 0.465*6990 = 4543+150
psi = 4694 psi.
3. Required minimum collapse rating of pipe is 4990-4694
psi = 296 psi
4. 22"-224 ppf, X-80, S-90MT has Collapse Rating of
3870 psi
5. So, collapse criteria is met for the given well.
Casing Design - Tension for 22”

• Investigate running a 22”, 224 lb/ft

string to 9140 ft.
• Design factor Ci=1.4
• Design for Tension only.
 Tension for 22” Casing

• Subtracting water depth and draft, casing length is (9140 -

5724 - 92) = 3324 ft
• The weight on the top joint of casing would be:
• 𝑊𝑖 = 224𝑙𝑏/𝑓𝑡 ∗ 3324 ft = 744576 lbf
• With a design factor of 1.4 for tension, we require a pipe
strength of:
• W = 1.4* 744576 lbf = 1042406 lbf or 1042 klbf
• 22"-224 ppf, X-80, S-90MT has Tensile Rating of 5278 klbf.
• So, given 22” casing will qualify tensile requirement for this
well.
How to back calculate Design Factors?

• So far, we considered safety design factors as given, ie Ni

= 1.1 (BDF) ; Ci = 1.0 and TDF = 1.4
• Another way to look at design factors is to look at the
casing burst rating and divide it by the calculated burst
load pressure from well. IF the ratio is more than 1, then
the casing works.
• This ratio is called the BDF
• Likewise, for collapse, we can calculate CDF and for
tension the TDF can be calculated.
BDF, CDF & TDF for Example Well

• Burst Internal Yield 4675 psi

• Burst rating : 6360 psi
• BDF = 6360 / 4675 = 1.36

• Collapse pressure = 296 psi

• Collapse rating: 3870 psi
• CDF = 13.0

• Tension Load = 1042 klbf

• Tensile rating : 5278 klbf
• TDF = 5.06
CASING DESIGN

59
CASING DESIGN

60
CASING DESIGN

61
 Combined Collapse & Tension

• It is clearly seen that as the

axial stress increases, the
pipe collapse resistance
decreases.
• Loads that fall within the
design envelope meet the
design criteria.
• The curved lower right corner
is caused by the combined
stress effects
 Combined Burst and Compression Loading

• Combined burst and compression loading corresponds to the upper left-hand quadrant of
the design envelope.
• This is the region where triaxial analysis is most critical because reliance on the uniaxial
criterion alone would not predict several possible failures.
• For high burst loads (i.e., high tangential stress and moderate compression), a burst failure
can occur at a differential pressure less than the API burst pressure.
• For high compression and moderate burst loads, the failure mode is permanent
corkscrewing (i.e., plastic deformation because of helical buckling). This combined loading
typically occurs when a high internal pressure is experienced (because of a tubing leak or a
buildup of annular pressure) after the casing temperature has been increased because of
production.
• The temperature increase, in the un-cemented portion of the casing, causes thermal
growth, which can result in significant increases in compression and buckling. The increase
in internal pressure also results in increased buckling.
 Combined burst and tension loading
• Combined burst and tension loading corresponds to the upper right-hand
quadrant of the design envelope. This is the region where reliance on the
uniaxial criterion alone can result in a design that is more conservative than
necessary.
• For high burst loads and moderate tension, a burst yield failure will not occur
until after the API burst pressure has been exceeded. As the tension
approaches the axial limit, a burst failure can occur at a differential pressure
less than the API value.
• For high tension and moderate burst loads, pipe body yield will not occur
until a tension greater than the uniaxial rating is reached.
• Taking advantage of the increase in burst resistance in the presence of
tension represents a good opportunity for the design engineer to save
money while maintaining wellbore integrity.
Use of tri-axial criterion for improved design
• Because of the potential benefits (both cost
savings and better mechanical integrity) that
can be realized, a triaxial analysis is
recommended for all well designs. Specific
applications include:
• Saving money in burst design by taking
advantage of the increased burst resistance in
tension
• Accounting for large temperature effects on the
axial load profile in high-pressure, high-
temperature wells (this is particularly important
in combined burst and compression loading)
• Accurately determining stresses when using
thick-wall pipe (D/t<12) (conventional uniaxial
and biaxial methods have imbedded thin-wall
assumptions)
• Evaluating buckling severity (permanent
corkscrewing occurs when the triaxial stress
exceeds the yield strength of the material)