Network of Excellence in Training

Hussain Rabia

Casing Design Principles

© COPYRIGHT 2001, NExT. All Rights Reserved

 Casing Design Principles
Course Contents

• Objectives
• Major steps in the casing design process
• FIT
• API specs ( 5C1-3) to find casing design
strengths
• Types of Load Cases used in Detailed Casing
Design
• Design for burst & collapse loads for both
drilling and production casings
• Tensile (Installation) calculations
• API connections
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 Objectives
1. List the 4 major steps in the casing design
process
2. Understand FIT
3. Understand and use API specs ( 5C1-3) to find
casing design strengths
4. Name the three types of Load Cases used in
Detailed Casing Design
5. Carry out design for burst & collapse loads for
both drilling and production casings
6. Carry out Tensile (Installation) calculations
7. List three API connections

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 Process

1. Data Collection
2. Casing Seat Selection
3. Detailed Design Calculations
Including Triaxial Checks
4. Documentation of Design Process

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 Data
1. Formation pressure & Frac Gradient
2. Lithology column (Problem zones , salt
zones, fractured formations etc)
3. Minimum hole size in reservoir
4. Temperature profile
5. Fluids present including any oil, gas , H2S or
CO2

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 Formation Integrity Tests

The term Formation Integrity is one of the most widely

misused terms in the oil industry. It is usually used to
indicate a test to determine the fracture gradient. In
reality, the term Formation Integrity Test has a more
encompassing meaning which includes :

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 1. Limit Test: A test carried out to a specified value,
always below the fracture gradient of the formation.
2. Leak off Test: A test carried out to the point where
the formation leaks off .
3. Fracture Gradient Test: A test carried out to the
leak off point and beyond until the formation around the
wellbore fails.

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 Fracture Gradient

The fracture gradient is dependent on several

factors, including type of rock, degree of anisotropy,
formation pore pressure, magnitude of overburden
and degree of tectonics within the area.

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1
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 Fracture Gradient

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 Casing Seat Selection

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 Casing Seat Selection

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 Casing Seat Selection

Working from the bottom up, define the

1. casing shoe depths (Pf /FG graph & geology)

2. hole & casing diameters ( production

requirements)

3. finalise mud and cement densities.

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 Shoe Depth Considerations

Refinements

! It is preferable to set casing into an increasing

pressure transition zone.
! The shoe formation should be competent and
impermeable.

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 Casing Strength Properties

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 API 5C2 exercise

Use API 5C2 Tables to find the strength

properties for the following casing.

95/8” OD , N80, 43.5 lb/ft

Which property has two values?

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 API 5C2 answer

43.5 ppf N80 has

Burst : 6,330 psi
Yield : 1,074,000 lbs.
Collapse: 3810 psi.

Yield strength of pipe body and

coupling

Also use attached tables Tables

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 DESIGN CRITERIA

1. Collapse

2. Burst

3. Tension

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 Collapse

Collapse pressure originates from the column of mud used to

drill the hole, and acts on the outside of the casing.
Collapse pressure is highest at the at bottom and zero at the
top

Pressure Pressure

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 Collapse

Collapse pressure at shoe = External pressure – Internal pressure

Pressure Pressure

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 Basic Collapse Assumptions

External Pressure

1) External pressure is caused by CSD

mud in which casing was run in

2) Effects of cement are TD

ignored

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 Basic Collapse Assumptions
Internal Pressure: Either

1. Casing is empty due to lost

circulation at shoe or at
TD…only valid for conductors
and shallow casings CSD

TD
2. Casing is partially empty
due to lost circulation

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 Collapse

The 100% evacuation condition can only occur when

(a ) the casing is run empty
(b) there is complete loss of fluid into a thief zone
(c) there is complete loss of fluid due to a gas blowout which
subsequently subsides.
None of these conditions should be allowed to occur in practice.

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Partial Evacuation
A
Air
Assuming that the thief zone is at
the casing seat, then: B

L
C
Thief Zone pressure at shoe Mud ρm1 CSD

= CSD x 0.465 Thief Zone

Internal pressure at shoe =

L x pm1 x 0.052 Pf TD

L= length of mud column inside the casing

L= CSD x 0.465
0.052 x pm1
Depth to top of mud column = CSD - L
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Partial Evacuation

Collapse pressure= External pressure – Internal pressure

External pressure: comes from mud in which you ran

casing in

Internal pressure pressure comes from current mud

inside casing

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 A
Air
Three collapse points
B

L
1) At surface A: C1 = Zero C
Mud ρm1 CSD

Thief Zone

2) Point B
At depth (CSD-L)=0.052 (CSD-L) x pm
-0 Pf TD

C2 = 0.052 (CSD-L) pm

3) Point C : at depth CSD

(C3) = 0.052 CSD x pm - 0.052 L x pm1

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 Burst Design is based on either

1. Gas to surface (extreme)

2. Kick Tolerance

Pressure

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 Gas to Surface: Extreme

CSD

TD

The burst criterion in casing design is sometimes

based on the maximum formation pressure
resulting from a kick during the drilling of the
next hole section.

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 Gas to Surface: Extreme

1. Assume a gas kick, thereby anticipating the worst

possible type of kick.

2. The gas gradient is of the order of 0.1 psi/ft.

This gradient causes a comparatively small decrease in

formation pressure as gas rises up the well.

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 Gas to Surface: Extreme Case
Surface (Top of Well)
1. internal pressure must be supported entirely by
CSD
the casing body
2. external pressure due to the hydrostatic head of
TD
mud is zero
Casing Shoe
at casing shoe internal pressure is resisted by the external
pressure originating from fluids outside the casing

Hence : burst pressure is highest at the top and lowest at the

casing shoe
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 Gas to Surface: Extreme

At Surface
CSD
Internal Pressure
assuming the hole is full of gas:
TD
Pi = Pf - G xTD

External Pressure ( Back-Up Load) = 0

Burst pressure at surface (B1) = Pf - G x TD

G= gas gradient

Pf = formation pressure from next TD…NOT form

current casing shoe
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 Gas to Surface: Extreme
Burst at Shoe

Internal Pressure
CSD
assuming the hole is full of gas:

Pi = Pf - G x (TD - CSD)
TD

External Pressure ( Back-Up Load)

Pe = 0.465 x CSD …coming from salt saturated water

Burst pressure at casing shoe (B2) = internal pressure - backup load

= Pi - 0.465 x CSD
B2 = Pf - G x (TD - CSD) - 0.465 x CSD)

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 Example

9 5/8” casing
CSD = 5000 ft
TD = 10,000 ft
Pf = 5000 psi
Mud for 9 5/8” casing = 10 ppg

Calculate 1. Collapse pressures, assuming casing is empty

2. Burst pressures assuming casing is full of gas, worst case

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 Collapse at shoe = 0.052 x 10 x5000 =2600 psi
Collapse at surface = 0

Burst

At surface
Pi at surface = 5000 – TD x 0.1= 5000 – 0.1 x10,000 = 4000 psi
Pe = 0
Burst at surface = 4000 – 0 = 4000 psi

2. Burst at Shoe

Pi = Pf - G x (TD - CSD)
= 5000 – 0.1 (10000-5000)= 4500 psi
Pe = 0.465 x CSD = 0.465 x 5000 = 2325 psi
= Pi – Pe = 4500 –2325 = 2175 psi
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 Collapse at shoe = 0.052 x 10 x5000 =2600 psi
Collapse at surface = 0

Burst at surface = 4000 psi

Burst at shoe = 2175 psi

Selection: L80 40# B = 5750 psi C =3090 psi

OR M65 : 40# B = 4670 psi C = 2770 psi

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 Collapse Design
Example

Design for partial loss

circulation
9 5/8” casing
CSD = 5000 ft
TD = 10,000 ft
Pf = 5000 psi
Mud for 9 5/8” casing = 10 ppg
Next mud weight = 12 ppg

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Solution

L = length of mud column inside the casing

L = CSD x 0.465
0.052 x pm1
= 5000 x 0.465
0.052 x 12
= 3726 ft
Depth to top of mud column = CSD - L
= 1274 ft

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Answer: Example

1)At surface A: C1 = Zero

L = 3726 ft

2)Point B
C2 = 0.052 (CSD-L) pm =0.052(5000-3726)10
= 662 psi

3) Point C : at depth CSD

(C3) = 0.052 x CSD x pm - 0.052 L x pm1
= 275 psi
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 Pressure

Casing is 100% empty

Depth

Partial Evacuation

276 psi
2600 psi
CSD = 5000 ft

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 Collapse Design in Salt Sections

External pressure = 1psi/ft x depth of salt

Internal pressure = mud column inside

casing after partial LC

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 Burst Design
Refinements
a. Conductor
CSD

b. There is no burst design for conductors.

TD
b. Surface and Intermediate Casings

For the appropriate kick size ,calculate the maximum internal

pressure when circulating out the kick . Calculate the
corresponding values for B1 and B2.

Kick Volumes from IPM manual

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 Production Casings and Liners

1. worst case occurs when gas leaks from

the top of the production tubing to the
casing.

2. gas pressure will be transmitted through

the packer fluid from the surface to the
casing shoe

3. external fluids will deteriorate with

time, reducing the back up loads
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 Burst Design
Production Casing: Tubing Leak

Burst pressure = Internal pressure - External pressure

Burst at surface (B1) = Pf - G x CSD

Burst at shoe (B2) = B1 + 0.052 pp x CSD - CSD x 0.465

G = gradient of gas, usually 0.1 psi/ft

Pf = formation pressure at production casing seat, psi
pp = density of completion (or packer) fluid, ppg
0.465 = the density of backup fluid outside the casing to represent the worst case,
4 psi/ft.
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 Production Casing

Example Calculate burst pressures

CSD = 15000 ft
Pf = 8500 psi
Packer fluid = 15 ppg

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 Production Casing
Example

Burst at surface (B1) = Pf - G x CSD

= 8500 – 0.1 x 15000 = 7000 psi

Burst at shoe (B2) = B1 + 0.052 pp x CSD - CSD x 0.465

= 7000 + 0.052 x 15 x 15000 - 15000 x 0.465

= 11,725 psi

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 Safety & Design Factors

Safety factor uses a rating based on

catastrophic failure of the casing

Design factor uses a rating based on

almost any strength value (i.e. an elastic
limit, minimum yield strength , yielding
criteria etc)

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 Design factors are usually based on
maximum service load relative to the
API minimum yield strength

Safety factors are never used in oilfield

tubular design as they indicate designing
to failure

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 Design Factor

Rating of the pipe

Design Factor =
Maximum Expected Service Load

A Design Factor is usually equal or

greater than 1.

Some forces are hard to calculate and using

a Design Factor can account for these (such
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as shock loads)
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 Safety Factor
Failure Load
Safety Factor =
Actual Applied Load

When the actual applied load equals the

failure load (safety factor =1), failure is
imminent. A failure will occur if actual load
is > failure load (safety factor < 1.0).

Safety factors are always greater than 1.

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 Recommended Design Factors
Collapse = 1.0
Burst = 1.1
Tension = 1.6 –1.8
Compression = 1.0
Triaxial Design = 1.1

Industry Range from various operators

Collapse = 1.0 – 1.1
Burst = 1.1 – 1.25
Tension = 1.3 –1.8
Compression = 1.0
Triaxial Design = 1.1-1.2
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 Example
If the burst strength (Minimum Internal Yield
Strength) of casing is 6300 psi.
What is the maximum burst pressure that this casing
should be subjected to in service?
Recommended DF = 1.1
Solution
Design burst strength

6300
= = 5727 psi
1.1

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 Example: Temperature Correction
If the burst strength (Minimum Internal Yield
Strength) of casing is 6300 psi.
What is the maximum burst pressure that this
casing should be subjected to in service if the
temperature is 350 F and the reduction in yiield
strength is 90%.? Recommended DF = 1.1
Solution
Design burst strength

6300 x0.9
= = 5155 psi
1.1

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 Reduction for casing wear is
sometimes required when long section
of hole are drilled as in extended
reach wells.

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 Graphical Presentation

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 CASING BURST AND COLLAPSE PRESSURES

0 1 2

1
Depth Collapse

(ftx1000) Line

2 Burst
Line

Casing Setting Depth

B2 C2

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 Mixed Grades/Weights
Section Based on
Pressure
Burst and
0 B1 Collapse Burst
Collapse

K55 N80
Collapse Burst
Line Strength

Burst
N80 N80
Line

Depth

K55

K55 K55
K55 N80

Collapse
Strength

Casing Setting
Depth
B2 C2

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 TDAS Example

To be done on TDAS

9 5/8” casing
CSD = 5000 ft
TD = 10,000 ft
Pf = 5000 psi
Mud for 9 5/8” casing = 10 ppg
Next mud weight = 12 ppg

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 Load Case One : Burst & Collapse

1. Casing seat selection: defined casing OD,

shoe depth and drilling fluid density for the
next hole section.

2. The first Load Case defines casing grades,

weights (hence ID’s) and connections to
withstand burst and collapse loads.

3. It is assumed that the casing is effectively an

open-ended and unrestrained pipe.

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 Load Cases
1. Uniaxial design is based on : burst & collapse
loads only. Casing treated as open ended
unrestrained vessel. Already discussed

2. Installation loads (running, cementing, pressure

testing and statics). Casing treated as a closed
ended vessel, restrained at the top only. Next

3. Service loads (buckling, annulus pressure due to

thermal heating etc). Casing treated as a closed
ended vessel, restrained at top and bottom.

Separate module Or TDAS

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 Tension Design
Installation loads come from axial tension due to:

weight of the casing itself …Buoyant weight

• bending
• drag
• shock loading
• pressure testing of casing

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 Tension

Tensile forces are determined as follows:

(a) calculate weight of casing in air (positive value) using

true vertical depth

Casing air weight = casing weight (lb/ft) x hole TVD

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 Tension

(b)calculate buoyancy force (negative value)

Buoyancy force = Pe ( Ae – Ai) for open-ended casing
Ae Ae

Ai Ai

Pi

Pi Pi
Pe
Open-ended Casing Closed Casing

Buoyancy force = Pe Ae – P iAi for closed casing

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 Tension

Buoyant weight = Air weight -Buoyancy force

Buoyancy force = Pe ( Ae – Ai) for open-ended casing

Buoyancy force = Pe Ae – P iAi for closed casing

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 Tension
Example: calculate buoyant weight using pressure area method
20 “ casing , ID = 18.71 inch , 133 lb/ft Open-ended casing
CSD = 2800 ft Mud =10 ppg

Solution π/4) (202)

Ae =(π
Pressure-Area Method = 314.16 in2

Air weight = 2800 ft x 133 lb/ft = 372,400 lb

Buoyancy force = Pe ( Ae – Ai) for open-ended casing
= 0.052 x 10 x 2800 x ( 314.16 – 274.94) = 57,104 lb

Buoyant weight = 372,400 – 57,104 = 315, 295 lb

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 Tension
( c ) calculate bending force in deviated wells (positive
value)

Bending force = 63 Wn x OD x θ

Wn = weight of casing lb/ft (positive force)

θ = dogleg severity, degrees/100 ft
= 0.75 – 3 ( use 2 degrees/100 ft as an average figure)

Vertical hole
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 Tension
(d) calculate pressure testing force

Force due to pressure = π (ID2) x test pressure

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It is usually sufficient to calculate this force at the top joint,
but it may be necessary to calculate this force at other joints
with marginal safety factors in tension.

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 Tension : Shock Loading

Shock loading results from:

• Sudden deceleration are applied

• Casing is picked off the slips
• Slips are kicked in while pipe is moving
• Casing hits a bridge or jumps off an edge downhole

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 Tension
(e) calculate shock loads due to arresting casing in slips

Shock load (max) = 1500 x Wn

BP Method

Fshock = 1780 v As
As= cross-sectional area
V= velocity in ft/s

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= 5 ft/s – instantaneous velocity
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 Static Running Pressure
Conditions conditions Testing
Conditions
F1
Buoyant = = =
Weight
F2
Shock Load =
F3
Bending Force = = =
F4
Pressure
Testing
=
Force
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 Tension
Example
20 “ casing , ID = 18.71 inch , 133 lb/ft CSD = 2800 ft
Mud =10 ppg

Test Pressure =2500 psi

Dogleg = 0.75 deg/100 ft

Calculate tension forces for the various

stages of the well

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 F1= Buoyant wt of casing (in 10 ppg mud) = 2800 x 133 x 0.847= 315,423 lbf

F2= Shock load = 1500x 133

= 199,500 lbf

F3= Bending force = 63 casing weight x OD x DLS = 63x133x20x0.75

= 125,685 lbf
F4= Pressure test force = π (casing ID) 2 x test pressure
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= π (18.71) 2 x 2500 = 687,349 lbf
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 Static Running Pressure
Conditions conditions Testing
Conditions
F1 315,423 315,423 315,423
Buoyant Weight

F2 0 199,500 0
Shock Load

F3 125,685 125,685 125,685

Bending Force

F4:Pressure Testing 0 0 687,349

Total 441,108 530,608 1,128,457

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 Detailed design

1. Define the casing grade, weight and connection

from expected load cases. Choose lowest
weights and grades suitable for job for cost
effectiveness

2. Further consider availability of casings in store

3. Do you require to order casing: check lead

times and cost .

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 Documentation

1. Document the decisions and calculations made

during the design process.

2. Document and summarise final casing grades

/weighs with design factors.

3. Document any special assumptions which would

affect drilling and completion operations

eg liner designed for drilling and not completion

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 Connection - definition

1. A coupling with threads cut inside it.

2. used to join lengths of pipe
3. Has same or greater strength properties as pipe
body

90% of casing failures occur at a connection.

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 API 5C2 defines 4 connections;

1. API Short Round - T&C, no seal, round thread

profile
2. API Long Round - similar to Short Round but
longer
3. Buttress - T&C, no seal, Buttress thread form
4. Extreme Line - IEU, integral connection, metal seal

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 API Short & Long Round Thread Casing (STC
& LTC) is externally threaded on both ends of
a non-upset pipe. The single lengths are joined
with an internally threaded coupling.

The thread profile has rounded threads & roots

with 30° angle to the vertical of the pipe axis
with 8 threads per inch on a 0.75” per foot
taper

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 Connections: API Round Threads
API round thread coupling: this coupling has eight round
threads per inch, having a V-shape with an included angle of
60 deg. The threads are cut with a taper of ¾ in per ft of
diameter for all pipe sizes. The thread crest and roots are
truncated with a radius. When the crest of one thread is mated
against the crest of another, the clearance is approximately
0.003 in., which provides a leak path.
In practice, a special thread compound is used when making
up two joints, to prevent leakage.

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 Connections: API Round Threads
API round thread couplings are of two types: short thread
coupling (STC); and long thread coupling (LTC). The STC
and LTC connections are weaker than the pipe body, the LTC
being capable of transmitting higher axial loads.
The API round thread is not suitable for gas wells (ie not gas
tight) and wells with high pressure or high temperature.

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 API Buttress Thread Casing Connection

Basic hand-tight position

Hand-tight standoff
A1 = 0.200” All sizes
A2 = 0.300” All sizes
Plane of
vanish point

Base of
triangle stamp
API Buttress Thread Casing (BTC) is
externally threaded on both ends of non-upset
pipe. The single lengths are joined with an
Basic power-tight Basic hand-tight internally threaded coupling.

The thread profile has flat crests & roots

parallel to the taper cone with 3° & 10° angles
to the vertical of the pipe axis with 5 threads
per inch. There is a 0.75” per foot taper for
sizes < 13 3/8”, & a 0.9996” per foot for sizes >
16”

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 API Buttress Thread Casing Connections

The Buttress thread has a square shape, with five threads per
inch and with a thread taper of ¾ in per ft for casing sizes up
to 7 5/8 in and a taper of 1 in per ft for casing sizes of 16 in or
larger. The individual pipes are again threaded on both ends
and joined together by buttress type couplings.
The buttress thread is capable of transmitting higher axial loads
than the API 8 round thread but still require a thread
compound to fill the gaps at the roots after make up to provide
effective sealing.

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 API Extreme Line Threads

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 Vallourec NEW VAM Casing Connection

The NEW VAM Casing Connection is

externally threaded on both ends of non-upset
pipe. The single lengths are joined with an
internally threaded coupling with an internal
torque shoulder & a metal to metal seal.

NEW VAM threads are compatible with the

previous VAM, VAM ATAC, VAM AG &
VAM AF connections.

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 Triaxial analysis

Triaxial analysis provides a pictorial view of all

forces acting at any point.

Detailed calculations can be done manually , but

are laborious.

Use TDAS.

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 Now YOU should be able to:

1. List the 4 major steps in the casing design

process
2. Understand FIT
3. Understand and use API specs ( 5C1-3) to find
casing design strengths
4. Name the three types of Load Cases used in
Detailed Casing Design
5. Carry out design for burst & collapse loads for
both drilling and production casings
6. Carry out Tensile (Installation) calculations
7. List three API connections
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 Network of Excellence in Training

End Of Module

© COPYRIGHT 2001, NExT. All Rights Reserved