Proceedings of the 2012 9th International Pipeline Conference IPC2012 September 24-28, 2012, Calgary, Alberta, Canada

IPC2012-90677
DEVELOPMENT OF HIGH COLLAPSE API 5CT CASING
Fathi Hamad, Ray Miller and Tom Lawrence TMK IPSCO 2650 Warrenville Road, Suite 700 Downers Grove Illinois, USA, 60515 ABSTRACT In this paper, the collapse resistance attributes of pipe will be identified. The qualitative and quantitative effect of each of the attributes will be demonstrated. Also, a correlation between the theoretical (calculated) collapse pressures for a number of API 5CT casing sizes and grades will be presented. The results will show that the most effective way to increase the collapse resistance of casing is to maximize the yield strength, minimize the out-of-roundness (ovality) and maximize the wall thickness of pipe. The paper will also compare the actual collapse pressures of number of casing sizes and grades with API 5CT collapse pressures. Key Words High collapse casing, Elastic collapse pressure, Plastic collapse pressure, Effect of ovality on collapse resistance of pipe, Correlation between actual and calculated collapse pressure. INTRODUCTION The collapse resistance of casing has been always one of the properties that needs to be considered during the selection of pipe for the final application. The critical outer hydrostatic pressure for elastic instability may be written as follows [2]: P
Where: E D t is Youngs Modulus is Poissons Ratio is the specified pipe outside diameter is the specified pipe wall thickness

Young's modulus of E = 30,000,000 psi and Poisson's Ratio of = 0.3. The critical outside hydrostatic pressure for plastic instability for perfectly round, thick-wall pipe is defined as: P
Where:

(2)
is the yield strength is the specified pipe wall thickness is the specified pipe outside diameter

y
t D

The critical outside hydrostatic pressure for plastic instability for perfectly round, thick-wall pipe, for different levels of yield strength is shown in Figure 2. Actual Collapse test results of API 5CT Grade L80 and Grade P110 [1] casing compared with the calculated elastic collapse pressure is shown in Figure 3.The actual collapse pressure of the same grades compared with the theoretical plastic collapse pressures are shown in Figure 4. The American Petroleum Institute (API) Technical Report on Equations and Calculations for Casing, Tubing and Line Pipe 5C3 [3] recommends the following equations for calculation of the collapse pressure for pipe: Elastic Collapse Pressure Equation =
Where: D pE t is the specified pipe outside diameter is the pressure for elastic collapse is the specified pipe wall thickness

(1)

(3)

Theoretically, it is entirely dependent on the Diameter-to-thickness ratio (D/t), Youngs modulus and Poisson's Ratio. The theoretical elastic-instability collapse pressure using Equation 1 is shown in Figure 1, using

Copyright 2012 by ASME

Transition Collapse Pressure Equation =

Where: D is the specified pipe outside diameter Fc is the empirical constant in historical API collapse equation fymin is the specified minimum yield strength Gc is the empirical constant in historical API collapse equation pT is the pressure for transition collapse t is the specified pipe wall thickness

(4)

The next step was to maximize those factors that improved the collapse property and minimize those factors that impaired the collapse property. TESTING PROGRAM The test program included 16 diameter/gauge/grade combinations of casing. Eight of the sixteen products were Electric Resistance Welded (ERW) pipe and the other eight were seamless casing. The description of the sixteen combinations is shown in Table 1. The test samples had minimum Length-To-Diameter ratio of eight. The testing was done in accordance with API5C3, Technical Report on Equations and Calculations for Casing, Tubing and Line Pipe, [2]. As per API-5C3 requirements, end loading whether being compression or tension was avoided. The collapse pressure was purely hydrostatic compression load. The test sample assembly incorporated internal axial component in the axial direction, two end caps, rubber O rings between the caps and the pipe ends as well as multiple wraps of thin metal and tape to bridge the gaps between caps and pipe. The assembly ensured no axial or radial end loads on the test pipes. Calibrated pressure transducers, ovality dial gauge, micrometers, and calibrated measuring tape was used in the measurements of pressure, ovality, thickness, diameter and length of the test samples. The tensile properties were determined using ISO9001 certified testing laboratories within the TMK Ipsco plants. The tensile test was done in accordance with API-5CT Standard requirements. TEST RESULTS Effect of yield strength on collapse resistance of pipe The effect of yield strength on the collapse pressure of different outside diameters and wall thicknesses of casing is shown in Figures 7, 8, 9, 10, 11 and 12. The figures show that the collapse resistance has proportional relationship with yield strength. That can be proven mathematically. Effect of wall thickness on collapse resistance of pipe The effect of wall thickness on the collapse pressure of pipe is shown in Figures 13, 14, 15, and 16. It can be shown mathematically, that the collapse resistance of a perfectly round pipe has direct relationship with the wall thickness. When a round section changes shape from round to oval, it presents another stress situation. Effect of Out-Of-Roundness (Ovality) on collapse resistance of pipe The effect of out-of-roundness (ovality) on the collapse pressure of pipe is shown in Figures 17, 18, 19, 20, and 21. Out-of-roundness changes a simple stress situation for perfectly round section into a combined stress condition where both compressive stress and bending stress are affecting the pipe cross-section. Combined effect of pipe geometry (D/t), modulus of elasticity, yield strength and out-of roundness

Plastic Collapse Pressure Equation =

Where: Ac Bc Cc D fymin pp t is the empirical constant in historical API collapse equation is the empirical constant in historical API collapse equation is the empirical constant in historical API collapse equation is the specified pipe outside diameter is the specified minimum yield strength is the pressure for plastic collapse is the specified pipe wall thickness

(5)

Yield Strength Collapse Pressure Equation =

Where: D fymin pYp t is the specified pipe outside diameter is the specified minimum yield strength is the pressure for yield strength collapse is the specified pipe wall thickness

(6)

A correlation between the calculated collapse pressure, based on specified minimum yield strength using API 5C3 relevant equations 3,4,5, and 6, and actual collapse pressure is shown in Figure 5. Also, correlation between the calculated collapse pressure, based on the actual yield strength using API Technical Report 5C3 relevant equations and actual collapse pressure is shown in Figure 6. The actual test results shown in figures 3, 4, 5 and 6were done at Ipscos Laboratories under ISO-9001 Quality Assurance system. DEVELOPMENT APPROACH The development program started by identifying the contributing factors to increase (or reduce) the collapse pressure of pipe, which were: Pipe Mechanical properties (yield strength and modulus of elasticity). Geometry (Diameter, wall thickness and out-ofroundness). Residual stresses.

Copyright 2012 by ASME

The combined effect of geometry physical properties (yield strength and modulus of elasticity, and out-ofroundness on the collapse pressure of a pipe was suggested by S.C. Haagsma [4] in the following format:

(7)

Figure 22 shows that the collapse pressure of a pipe can be predicted by an equation such as the one presented by S.C. Haagsma, provided that the relevant attributes such as tensile properties (yield strength and modulus of elasticity), pipe geometry (D/t) and out-of-roundness have been included. The collapse tester used for performing most of tests used in this study is shown in Figure 23. During the development work, the effect of residual stress on collapse resistance was examined. Tensile residual stress was found to be beneficial; however the effect was not significant. CONCLUSIONS The present study has led to the following conclusions:

(8)
Where: W P Pe Pp E D t is the ovality is the collapse pressure is the elastic collapse pressure is the plastic collapse pressure is Youngs modulus is Poissons ratio is the specified outside pipe diameter is pipe wall thickness

1.

Production of high collapse casing was achieved though the following: Minimizing pipe out-of-roundness (ovality) Optimizing the geometry of the pipe (D/t) Optimizing the mechanical properties.

2.

The accuracy of the predictability of collapse pressure using Haagsma equation is demonstrated in Figure 22. DISCUSSION The test results presented in Figures 7 to 12 show clear and predictable correlations between the yield strength of the casing and the actual collapse pressure, with everything else equal. The scatter in the results can be attributed to the other variables such as wall thickness and ovality (out-ofroundness). As such, maximizing the yield strength without sacrificing other valuable characteristics such as toughness and resistance to an aggressive environment is one of the means that can be utilized to improve the collapse resistance of casing. As shown in Figures 13 to 16, the increase in wall thickness has proportional effect on the increase in collapse pressure of the pipe. On the other hand, a reduction in wall thickness over a large section of the pipe is expected to reduce its collapse resistance. Figures 17 to 21 show the effect of out-of-roundness (ovality) on the collapse pressure of casing. Improving (reducing) ovality contributes nothing but beneficial effects to casing. In addition to improving the collapse resistance, it also contributes to the ease of machining of full threads as well as improving connection performance.

3.

Correlation between collapse resistance of pipe and the above identified attributes can be made through a mathematical relation similar to the one presented by S.C. Haagsma. This study is a documentation of successful fullscale production of casing with high collapse resistance utilizing both the seamless and ERW processes, by TMK Ipsco.

ACKNOWLEDGEMENTS The authors would like to extend their appreciation to all former IPSCO Inc colleagues for their contribution to the actual testing of casing. Appreciation is also expressed to the technologists at the TMK IPSCO Baytown Quality Lab for collapse testing the seamless casing. The full support of TMK IPSCOs senior management has made this project a success. REFERENCES 1. 2. 3. Specification for Casing and Tubing, API Specification 5CT, Ninth Edition, July 2011. Timoshenko, S.P. and Gere. J.M.: Theory of Elastic Stability, McGraw Hill Kogakusha, Tokyo (1961). The American Petroleum Institute (API) Technical Report on Equations and Calculations for Casing, Tubing and Line Pipe 5C3. S.C. Haagsama and D. Schaap, Potech International B.V., Schiedam, Netherlands. Oil and Gas Journal, Feb 2, 1981.

4.

Copyright 2012 by ASME

Table 1: Casing Sizes and Grades Tested in the Program. Outside Diameter (in) 4 1/2 4 1/2 4 1/2 4 1/2 4 1/2 4 1/2 4 1/2 4 1/2 5 1/2" 5 1/2" 5 1/2" 5 1/2" 5 1/2" 7" 7" 7" Gauge (in) 0.250" 0.250" 0.250" 0.290" 0.250" 0.337" 0.337" 0.337" 0.304" 0.304" 0.304" 0.361" 0.415" 0.317" 0.362" 0.362

Grade API-L80 API-P110 API-P110 API-P110 TMK I100 API-L80 API-P110 API-Q125 API-L80 API-P110 API-P110 API-P110 API-P110 API-L80 API-L80 API-P110

Process ERW Seamless ERW Seamless ERW Seamless Seamless Seamless ERW ERW Seamless Seamless Seamless ERW ERW ERW Figure 1: Theoretical elastic collapse pressure of pipe.

Figure 2: Theoretical plastic collapse pressure of pipe.

Figure 3: Calculated (theoretical) elastic collapse pressures and actual test results versus Diameter/Thickness ratio

Copyright 2012 by ASME

. Figure 4: Calculated (theoretical) plastic collapse pressures and actual collapse test results versus Diameter/Thickness ratio Figure 5: Actual test results vs. calculated values using API 5C3 relevant equations based on minimum yield strength and nominal dimensions.

Figure 6: Actual test results versus calculated values using API 5C3 relevant equations, based on actual yield strength and actual dimensions.

Figure 7: Correlation between average collapse pressure and nominal yield strength of 4" outside diameter x 0.337" wall thickness seamless casing.

Copyright 2012 by ASME

Figure 8: Correlation between actual collapse pressure and actual yield strength of 4" outside diameter x 0.250" wall thickness ERW casing.

Figure 9: Correlation between actual collapse pressure and actual yield strength of 5" outside diameter x 0.304" wall thickness ERW casing.

Figure 10: Correlation between actual collapse pressure and actual yield strength of 7" outside diameter x 0.317" wall thickness ERW casing.

Figure 11: Correlation between actual collapse pressure and actual yield strength of 7" outside diameter x 0.362" wall thickness ERW casing.

Copyright 2012 by ASME

Figure 12: Correlation between actual collapse pressure and actual yield strength of 4" outside diameter x 0.250" wall thickness, ERW Grade 100 casing.

Figure 13: Correlation between nominal wall thickness and average collapse pressure of 4" outside diameter, Grade P110 seamless casing

Figure 14: Correlation between nominal wall thickness and average collapse pressure of 5" outside diameter, Grade P110 seamless casing.

Figure 15: Correlation between nominal wall thickness and average collapse pressure of 7" outside diameter, ERW L80 casing.

Copyright 2012 by ASME

Figure 16: Correlation between nominal wall thickness and average collapse pressure of 4-1/2" outside diameter, ERW Grade 100 casing.

Figure 17: Correlation between ovality and actual collapse pressure of 4" outside diameter x 0.250" wall thickness, ERW Grade L80 and P110 casing.

Figure 18: Correlation between ovality and actual collapse pressure of 5" outside diameter x 0.304" wall thickness, ERW Grade L80 and P110 casing.

Figure 19: Correlation between ovality and actual collapse pressure of 7" outside diameter x 0.317" wall thickness, ERW Grade L80 casing.

Copyright 2012 by ASME

Figure 20: Correlation between ovality and actual collapse pressure of 7" outside diameter x 0.362" wall thickness, ERW Grade L80 and P110 casing.

Figure 21: Correlation between ovality and actual collapse pressure of 4" outside diameter x 0.250" wall thickness, ERW Grade 100 casing.

Actual versus calculated Collapse Pressure using Haagsma Equation, E=30Mpsi,u=0.3 for 225 L80 and 189 P110 tests
14000 12000

Measured, psi

10000 8000 6000 4000 2000 0 0 2000 4000

Calculated, psi
L80 P110

6000

8000

10000

12000

14000

Figure 22: A correlation between the actual collapse pressure and the calculated values using Haagsmas equation.

Figure 23: TMK IPSCO Collapse Tester.

Copyright 2012 by ASME