Chapter 11

Casing and Tubing Concepts

Casing and tubing play vital role in drilling operations. The design of the tubulars
requires a knowledge of the operating conditions to be imposed on the pipe as well as a working
understanding of various concepts related to pipe properties. The drilling engineer must be aware
of these concepts before beginning the actual design operations. These concepts include items
such as manufacturing processes, physical properties, and testing procedures.
Over the years, the API has developed a number of guidelines for petroleum practices and
equipment. Many of these guidelines relate to oil-field tubular goods. Table 11-1 lists some of
the more important specifications, bulletins, and recommended practices. These documents, and
others not shown in Table 11-1 should be reviewed thoroughly by the practicing drilling engineer
to complement his field experiences.
Most of this chapter is devoted to conventional non-expandable casing. The relatively
recent introduction of expandable tubular technology provides some substantial benefits for
certain drilling operations. The last section in this chapter is devoted to expandable technology.

Table 11-1
Summary of Various Pertinent API
Publications Relating to Casing and Tubing
Specifications Title
Spec 5A Specification for Casing, Tubing, and Drill Pipe
Spec 5AC Specification for Restricted Yield Strength Casing
and Tubing
Spec 5AX Specification for High-Strength Casing, Tubing, and
Drill Pipe
Std 5B Specification for Threading, Gaging, and Thread
Inspection of Casing, Tubing, and Line Pipe
Threads
Spec 5L Specification for Line Pipe

Recommended Practices
RP 5C1 Recommended Practice for Care and Use of Casing
and Tubing

Bulletin
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
The American Petroleum Institutes Committee on Standardization of Tubular Goods had prepared
numerous valuable documents relating to tublar goods in addition to those listed in Table 11-1.
The documents are available there the API.

11.1
Pipe Body Manufacturing

API's Specification 5A states that casing, liners, and tubing conforming to this standard
must be seamless or electric welded. Seamless pipe is a wrought steel tubular product made
without a welded seam. It is manufactured by hot-working steel and, if necessary, by
subsequently cold-finishing the hot-worked tubular product to produce the desired shape. The
process may involve a plug mill or mandrel mill rolling. A typical seamless process is shown in
Fig. 11-1.
Electric-welded (ERW) pipe has one longitudinal seam formed by electric-flash welding
or electric-resistance welding without adding extraneous metal. The weld seam of electric-
welded pipe is heat-treated after welding to a minimum temperature of 1,000F or is processed
so no untempered martensite remains. Fig. 11-2 illustrates a typical ERW process.

Fig. 11-1 Plug mill rolling process for Kawasakis 7-16 -in. pipe.

11.2
 Fig. 11-2 Medium-diameter ERW mill process for Kawasakis 6.5-26-in.pipe.

Casing Physical Properties

The physical properties of oil-field tubular goods include grade, pressure resistance, drift
diameter and weight. These properties relate to the pipe's ability to meet the demands of the
imposed drilling conditions. The limitations of the properties must be considered before final
pipe selection.
Grade. The pipe grade is a designation that defines the pipe's yield strength and certain
special characteristics. The grade usually consists of a letter and a 2- or 3-digit number such as
N-80. In most cases as the letter proceeds toward the end of the alphabet, the pipe increases in
yield strength. For example, N-80, or N-grade, pipe has a greater yield strength than H-40.
The numerical code indicates the minimum yield strength in thousands of psi. As an
example, N-80 has a minimum yield strength of 80,000 psi. The average yield strength is usually
10,000 psi greater than the minimum yield, or 90,000 psi for N-80 pipe. The minimum value is
used in burst and collapse resistance calculations, whereas the average is used for biaxial
evaluations. API grades are shown in Table 11-2.

Table 11-2
API Grades
H-40 L-80
J-55 C-95
K-55 P-105
C-75 P-110
N-80 V-150

C pipe is a controlled yield pipe used primarily in environments such as H 2S. It is

seldom used in noncorrosive environments since it is more expensive than some higher grades of
pipe. Engineers desiring to use C-grade pipe should review API Specifications 5AC.
L-grade pipe has the same burst, collapse, and yield values as N pipe. However, the
hardness of the pipe is a critical value due to potential hydrogen embrittlement in H 2S
environments. N pipe may have joints that exceed a 22 Rockwell hardness. Since this 22
hardness is an often-used upper range, certain joints of N-80 are not suitable for sour service. L-
80 pipe, normally more expensive than N-80, is tested to ensure all joints have a hardness of 22
or less. The supplier must certify that these testing procedures have been performed.
11.3
 Many non-API grades of pipe are available and widely used in the drilling industry. The
"non-API" label applies to items for which API standards have not been established. For
example, SOO-155 pipe manufactured by Algoma mills is non-API because standards do not
exist for 155 yield pipe. In most cases, the mills use API-type equations in determining the burst
and collapse resistances of the pipe. The tables in the Appendix include many non-API grades.
Weight. The pipe weight is usually defined in pounds per foot. The calculated weights, as
defined by the API, are determined by the following formula:

WL ( w pe L) e w (11.1)

Where:
WL = calculated weight of a pipe of length L, lb
Wpc = plain-end weight, lb/ft
L = length of pipe including end finish, ft
ew = weight gain or loss due to end finishing, lb; for plain-end pipe, ew equals zero

The cross-sectional area of the pipe can be approximated from the pipe weight with Eq. 11.2:

A p 0.29 Wpe (11.2)

where Ap is the cross-sectional area in square inches.

Range. Pipe range is a value for approximating the length of a section of pipe. Normal
range sizes are 1, 2, or 3. Table 11-3 illustrates some of the API standards with respect to range
definitions.

Table 11-3
API Range Lengths
Range, ft
1 2 3
Casing
Total range length, inclusive 16-25 25-34 34-48
Range length for 95% or more of carload:
permissible variation, maximum 6 5 6
permissible variation, minimum 18 28 36

Tubing
Total range length, inclusive* 20-24 28-32 ----
Range length for 95% or more of carload:
permissible variation, maximum 2 2 ----
Permissible variation, minimum 20 28 ----

Pup joints
Lengths 2, 4, 6, 8, 10, and 12 ft
Tolerance 3 in.
* By agreement between purchaser and manufacturer, the total range length for Range 1 tubing may be 20-28 ft.
Courtesy American Petroleum Institute

Diameter. The drilling engineer must consider three types of diameter data when
planning the tubular program: outer, inner, and drift diameters. Each has separate tolerance levels
as specified by API Specification 5A.
The following tolerances apply to the outside diameter (OD) of the casing body
immediately behind the upset for a distance of approximately 5 in. for sizes 5 -in. OD and
smaller and a distance approximately equal to the OD for sizes larger than 5 in. The inner

11.4
diameter (ID) is controlled by the outside diameter and weight tolerances. The weights are
constrained to a +6.5 to 3.5% variation. The wall thickness, t, of the pipe body has a 12.5%
tolerance. The thickness tolerance is used in burst calculations.
API Spec. 5A addresses pipe eccentricity. The maximum eccentricity of the OD,
measured with a saddle gauge at a distance of 5-6 in. from the end of the upset, may not exceed
0.093 in. The eccentricity constraints on the bore of the upset with respect to the outside surface
of the drillpipe may not be more than 1/16 in. ( in. total indicator reading). Maximum ovality,
measured with a micrometer on the OD of the upset may not exceed 0.093 in.
The drift diameter of the casing relates to the diameter of a mandrel that can pass through
the casing bore without exerting unreasonable forces. The drift diameter is smaller than the I.D.
due to eccentricity and nonstraightbore tolerances. For drilling considerations, the drift diameter
is usually considered as the bit size that can be safely run through the casing. It is common
practice to drift test the casing before it leaves the mill and immediately before running it into the
well.
Each length of casing and tubing must be tested throughout its entire length with a
cylindrical drift mandrel conforming to the following requirements if the casing is to carry the
API monogram ( Table 11-4). The leading edge of the drift mandrel must be rounded to permit
easy entry into the pipe. It must pass freely through the pipe with a reasonable exerted force
equivalent to the weight of the mandrel being used for the test. Pipe cannot be rejected until it
has been drift tested when it is free of all foreign matter and properly supported to prevent
sagging.

Table 11-4
Drift Mandrel Specifications
Drift Mandrel Size, in.
Product and Size, in. Length Diameter
Casing and Liners
8-5/8 and smaller 6 d 1/8
9-5/8 to 13-3/8 12 d 5/32
16 and larger 12 d 3/16
Tubing
2-7/8 42 d 3/32
3-1/2 42 d 1/8
Courtesy American Petroleum Institute

Burst. The burst rating of the casing is the amount of internal pressure that the pipe can
withstand prior to failure. The internal yield pressure for pipe is calculated from Eq. 11.3. The
factor of 0.875 accounts for minimum wall thickness.

2YP t
PB 0.875 (11.3)
OD

Where:
PB = burst pressure rounded to the nearest 10 psi
YP = specified minimum yield strength, psi
t = nominal wall thickness, in.
OD = nominal outside diameter, in.

Example 11.1 Illustrates use of Eq. 11.3

11.5
Example 11.1

Calculate the interval yield (burst) pressure for 26.40-lb/ft, N-80 grade, 7.625-in. pipe.
Assume it has a wall thickness (t) of 0.328 in. Use the API minimum wall thickness
factor of 0.875. Recalculate the results and use 95% wall thickness.

Solution:
1. The internal yield pressure (burst) is calculated with Eq. 11.3:

2YP t
P 0.875
OD
2 (80,000 psi)(0.328 in.)
0.875 (11.3)
7.625 in.
6,022 psi
6,020 psi

2. Recalculate the results with a 95% wall thickness:

2 (80,000 psi)(0.328 in.)

P 0.95
7.625 in.
6,538 psi
6,540 psi

Where pipe will be used in sour gas service, it often must be rolled with a large wall
thickness. This approach allows the use of softer metal that is less susceptible to sulfide cracking.
The engineer must specify the desired burst rating and the allowable yield rating on the pipe. In
addition, the OD or ID must be specified, depending on the requirements to run the casing into a
restricted hole size or the necessity of passing a certain bit size inside the casing to be rolled.

Example 11.2

A drilling engineer must design a production casing string for sour gas service. The
maximum anticipated surface pressure for the 5.5-in. OD pipe is 20,800 psi. The
engineer's company philosophy dictates that pipe used in sour service will not have a
yield strength greater than 90,000 psi. After the engineer reviewed the available,
commonly used weights and grades of casing, he realized that the string must be specially
rolled to meet his requirements.
Determine the wall thickness requirements for the pipe. Use a yield strength of
90,000 psi and assume the API tolerance of 87.5% wall thickness. Round up the wall
thickness to the nearest 1/8 in.

Solution:
1. The API equation for internal yield resistance is:

2YP t
PB 0.875 (11.3)
OD

2(90,000 psi)t
2. 20,800 psi 0.875
5.5 in.

11.6
 3. t 0.726 in.
4. Rounding up to the nearest one-eighth,
t 0.750 in.

Collapse. Unlike internal yield resistance of the pipe, collapse resistance equations vary
depending on the D/t ratio. The collapse resistances are separated into four categories:

yield strength collapse pressure

plastic collapse
transition collapse
elastic collapse

The D/t range must be evaluated and the proper equation must be selected. Formula factors must
be used in collapse calculations.
The yield strength collapse pressure is not a true collapse pressure, rather the external
pressure (Pyp) that generates minimum yield stress (Yp) on the inside wall of a tube:

(D/t) 1
Pyp 2 Yp 2 (11.4)
(D/t)

The formula for yield strength collapse pressure is applicable for D/t values up to the value of
D/t corresponding to the intersection with the plastic collapse formula, Eq 11.5. The intersection
is calculated as follows:

(D/t) y p ( A 2) 2 8 (B C/Yp ) (A 2) (11.5)

The applicable D/t ratios for yield strength collapse are shown in Table 11-5.

Table 11-5
Yield Collapse Pressure Formula Range
1 2
Grade* D/t Range
H-40 16.44 and less
-55 15.24 and less
J-K-55 & D 14.81 and less
-60 14.44 and less
-70 13.85 and less
C-75 & E 13.60 and less
L-80 & N-80 13.38 and less
-90 13.01 and less
C-95 12.85 and less
-100 12.70 and less
P-105 12.57 and less
P-110 12.44 and less
-120 12.21 and less
-125 12.11 and less
-130 12.02 and less
-140 11.92 and less
-145 11.84 and less
-150 11.67 and less
-155 11.59 and less
-160 11.52 and less

11.7
 -170 11.37 and less
-180 11.23 and less
* Grades indicated without letter
designation are not API grades but are
grades in use or grades being considered
for use and are shown for information
purposes.
Courtesy American Petroleum Institute
The minimum collapse pressure for the plastic range of collapse (Pp) is calculated by Eq.
11.6:

A
Pp Yp B C (11.6)
D/t

The formula minimum plastic collapse pressure is applicable for D/t values ranging from (D/t) pt
in Eq. 11.7 (yield point collapse pressure) to the intersection with Eq. 11.8 for D/t) t, transition
collapse pressure. Values for (D/t)pt are calculated by means of Eq. 11.7:

Yp (A F)
(D/t) pt (11.7)
C Yp (B G)

The factors and applicable D/t range for the plastic collapse formula are shown in Table 11-6.

Table 11-6
Formula Factors and D/t Ranges for Plastic Collapse
1 2 3 4 5
Formula Factor
Grade* A B C D/t Range
H-40 2.950 0.0465 754 16.44 to 27.01
-50 2.976 0.0515 1,056 15.24 to 25.63
J-K-55 & D 2.991 0.0541 1,206 14.81 to 25.01
-60 3.005 0.0566 1,356 14.44 to 24.42
-70 3.037 0.0617 1,656 13.85 to 23.38
C-75 & E 3.054 0.0642 1,806 13.60 to 22.91
L-80 & N-80 3.071 0.0667 1,955 13.38 to 22.47
-90 3.106 0.0718 2,254 13.01 to 21.69
C-95 3.124 0.0743 2,404 12.85 to 21.33
-100 3.143 0.0768 2,553 12.70 to 21.00
P-105 3.162 0.0794 2,702 12.57 to 20.70
P-110 3.181 0.0819 2,852 12.44 to 20.41
-120 3.219 0.0870 3,151 12.21 to 19.88
-125 3.239 0.0895 3,301 12.11 to 19.63
-130 3.258 0.0920 3,451 12.02 to 19.40
-135 3.278 0.0946 3,601 11.92 to 19.18
-140 3.297 0.0971 3,751 11.84 to 18.97
-150 3.336 0.1021 4,053 11.67 to 18.57
-155 3.356 0.1048 4,204 11.59 to 18.37
-160 3.375 0.1072 4,356 11.52 to 18.19
-170 3.412 0.1123 4,660 11.37 to 17.82
-180 3.449 0.1173 4,966 11.23 to 17.47
* Grades indicated without letter designation are not API grades but are grades in use or
grades being considered for use and are shown for information purposes.
Courtesy American Petroleum Institute

Example 11.3

11.8
 An engineer must calculate the collapse rating for the following section of pipe. Using
the API tables and equations, calculate the collapse pressure to the nearest 10 psi.

Data:
pipe diameter = 9.625 in.
wall thickness = 0.472 in.
grade = N-80
weight = 47.0 lb/ft

Solution:

1. Determine the D/t ratio:

9.925 in.
D/t 20.392
0.472 in.

2. From Table 11-6, the formula factors are:

A 3.071
B 0.0667
C 1,955

3. Eq. 11.6 is used to calculate the collapse pressure:

A
Pp Yp B C
D/t
3.071
80,000 0.0667 1,955 (11.6)
20.392
4,756.8 psi
4,750 - 4,760 psi

(Rounding the solution may cause slight variations with published data)

The minimum collapse pressure for the plastic to elastic transition zone (Pt) is calculated
from Eq. 11.8:

F
Pt Yp G (11.8)
D/t

Eq. 11.8 for Pt is applicable for D/t values from (D/t)pt, Eq. 11.7, for plastic collapse pressure to
the intersection (D/t)te, Eq 11.9, for elastic collapse. Values for (D/t) te are calculated from Eq.
11.9:

2 B/A
(D/t) te (11.9)
3 B/A

The factors and applicable D/t range for the transition collapse pressure formula are shown in
Table 11-7.

11.9
 Table 11-7
Formula Factors and
D/t range for Transition Collapse
1 2 3 4
Formula Factor
Grade* F G Dt/ Range
H-40 2.063 0.0325 27.01 to 42.64
-50 2.003 0.0347 25.63 to 38.83
J-K-55 & D 1.989 0.0360 25.01 to 37.21
-60 1.983 0.0373 24.42 to 35.73
-70 1.984 0.0403 23.38 to 33.17
C-75 & E 1.990 0.0418 22.91 to 32.05
L-80 & N-80 1.998 0.0434 22.47 to 31.02
-90 2.017 0.0466 21.69 to 29.18
C-95 2.029 0.0482 21.33 to 28.36
-100 2.040 0.0499 21.00 to 27.60
P-105 2.053 0.0515 20.70 to 26.89
P-110 2.066 0.0532 20.41 to 26.22
-120 2.092 0.0565 19.88 to 25.01
-125 2.106 0.0582 19.63 to 24.46
-130 2.119 0.0599 19.40 to 23.94
-135 2.133 0.0615 19.18 to 23.44
-140 2.146 0.0632 18.97 to 22.98
-150 2.174 0.0666 18.57 to 22.11
-155 2.188 0.06825 18.37 to 21.70
-160 2.202 0.0700 18.19 to 21.32
-170 2.231 0.0734 17.82 to 20.60
-180 2.261 0.0769 17.47 to 19.93
*Grades indicated without letter designation are not API grades but are
grades in use or grades being considered for and are shown for information
purposes.
Courtesy American Petroleum Institute

The minimum D/t range for elastic collapse range of collapse is calculated from Eq.
11.10:

46.95 10 6
Pe (11.10)
( D/t) [(D/t) 1]2

The applicable D/t range for elastic collapse is shown in Table 11-8.

Table 11-8
D/t Range for Elastic Collapse
1 2
Grade* D/t Range

11.10
 H-40 42.64 and greater
-50 38.83 and greater
J-K-55 & D 37.21 and greater
-60 35.73 and greater
-70 33.17 and greater
C-75 & E 32.05 and greater
L-80 & N-80 31.02 and greater
-90 29.18 and greater
C-95 28.36 and greater
-100 27.60 and greater
P-105 26.89 and greater
P-110 26.22 and greater
-120 25.01 and greater
-125 24.46 and greater
-130 23.93 and greater
-135 23.44 and greater
-140 22.98 and greater
-150 22.11 and greater
-155 21.70 and greater
-160 21.32 and greater
-170 20.60 and greater
-180 19.93 and greater
*Grades indicated without letter designation are not API grades but are
grades in use or grades being considered for and are shown for
information purposes.
Courtesy American Petroleum Institute

Example 11.4

The collapse rating for 47.0-lb/ft, C-95 grade, 9.625-in. pipe must be calculated. The wall
thickness is unknown. Use the API formulas and tables.

Solution:

1. Compute the cross-sectional area of the pipe:

A P 0.29 WP
0.29 (47 lb/ft)
13.63 in.2

2. Determine the wall thickness of the pipe from the cross-sectional area:

AP (OD 2 ID 2 )
4

13.63 in.2 (9.6252 ID 2 )
4
4
[(13.63 in.2 ) 9.625 2 ] ID

ID 8.676 in.
OD ID
t
2
(9.625 in. 8.676 in.)/2
0.4745
11.11
 3. The D/t ratio is

9.625 in.
D/t
0.4745 in.
20.284

4. The formula factors for C-95 pipe with a D/t ratio of 20.284 are:

A 3.124
B 0.0743
C 2,404

5. From Eq. 11.6, the collapse pressure is computed as:

A
Pp Yp B C
D/t
3.124
95,000 0.0743 2,404 (11.6)
20.284
5,168 psi
5,170 psi

(Rounding may cause slightly different results than published values)

The API modified and published a collapse calculation procedure to account for axial
tension stress (April 1983). The collapse resistance of casing in the presence of an axial stress is
calculated by modifying the yield stress to an axial stress equivalent grade according to Eq.
11.11:

Yp
1 0.75 (Sa Yp ) 2 0.5 Sa Yp Yp (11.11)

Where:
SA = axial stress
YP = minimum yield strength, psi
YPA = yield strength of axial stress equivalent grade, psi

Tension is considered positive with respect to S A. Eq. 11.11 is based on the Hencky-von Mises
maximum strain energy of distortion theory of yielding.

Example 11.5

A engineer must calculate the collapse pressure for the following pipe characteristics:

size = 7-in. OD
weight = 26 lb/ft
grade = P-110
SA = 11,000 psi

11.12
 t = 0.362

Solution:
1. The axial stress equivalent grade is calculated as follows:

Yp
1 0.75 (Sa Yp ) 2 0.5 Sa Yp Yp

1 0.75 (11,000 110,000 ) 2 0.5 11,000 110,000 110,000 (11.11)

104,082 psi

2. D/t 7 0.362 19.34

3. The D/t range of 19.34 uses the factors A, B, and C from Table 11-6

A 3.181
B 0.0819
C 2,852

4.
A
P Ypa B C
D/t
3.181 (11.6)
104,082 0.0819 2,852
19.84
5,742 psi

Pipe Body Yield Strength. The pipe body yield strength is the axial load required to
yield the pip. It is the product of the cross-sectional area and the specified minimum yield
strength for the particular grade of pipe:

PY 0.7854 (OD ID 2 ) YP (11.12)

Example 11.6

A section of 10.75-in., 55.00-lb/ft, N-80 casing is to be run into a well. It has a wall
thickness of 0.495 in. Determine the pipe body yield strength.

Solution:
1. The ID is computed as follows:

ID OD 2t
10.75 in. 2 (0.495 in.)
9.76 in.

2. The yield strength is calculated from Eq. 11.12:

11.13
 PY 0.7854 (OD 2 ID 2 ) YP
0.7854 (10.752 9.76 2 in.)(80,000 psi)
1,275,797
1,275,000

Biaxial Effects. Burst and collapse resistances of casing are altered when the pipe is
under a tension (or compression) load. These changes may, but do not necessarily, apply to
connectors. Couplings manufacturers should be consulted in stringent operating conditions. The
qualitative changes for pipe are as follows:

Type of Load Results

Tension Burst Increase
Collapse Decrease
Compression Burst Decrease
Collapse Increase

The alterations in the burst and collapse resistances must be considered because 1) decreases in
pipe pressure resistance may require upgrading some sections and 2) increases in pressure
resistance may allow the use of lower grade or weight casing.
Figs. 11-3 and 11-4 illustrate the burst and collapse resistance changes for 10,000 ft of 9
-in. casing set in 12.0 lb/gal mud.
The most common graphical method of determining the biaxial effects of tension may be
with the use of Fig. 11-5. The percent change is dependent on the ratio of the actual stress to the
yield stress. Eq. 11.13 can be used to compute these changes. Example 12.2 illustrates the
calculations for determining the biaxial effects. This method is an alternative to Eq. 11.11 and
Example 11.5 and is widely used in the industry. Neither approach is a rigorous treatment of the
topic.

PA Pi {[1 0.75 (SA YP ) ] (SA YP )

2 12 (11.13)

Where:
PA = actual pressure rating under loaded conditions, psi
Pi = pressure rating in an unloaded condition, psi
SA = axial stress, psi
YP = minimum yield of the pipe, psi

11.14
 Fig. 11-3 Tension effect on burst.

Fig. 11-4 Tension effect on collapse.

11.15
 Fig. 11-5 Graphical solution for effect of tension on burst and collapse.

Pipe Connectors

Pipe sections are joined with either the thread-and-coupled connectors or are integral
connected. Couplings can be used to join two ends of the pipe, as shown in Fig. 11-6. This
illustration depicts the three types of coupled connections standardized by the API. The
dimensions for various couplings are given in Tables 11-9 and 11-10.
Many coupled connections are non-API and are often termed premium connections. They
may have special corrosion or leak resistance characteristics. In addition, they may have a
smaller outer clearance than API coupled connections (Fig. 11-7)
Integral connections do not use separate coupling devices. The ends of the joints are
milled so the pin end of one joint screws into the box end of another joint. Manufacturers offer a
variety of coupled and integral-joint connections (Fig. 11-8).
Coupling selection is normally based on design criteria such as the following:

burst
collapse
joint strength
corrosion resistance
leak resistance

Since many investigators have documented casing and tubing failures due to the couplings,
proper evaluation and selection is an important issue. It is advisable to consider premium
couplings if corrosion, leak resistance, or high pressures are considerations. Coupling
manufacturers and distributors should be consulted in these cases. Example 11.6 illustrates
coupling selection in a high pressure environment.

11.16
 Fig. 11-6 STC, LTC, and BTC-coupled API connections.
(Courtesy American Petroleum Institute)

Table 11-9
Round-Thread Casing
Coupling Dimensions, Weights, and Tolerances
1 2 3 4 5 6 7 8
Minimum Length Weight, lb

Outside Diameter of Width of

Diameter, W Recess, Q Bearing
Size* Short NL Long NL Face, b Short Long
4-1/2 5.000 6-1/4 7 4-19/32 5/32 8.05 9.07
5 5.563 6-1/2 7-3/4 5-3/32 3/16 10.18 12.56
5-1/2 6.050 6-3/4 8 5-19/32 1/8 11.44 14.03
6-5/8 7.390 7-1/4 8-3/4 6-23/32 1/4 19.97 24.82
7 7.656 7-1/4 9 7-3/32 3/16 18.34 23.67
7-5/8 8.500 7-1/2 9-1/4 7-23/32 1/4 26.93 34.23
8-5/8 9.625 7-3/4 10 8-23/32 9/32 35.58 47.48
9-5/8 10.625 7-3/4 10-1/2 9-23/32 3/32 39.51 55.77
10-3/4 11.750 8 ---- 10-27/32 9/32 45.53 ----
11-3/4 12.750 8 ---- 11-27/32 9/32 49.61 ----
13-3/8 14.375 8 ---- 13-15/32 5/16 56.23 ----
16 17.000 9 ---- 16-3/32 5/16 78.98 ----
18-5/8 20.000 9 ---- 18-23/32 5/16 118.94 ----
20 21.000 9 11-1/2 20-3/32 5/16 98.25 126.74
Tolerance on outside diameter W, 1 percent but not greater than 1/8 in.
*The size of the coupling is the same as the corresponding pipe size
Courtesy American Petroleum Institute

11.17
 Table 11-10
Buttress Thread Casing Coupling
Dimensions, Weighs, and Tolerances
1 2 3 4 5 6 7 8
Minimum Length Weight, lb
Outside Diameter of Width of
Diameter, W Recess, Q Bearing
Size* Short NL Long NL Face, b Short Long
4-1/2 5.000 4875 8-7/8 4.640 1/8 10.11 7.67
5 5.563 5375 9-1/8 5.140 5/32 12.99 8.81
5-1/2 6.050 5875 9-1/4 5.640 5/32 14.14 9.84
6-5/8 7.390 7000 9-5/8 6.740 1/4 24.46 12.44
7 7.656 7375 10 7.140 7/32 23.22 13.82
7-5/8 8.500 8125 10/3/8 7.765 5/10 34.84 20.45
8-5/8 9.625 9125 10-5/8 8.765 3/8 45.94 23.77
9-5/8 10.625 10125 10-5/8 9.765 3/8 50.99 26.47
10-3/4 11.750 11250 10-5/8 10.890 3/8 56.68 29.49
11-3/4 12.750 ---- 10-5/8 11.890 3/8 61.74 ----
13-3/8 14.375 ---- 10-5/8 13.515 3/8 69.95 ----
16 17.000 ---- 10-5/8 16.154 3/8 87.66 ----
18-5/8 20.000 ---- 10-5/8 18.779 3/8 138.03 ----
20 21.000 ---- 10-5/8 20.154 3/8 110.33 ----
Tolerance on outside diameter W, 1 percent but not greater than 1/8 in.
Tolerance on outside diameter We, + 1/32, 1/64 in.
*The size of the coupling is the same as the corresponding pipe size
Courtesy American Petroleum Institute

Fig. 11-7 Coupled non-API pipe.

11.18
 Fig. 11-8 Integral connections

Example 11.7

The Wisler-Burnett Oil Company intends to run a 22,300-ft string of 47.0- lb/ft, P-110
grade, 7.625-in. production casing. The maximum expected burst pressure is 14,000 psi.
Select the appropriate couplings. A 17.0-lb/gal mud will be used in the well. Company
policy dictates that the tension design factor is 1.8. Use the tables in the Appendix.

Solution:
1. Determine the maximum tension load:
Pipe weight depth lb/ft
22,300 ft 47.0 lb/ft
1,048,100 lb
Buoyed weights pipe weight buoyancy factor
17.0
1,048,100 lb 1
65.5
776,074 lb
Design Load buoyed weight design factor
776,074 lb 1.8
1,396,933 lb

2. The tables in the Appendix provide the following information:

11.19
 Coupling Burst Rating Joint Strength
Type (psi) (lb)
LTC 14,430 1,353,000
LTC 13,460 1,545,000

3. The LTC coupling is unsatisfactory for the joint strength requirements, while the BTC
is underdesigned in burst.

4. Some of the design options are as follows:

run LTC or BTC couplings, realizing they do not meet the design
requirements
reevaluate the burst criteria
reduce the tension design factor

5. This example illustrates that stringent operating conditions may place demands on
pipe design beyond the "standard" situation such that conventional design procedures
are not applicable.

Expandable Tubular Technology

The expandable tubular technology concept is, in it simplest form, cold-working steel down hole.
A mandrel or pig is used to permanently mechanically deform the pipe. The pig is propagated
either by pressure across the pig itself or by a direct pull or push force, deforming the pipes
metal into its plastic region. Typically, expansions over 25%, based on the diameter of the pipe,
can be accomplished. However, most applications use 3-1/2- to 16 in. tubulars and require less
than a 25% expansion.

Table 11-11
Expandable Tubular
System
(Approximate inches)
Base Case Expanded
(OD) Case
(OD)
4-1/4 5-1/2
7-5/8 9-5/8
8-5/8 10-3/4
9-5/8 11-3/4
11-3/4 13-3/8
11-3/4 16
13-3/8 16

Multitudes of applications exist for this technology; however, three initial applications have been
identified and will be discussed. They are as follows:

1. Open hole liners

2. Cased hole liners
3. Liner hangers

11.20
The first application, the expandable openhole drill-liner system is used for problem solving lost
circulation problems and sealing off trouble zones, such as those encountered in sub-salt rubble
zones, or in zones where the pore pressure/fracture gradient relationship is of concern.

The second is the expandable cased-hole liner system application for remediation work. This
system can be used in older or damaged wells for casing repair over several thousand feet of
casing, resulting in a liner than can be drilled through and that causes minimal hole reduction.
This application is particularly ideal for well conditions where a very long corroded interval
needs to be repaired for current production, sidetracking or for deepening. The cased-hole liner
can also be used to seal off perforations that cannot be sealed off using conventional methods,
such as a cement squeeze job.

The third application, the expandable liner hanger system, uses expandable tubulars to create a
liner hanger. Data suggests that as much as 45-60% of liner exhibit hydraulic leakage after
installation, requiring the use of cement jobs or liner hanger packers, or both, to create the
necessary hydraulic integrity. The expandable liner hanger can minimize the occurrence of this
type of hydraulic leakage. Prototypes have exhibited excellent performance properties.

Mechanical Properties after Expansion

The stress-strain curve for expandable tubulars shows the expansion occurs in the plastic
region of the curve. (Fig 11-9)
Studies on the effects of expansion on the mechanical properties of post-expansion
casing, the resistance of expanded casing to sulfide stress cracking, and hoop-stress resilience
during expansion have demonstrated the viability of the process for field applications.

Expansion decreases the collapse

rating of tubular goods, probably a
result of the Bauschinger effect. The
Bauschinger phenomenon occurs
when plastic flow in one direction
(expansion) lowers the applied stress
at which plastic flow begins in the
reverse direction (collapse). The test
data for grade L-80 indicate that, if
the pre- and post-expansion
dimensions are the same, collapse
resistance should decrease by about
30% as a direct result of the
expansion process. Collapse test
data on 5-1/2 in. X 17-lbf/ft grade L-
80 shows that post-expansion
collapse resistance was near or
slightly below the minimum
required by API Bulletin 5C3.
Fortunately, studies have also shown

11.21
that a significant portion of the materials initial collapse resistance can be recovered in-situ
through a process currently under development.

The expansion process appears to have no detrimental effects on burst strength. Burst pressure
of expanded L-80 casing meets or exceeds general formulae expectations, and the fracture
surface of all samples tested has shown ductile fracture behavior.

Expandable openhole drill liner. The expandable openhole drill liner system provides
effective, cost-saving solutions for many planned and contingency openhole operations by giving
operators an extra string of casing. Increased casing length with negligible reduction in diameter
can be especially useful in operations for which very large casing programs in the upper section
of the hole are otherwise cost-prohibitive. In effect, it can give the operator two casing strings
for the cost of one hole size in a normal well.

The system enables operators to extend conventional casing programs for exploratory wells to
reach promising zones that are deeper than expected. The expandable tubular solution, once
expanded inside the existing casing, allows the operator to drill to deeper ones and evaluate them
with conventional logs, without restrictions requiring slim hole logging tools. Liner diameter at
total depth is greater than normally possible with a conventional program and facilitates
conversion of an exploratory well for production.

The expandable openhole drill liner system can also provide an additional type of contingency
tool. The operator can use it in lost circulation or shallow water flow zones in deepwater and
sub-salt environments. The system can also offer another option for original casing that is stuck
high or for reaching total depth with larger production casing. The system allows to simply drill
another hole section and bypass the unexpected trouble zones.

In older fields undergoing development, the expandable openhole drill liner can aid in reaching
deeper reserves and isolate water zones that have penetrated horizontal re-entry wells.

The running sequence for the expandable openhole drill liner begins once the hole section is
drilled. (Fig. 11-10) The expandable drill liner is run into the hole and set in the slips on the
surface. One or two elastomer-coated pipe joints are made up to the top of the expandable
openhole drill liner. This coated section ultimately serves as the liner hanger and as the liners
top seal, replacing any liner top packer as well as the liner hanger. At the bottom of the system is
a canister containing the mandrel or pig. It is commonly known as the pig launcher. The pig
launcher is constructed of thin-wall high-strength steel that is thinner than the expandable casing.
Because the pig launcher has a thinner wall, it can be tripped into the hole through the previous
casing string. The difference in wall thickness between the pig launcher and the elastomer-coater
expandable pipe allows the expanding pipe to be sealed, or cladded to the previous casing
string as the pig moves through the expanded pipe that is positioned inside of the previous
strings casing shoe. The expanded pipe ends up with an outer diameter for expansion that is
greater than the pig launcher, while the inner diameter of the pipe and launcher remains the same.

11.22
The pig launcher varies from 3-
6 ft in length, depending on the
size of the pig assembly. A fill-
up port within the work string
can be installed, allowing fluid
to come up the work string and
into the annulus if there is a
concern about surge pressures.
Calculations for a deepwater
application on the 13-3/8 in. X
16-in. system have been
performed and several operators
have elected to not utilize the
fill-up port, because the surge
pressures calculated to be within
their acceptable tolerances.

The first step is to run the pig

launcher and casing to be
expanded, hanging off in the
slips. Then the drill string or
work string is run and latches in
on top of the pig. The entire
assembly is run on drill pipe or on the work string. Centralizers or stabilizers are used to prevent
buckling during the running operations.

After the string is run, an inner string cement job is performed, using a special cement slurry.
Special cement slurries are required when employing expandable openhole drill liners. The
cements properties must allow for longer thickening times (the cement must stay fluid during
the expansion process) as well as create an effective zonal isolation seal in a smaller annulus than
normally encountered. The cements strength properties have to be maintained to effect zonal
isolation.

A latching dart follows the tail end of the cement job. The dart is pumped to seal off the float
equipment at the bottom and create a pressure chamber.

The mechanism used to extrude the expandable casing downhole includes a hydraulic and
mechanical component. The pipe should be sat 10 feet off the bottom as hydraulic pressure
begins to build in the chamber. The surface pumping unit increases hydraulic pressure from the
surface, down the work string, through the pig and into the pressure chamber area. When the
pressure inside the pressure chamber exceeds the pressure required to develop enough
mechanical force across the pig/expandable-casing interface, the casing begins to extrude over
the pig. By monitoring the hook load indicator at 5 or 10 thousand pounds sitting on bottom, the
work string and pig is pumped out of the hole while extruding the pipe over the pig. A set string
is pulled for this particular application.

One concern has been the lubrication properties necessary to maintain pig movement. Several
lubricants are available and, depending on the pipe size, a conditioned drilling move proves
successful.

11.23
When the expansion process enters into the previous casing string, the elastomer clads the two
pipes together. The elastomer serves a dual purpose. First, the elastomer takes up the voids
caused by ovality problems or drill wear. Secondly, it improves the mechanical and hydraulic
integrity. Typically, this seal forms a mechanical connection with a pullout strength of 225,000
lbf/ft of cladded pipes.

Expanded cased-hole liner. The expandable cased hole liner system enables operators to repair
existing damaged or worn casing for deeper drilling or other contingencies. The system makes
its possible to upgrade exploration-grade casing to a sturdier production casingwith minimal
loss of casing IDby cladding it downhole with the expandable product. The resultant ID is still
large enough for running production equipment and can support drilling operations below the
installed liner.

Expanding this system inside existing casing repairs and reinforces the larger casing for
completion. The same reinforcing quality can be used to shut off perforations in production
casing for recompletion of deeper drilling.

This liner system can enhance control of existing injectors and producers by shutting off
unwanted gas or water production and helping to correct fluid placement.

The running sequence for the expandable liner system is similar to the openhole liner system.
First, the section of the candidate wellbore that needs to be lined must be cleaned and its
condition and inside diameter needs to be evaluated. The cleaning of the wellbore allows the
liner to be positioned without the expandable liner system becoming stuck out of position. The
condition of the pipe needs to be evaluated for mechanical wear from both the inside and out.
The inside diameter of the casing, to which the mechanical and hydraulic seal is to be effected,
must be determined within an accuracy of 0.05 inches so the sealing mechanism can be correctly
designed. This evaluation can be accomplished by using an ultrasonic acoustic caliper. This
type of preparation and evaluation help ensure that the entire interval that needs to be repaired is
initially identified and that a competent seal between the expandable liner and the casing to be
repaired is made.

The system can be run

into the hole open-ended
or can be run into the hole
with a bull nose at the
bottom of the liner. The
system is also expanded
from the bottom up;
however, the elastomer
coating (Fig 11-11) covers
the entire interval to
facilitate the hydraulic
integrity of the liner. The
plug can be drilled out
later if needed. The
elastomer fills the kind
voids illustrated in this
photograph such as the
ovality difference between

11.24
the pipes. When the pig is pumped through the expanded pipe, the pipe is completely circular
because it assumes the shape of the pig. However, the previous string is rarely this perfectly
cylindrical; therefore, voids are created between the pipes that must be filled so that the hydraulic
seal can be created. It should be noted that the mechanical pullout strength without the use of the
elastomer is dramatically reduced from 225,000 lbf/ft to approximately 13,000 lbf/ft.

Expandable liner hanger. The expandable liner hanger system provides operators with a
simpler, cost effective alternative to conventional liner hangers and liner top packers. This
system combines the functional requirements of a liner hanger and liner-top seal, while
minimizing the need for liner-top squeezes. The construction of the system eliminates possible
leaks in the annulus during setting and for the life of the hanger. Once the expanded liner hanger
is set, the minimal annular profile increases the interior cross-section available for flow.
A conceptual running sequence for the liner hanger system is shown in Fig 11-12. Again,
the system is both a liner hanger and a liner-top seal. Conversely from the other expandable
systems discussed within this paper, different techniques accomplish the expansion.
Instead of expanding the full liner, there is a short interval that is expanded to form the
hanger system. The pig also polishes the surface resulting in a smooth bore, so the liner hanger
may act as a receptacle for a mono-bore completion or for other types of tie-backs.
During the expansion process for the hanger, ribs are also expanded as shown in Fig. 11-
13. The ribs latch the liner top into the existing casing string.

11.25
.

11.26
 Problems

11.1 Calculate the internal yield (burst) pressure for 43.5-lb/ft, N-80 grade, 9.625-in. pipe with
a wall thickness of 0.435 in.

11.2 A section of 8.625-in., P-110 grade pipe has a wall thickness of 0.450 in. Calculate the
internal yield of the pipe.

11.3 A 9.625-in., N-80 string has a wall thickness of 0.30, 0.35, 0.40, 0.45, 0.5, 0.55 in.
Calculate the internal yield pressure and plot the results.

11.4 Recalculate Problem 11.1 and use a 95% wall thickness.

11.5 Recalculate Problem 11.2 and use a 95% wall thickness.

11.6 Recalculate Problem 11.3 and use a 95% wall thickness.

11.7 A 9.625-in. string must be designed for sour service and have an internal yield pressure of
9,700 psi. The maximum allowable yield strength is 90,000 psi. Determine the wall
thickness requirements for the pipe and assume an API wall tolerance of 87.5%. Round
up the wall thickness to the nearest eighth inch.

11.8 For problem 11.7, determine the minimum acceptable wall thickness for a 7.0-in. sour
service string. Use a maximum yield strength of 80,000 psi. Round up to the nearest
eighth inch. Use the API wall thickness value of 87.5%.

11.9 Calculate the collapse rating for the following sections of pipe. Using the API tables and
equations, calculate the collapse rating to the nearest 10 psi. Show all calculations.

Pipe diameter, in. 10.75 9.625 5.0 13.375

Wall thickness, in. 0.40 0.545 0.362 0.480
Grade K-55 N-80 P-110 K-55
Weight, lb/ft 45.5 53.5 18.0 68

11.10 Calculate and plot the collapse ratings for the following weights of N-80, 7.625-in. pipe.

Section Weight, lb/ft Wall Thickness, in.

1 26.4 0.328
2 29.7 0.375
3 33.7 0.430
4 39.0 0.500
5 45.3 0.595
6 47.1 0.625
7 52.8 0.712

11.10 The collapse rating for 72.0-lb/ft, P-II0 grade, 13.375-in. pipe must be calculated. Use the
API formulas and tables.

11.11 Refer to Problem 11.10; determine the pipe body yield strength.

11.27
11.12 Refer to Problem 11.12; recalculate the results for P-II0 grade pipe.

References

Applied Drilling Services Volume I User's Guide. Lafayette, LA: Adams and Rountree
Technology Inc., 1981.

Casing, Tubing, and Drill Pipe. API Specification 5A, 1981.

Casing, Tubing, Drill Pipe, and Line Pipe Properties. API Bulletin 5C3.1980 with Supplement 2,
1983.

Holmquist and Nadai. "Collapse of Deep Well Casing." API Drilling and Production Practices,
1939.

Hydril tubular brochures.

Kawasaki Tubular Reference Catalog.

Mudge, Kris. Council Petroleum Services Inc., personal discussions. N .L. Atlas Bradford
tubular brochures.

11.28