Advanced Drilling Practices - Casing Design

Master of Petroleum Well
Engineering
Advanced Drilling Practices
CASING DESIGN
April 2005
Assoc. Prof. Sampaio
jsampaio@peteng.curtin.edu.au
1
Casing Design
Why Run Casing?
Types of Casing Strings
Classification of Casing
Wellheads
Burst, Collapse and Tension

Examples
Effect
of Axial Tension on Collapse
Strength
Examples
2
Casing Design - Introduction
Casing
What is casing?
Why run casing? Cement

1. To prevent the hole
from caving in,
2. Onshore - to prevent
contamination of fresh
water sands,
3. To prevent water
migration to producing
formation,
3
Casing Design - Why run casing - contd
4. To confine production to the wellbore,
5. To control pressures during drilling,
6. To provide an acceptable environment for
subsurface equipment in producing wells,
7. 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 to do?
4
Functions of Casing Individually
Drive pipe Conductor pipe
Provides a means Same as Drive pipe
of nippling up Supports the
diverters weight of next
Provides a mud casing strings
return path Isolates very weak
Prevents erosion of formations
ground below rig
5
Functions of Casing Individually
Surface casing Intermediate casing
Provides a means of Usually set in the first
nippling up BOP abnormally pressured
Provides a casing seat zone
strong enough to Provides isolation of
safely close in a well potentially
after a kick troublesome zones
Provides protection of Provides integrity to
fresh water sands withstand the high
Provides wellbore mud weights
stabilization necessary to reach TD
or the next csg. seat
6
Functions of Casing Individually contd
Production casing Liners

Provides zonal Drilling liners
isolation (prevents Same as Intermediate
migration of water to casing
producing zones and Production liners
isolates different Same as production
production zones) casing
Confines production to Tieback liners
wellbore Tie back drilling or
production liner to the
Provides the surface. Converts liner
environment to install to full string of casing
subsurface completion
equipment
7
Types of Strings of Casing
Diameter Example
1. Drive Pipe or Structural
Pile (Gulf Coast and
16-60 30
offshore only)
150-300 BML
2. Conductor String
16-48 20
100 - 1,600 BML
3. Surface Pipe
85/8-20 133/8
2,000 - 4,000 BML
8
Types of Strings of Casing contd
Diameter Example
4. Intermediate
75/8-133/8 95/8
String
5. Production String 4-95/8 7
6. Liner(s)
7. Tubing String(s)
9
Example Hole and String Sizes (in)
Hole Size Pipe Size
36 Structural casing 30
26 Conductor string 20
17 Surface pipe 133/8
12 Intermediate String 95/8
83/8 Production Liner 7
10
Classification of CSG.
Outside diameter of pipe (e.g. 95/8)
Wall thickness (e.g. )
Grade of material (e.g. N-80)
Type to threads and couplings (e.g. API
LCSG)
Length of each joint (e.g. Range III)
Nominal weight (e.g. 47 lb/ft)
11
Most Common Minimum Yield Ultimate Tensile
Grades Strength (KPSI) Strength (KPSI)
H-40 40 60
J-55 55 75
K-55 55 95
C-75 75 95
L-80 80 95
N-80 80 100
C-90 90 100
C-95 95 105
P-110 110 125
V-150 150 160
12
Length of Casing Joints
LENGTH
RANGE
(ft)
I 16 - 25
II 25 - 34
III > 34
13
Casing Threads and Couplings
API round threads short ( CSG )

API round thread - long ( LCSG )
Buttress ( BCSG )
Extreme line ( XCSG )
Other
See Halliburton Book...
14
Casing Threads and Couplings contd
Rounded Threads Square Threads Integral Joint

8 threads per inch Longer Smaller ID, OD
4 to 20 Stronger Costs more
4 to 20 Strong
5 to 103/4
15
16
17
Wellhead & Christmas Tree
Wellhead
Hang Casing Strings
Provide Seals
Christmas Tree
Control Production
from Well
18
Wellhead & Christmas Tree contd
19
Casing Performance - Uniaxial
Loadings
Axial Tension (couplings & body)
Burst Pressure
Collapse Pressure
Bending
Buckling
20
Tension Strength/Failure
21
Tension Strength
Tension Strength
Couplings: API
Tables for various
couplings
Body (perm. deform.)

Ften =
4
(d 2
n )
d 2 yield
Ften = pipe body yield strength

dn = nominal diameter
d = internal diameter
yield= yield stress
22
Tension Strength Example 1
Compute the body-yield strength for a

7, N-80, 23 lb/ft casing.
Solution:
From API Table (1 & 2)
d n = 7 in
d = 6.366 in
yield = 80,000 psi

Ften =
4
(7 2
)
6.366 2 80,000 = 532 kips
23
Tension Strength Formula
Uses Nominal Diameter

API minimum Thickness 87.5% of
original (nominal) thickness
Yield Strength
Rupture much larger
May deform plastically
24
Burst (Internal Pressure)

Yield the body P
Yield the coupling
Leak the coupling
25
Burst (Internal Pressure)
Barlow (API allows 87.5% of thickness)

Thin Wall Assumption
2(0.875 t )
Pbr = yield
dn
Pbr = pipe body burst pressure

yield= yield stress
26
Burst (Internal Pressure) Example 2
Compute the body burstpressure for a

7, N-80, 23 lb/ft casing.
Solution:
From API Table
d n = 7 in
7 6.366
d = 6.366 in t = = 0.317 in
2
yield = 80,000 psi
2(0.875 0.317 )
Pbr = 80,000 = 6340 psi
7
27
Collapse (External Pressure)
28
Collapse (External Pressure) contd
The following factors are important:

The collapse pressure resistance of a pipe
depends on the axial stress (biaxial stress)
There are different regimes of collapse
failure (depends on ratio dn/t)
Yield Strength Collapse (thick wall)
Plastic Collapse
Transition Collapse
Elastic Collapse
(Empirical Formulation from API)
29
Yield Strength Collapse Pressure
(d n t ) 1
( pcr )yield = 2( yield )e 2
(d n t )
Pcr = pipe body collapse pressure
t = wall thickness
(yield)e= yield stress (effective for biaxial stress)
30
Plastic Collapse Pressure
F1
( pcr ) plastic = ( yield )e F2 F3
(d n t )
t = wall thickness
F1, F2, F3, F4, F5, Material (and stress) dependent coefficients
31
Transition Collapse Pressure
F4
( pcr )trans = ( yield )e F5
(d n t )
t = wall thickness
F1, F2, F3, F4, F5, Material (and stress) dependent coefficients
32
Elastic Collapse Pressure
46.95 10 6
( pcr )elast =
(d n t )(d n t 1) 2

t = wall thickness
33
F1, F2, F3, F4, F5

These values are for
the uniaxial stress
Different values for
effective yield stress
For Biaxial calculate
the effective Yield
Stress and
interpolate the Fs
(Fs depend on Yield Stress)
34
Upper Limit for Yield Strength Collapse

(F1 2) + 8 F2 +
2
F 3 + (F1 2 )

dn ( )
yield e

t F

2 F2 + 3
( )
yield e
35
Upper Limit for Plastic Collapse
dn ( yield ) e (F1 F4 )

t F3 + ( yield ) e (F2 F5 )
36
Upper Limit for Transition Collapse
d n 2 + F2 F1

t 3 F2 F1
37
Boundaries for Axial Stress = 0
38
Collapse (External Pressure) Example 3
Calculate the Collapse pressure rating for a 7 in,

N-80, 23 lb/ft casing.
Solution:
Solution 7 in, N-80, 23 lb/ft t = 0.317 in
Grade F1 F2 F3 F4 F5
N-80 3.071 0.0667 1,955 1.988 0.0434
dn 7
= = 22.08 Plastic collapse for N-80
t 0.317
39
Collapse (External Pressure) Example 3
F1
( pcr ) plastic = ( yield ) F2 F3
( dn t )
e

3.071
( pcr ) plastic = 80,000 0.0667 1,955 = 3,836 psi
22.08
40
Triaxial Collapse
Effect of Axial Stress in the Collapse
Resistance Effective Yield Stress
Von Mises Criteria (Distortion Energy)
Material fails (ductile yield failure) when
total distortion energy equals uniaxial test
energy
( z r ) + ( r t ) + ( t z ) 2
2 2 2 2
yield
41
Triaxial Collapse contd
Triaxial
z + pi z + pi
2
( )
yield e = 2
yield 3 + 3 z pi
2 2
Biaxial
z
( )
yield e = 2
yield 0.75 z
2

2
(yield)e = effective yield stress
yield = uniaxial stress t
z = axial stress
pi = internal pressure (pi >> po)
42
Triaxial Collapse contd
Linear Interpolation for Fs

Fs depend on Yield Stress
For A < e < B interpolate using (linear)
e A
Fe = FA + (FB FA )
B A
43
Fs Formulas (API Bull. 5C3)
F1 = 2.8762 + 0.10679 10 5 Y + 0.21301 10 10 Y2 0.53132 10 16 Y3

F2 = 0.026233 + 0.50609 10 6 Y
F3 = 465.93 + 0.030867 Y 0.10483 10 7 Y2 + 0.36989 10 13 Y3
3
3( F2 / F1 )
46.95 10 6

2 + ( F / F1
)
F4 = 2
2
3( F2 / F1 ) 3( F2 / F1 )
Y ( F2 / F1 ) 1
2 + ( F2 / F1 ) 2 + ( F2 / F1
)
F5 = F4 ( F2 / F1 )
44
Triaxial Collapse Example 4
For the casing of Example 3, calculate the

corrected critical collapse pressure if a
section of 2000 ft, 7 in, N-80, 23 lbm/ft
casing is suspended below it (assume
linear weight of 23 lbf/ft and empty
borehole - no buoyancy effect). What is
the corrected collapse pressure if the
internal pressure is 1000 psi?
45
Solution:
Weight of Casing Below Point in Question
F = 2000 ft 23 lbf/ft = 46,000 lbf
Cross Section Area

(7 2 6.366 2 )
Ac = = 6.6555 in 2
4
Axial Stress
46,000 lbf
z = 2
= 6,912 psi
6.6555 in
46
Effective Yield Stress (biaxial)
z
( )
yield e = 2
yield 0.75 z
2

2
( )
yield e
2 6,912
= 80,000 0.75 6,912 = 76,320 psi
2
(an equivalent N-76.32)
47
Interpolated Fs
Grade F1 F2 F3 F4 F5
C-75 3.054 0.0642 1,806 1.990 0.0418
N-76.32 3.058 0.0649 1,845 1.992 0.0422
N-80 3.071 0.0667 1,955 1.998 0.0434
API Fs Formulas (MsExcel Spreadsheet)
y ield 76320
F1 F2 F3 F4 F5
3.058 0.0649 1845 1.992 0.0422
48
dn 7
Collapse Regime = = 22.08
t 0.317
Yield Regime U-Limit:

(F1 2) + 8 F2 +
2 F 3 + (F1 2 )

dn ( yield ) e

t F
2 F2 + 3
( yield ) e

1,845
(3.058 2) + 8 0.0649 +
2
+ (3.058 2)
76,320
= 13.54 < 22.08
1,845
2 0.0649 +
76,320
49
Plastic Regime U-Limit:
dn ( yield ) e (F1 F4 )

t F3 + ( yield ) e (F2 F5 )
76,320 (3.058 1.992 )

22.08 = 22.79
1,845 + 76,320 (0.0649 0.0422 )
Collapse occurs in the Plastic Regime
50
Plastic Collapse Strength

F
( p ) = ( ) F F 1
(d n t )
cr plastic yield e 2 3

3.058
( pcr ) plastic = 76,320 0.0649 1,845 = 3,772 psi
22.08
(compare with 3,830 psi for the unstressed

casing)
51
Effect of Internal Pressure

Critical pressure expressions are for pressure
differential. However, the effective yield stress
should account or the internal pressure, since
the yield will start at the internal wall.
The triaxial expression must be used:
z + pi z + pi
2
( )
yield e = 2
yield 3 + 3 z pi
2 2
52
6.912 + 1 6.912 + 1
2
( )
yield e = 80 3
2
2
+ 3 6.912 1
2

( ) yield e = 75.800 ksi = 75,800 psi
y ield 75800
F1 F2 F3 F4 F5
3.056 0.0646 1830 1.991 0.0421
3.056
( pcr ) plastic = 75,800 0.0646 1,830 = 3, 764 psi
22.08
( pext )max = 3, 764 + 1, 000 = 4, 764 psi

53
Pressure Collapse Table
54
Casing Design Criteria
Biaxial Method or Uniaxial Method
Burst
Conductor
Surface and Intermediate Casing
Production Casing
Collapse
Tension
55
Casing Design Criteria contd
Burst Conductor:
External pressure is zero
The maximum internal pressure is the
formation fracture pressure at the depth of the
conductor set depth. If the fracture pressure is
unknown, assume pff=1 psi/ft
F.S.=1.1
Neglect the gas density inside the conductor
56
Burst of Conductor
57
Burst of Surface & Intermediate Csg.:

External pressure: hydrostatic pressure of the heaviest mud
used to drill the hole and set the casing
Internal pressure: based on pore pressure at the final depth
of the next casing. If the pore pressure at the bottom of the
next casing is not known, assume the following:
p p = 0.564 psi/ft Depth next casing < 8000 ft

p p = 0.650 psi/ft Depth next casing 8000 ft
Assume that a fraction f (usually not less than 40%) of the
length is evacuated by gas and (1-f) fraction of the length
remains filled with drilling fluid.
Neglect the gas density inside the conductor.
F.S.=1.1
Worse scenario at the top of string
58
Burst of Surf. & Interm. Csg.
59
Burst of Production Casing:
External pressure: hydrostatic pressure due to formation saltwater (SGsw
= 1.1542)
Internal pressure: based on pore pressure at the final depth Dc
(production depth). If the pore pressure at the bottom of the casing is not
known assume the following:
p p = 0.564 psi/ft Depth casing < 8000 ft

p p = 0.650 psi/ft Depth casing 8000 ft
Assumed the whole internal casing filled with gas (gas lift production)
Pressure inside the casing determined as follows:
DC D

Mg
( DC D )
pi = pb e RT
pb e 40000
F.S.=1.1 is used
Worse scenario at the top of string
60
Burst of Production Casing
61
Collapse:
Collapse due to fluid in the annulus between the
casing and the borehole
Considered the heaviest drilling fluid used to drill
the hole and set the casing
Assume casing empty
No buoyancy
F.S.=1.0 (neglect the strengthening effect of
cement; most of the casing will not be empty)
Worse scenario at the bottom of string
62
Collapse of Casing
63
Tension:
Corresponds to the weight of the
casing weight measured in the air
(no buoyancy effect)
F.S.:
1.6 for couplings
1.8 for casing body
Worse scenario at the bottom of string
64
Casing Design Example
Evaluate the burst and collapse pressure
loadings and design an appropriate surface
casing using the biaxial method. Check for
axial load.
Setting depth of the casing string: 4000 ft
Mud density as setting the string: 10.0 lb/gal
Setting depth of the next csg. string: 11000 ft
Mud density of the next phase: 10.5 lb/gal
Casing size and coupling: 103/4 Buttress
threads, minimum grade K-55
Assume f = 40%.
65
Casing Design Example contd
Burst Loading (this is a surface csg.)
External Pressure:
po(psi) = 0.052 x 10 lb/gal x D(ft)

po = 0.52 x D
66
Internal Pressure:
pp=0.650 psi/ft (Dnc>8,000 ft)
pp = 11,000 x 0.650 = 7,150 psi
(1-0,4)xDnc = 6,600 ft
p6600= 7,150-0.052x10.5x6,600=3,546 psi
pi= 3,546 psi
67
Burst Pressure contd:

F.S. = 1.1
pab = (pi-po)
pab= 3,546 0.52D
68
Collapse Loading
External Pressure:
po = 0.52 x D
Internal pressure = 0 psi
F.S. = 1.0
pac = 0.52 x D
69
Design for Burst
Start at bottom (minimum burst pressure)
pab,4000 = 3,546 0.52 x 4000 = 1,466 psi
Cheapest casing: (p.320-321)

K-55, 40.50 lb/ft, Burst Strength 3,130 psi
Minimum depth that can go:

pab,D = 3,546 0.52 x D = 3130 psi / 1.1
Dmin = 1347 ft
70
Continue with next cheapest Casing


pab,D = 3,546 0.52 x D = 3,580 psi / 1.1
Dmin = 561 ft
71


pab,D = 3,546 0.52 x D = 4,030 psi / 1.1
Dmin = -226 ft (above surface)
72
Burst Diagram
0 ft
103/4 K-55 51.00 lb/ft
561 ft
103/4 K-55 45.50 lb/ft
1347 ft
103/4 K-55 40.50 lb/ft
4000 ft 73
Design for Collapse (uniaxial)
Start at top (minimum collapse pressure)
pac = 0.52 x D
Cheapest casing:
K-55, 40.50 lb/ft, Collapse Strength 1,580 psi
Maximum depth that can go:

pac,D = 0.52 x D = 1,580 psi / 1.0
Dmax = 3,038 ft
74

K-55, 45.50 lb/ft, Collapse Strength 2,090 psi

pac,D = 0.52 x D = 2,090 psi / 1.0
Dmax = 4.019 ft
75
Collapse Diagram
0 ft
103/4 K-55 40.50 lb/ft
3038 ft
103/4 K-55 45.50 lb/ft
4000 ft 76
Combine Two Diagrams
0 ft
103/4 K-55 51.00 lb/ft
561 ft
103/4 K-55 45.50 lb/ft
1347 ft
burst
+ = 103/4 K-55 40.50 lb/ft
collapse
3038 ft
103/4 K-55 45.50 lb/ft
4000 ft
77
Collapse Adjustment (Biaxial)

Start at bottom (Iterative Process)
No need to check at bottom of 45.50 lb/ft
Bottom of 103/4 K-55 40.50 lb/ft - 3,038 ft
d n 10.75
= = 30.71
t 0.350

A=
4
(10.75 2
10.050 2
) = 11.44 in 2
W = 45.50 lb/ft (4000 ft 3038 ft) = 43, 771 lbf

43, 771 lbf
z = 2
= 3,828 psi
11.44 in
78
3,828
( yield )e = 55, 0002 0.75 3,8282
2
= 52,986 psi
y ield 52986
F1 F2 F3 F4 F5
2.985 0.0530 1146 1.994 0.0354
79
Yield Regime U-Limit
1,146
( 2.985 2 ) + 8 0.0530 + + ( 2.985 2 )
2

52,987
= 14.98 < 30.71
1,146
2 0.0530 +
52,987
Not Yield Regime
80
Plastic Regime U-Limit
52,987 (2.985 1.994 )

= 25.26 < 30.71
1,146 + 52,987 (0.0530 0.0354)
Not Plastic Regime
81
Transition Regime U-Limit
2 + 0.0530 2.985
= 37.84 < 30.71
3 0.0530 2.985
Collapse occurs in the Transition Regime
82
1.994
( pcr )trans = 52,986 0.0354 = 1,562 psi
30.71

pac,D = 0.52 x D = 1,562 psi / 1.0
Dmax = 3,004 ft
83
2nd Iteration
Bottom of 103/4 K-55 40.50 lb/ft - 3,001 ft
W = 45.50 lb/ft (4000 ft 3009 ft) = 45,318 lbf

45,318 lbf
z = 2
= 3,963 psi
11.44 in
84
3,963
( )
yield e = 55, 000 2
0.75 3,9632

2
= 52,911 psi
y ield 52911
F1 F2 F3 F4 F5
2.984 0.0530 1143 1.994 0.0354
85
Plastic Regime U-Limit
52,911 ( 2.985 1.994 )

= 25.26 < 30.71
1,144 + 52,911 ( 0.0530 0.0354 )
Not Plastic Regime
86
Transition Regime U-Limit
2 + 0.0530 2.985
= 37.86 > 30.71
3 0.0530 2.985
Collapse occurs in the Transition Regime
87
1.994
( pcr )trans = 52,911 0.0354 = 1,561 psi
30.71

pac,D = 0.52 x D = 1,561 psi / 1.0
Dmax = 3,002 ft
Close Enough!
88
Final Diagram
0 ft
1 103/4 K-55 51.00 lb/ft
561 ft
2
103/4 K-55 45.50 lb/ft
1347 ft
3
103/4 K-55 40.50 lb/ft
3006 ft
3038 ft 4
103/4 K-55 45.50 lb/ft
4000 ft
89
Check for Tension

Critical section: Top of section 3
Axial Load
W=45.50x(4000-3006)+40.50x(3006-1347)=112,417 lbf
103/4 K-55 40.50 lb/ft

Body Strength: 629 kips/1.8 = 349 kips
Coupling Strength: 819 kips/1.6 = 512 kips
90
Csg. Design & Pore Pressure
pressure
Abnormal
P: >0.4365 psi/ft
depth
Normal
P: 0.433-0.4365 psi/ft
91
Casing Set Depth
Need for:
Pore Pressure
Gradient
Formation
Fracture
Gradient
92

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Master of Petroleum Well

Burst, Collapse and Tension

Why run casing? Cement

e.g., you need 14 ppg to control a lower zone,

Production casing Liners

5. Production String 4-95/8 7

17 Surface pipe 133/8

12 Intermediate String 95/8

83/8 Production Liner 7

API round threads short ( CSG )

See Halliburton Book...

Rounded Threads Square Threads Integral Joint

Ften = pipe body yield strength

Compute the body-yield strength for a

Uses Nominal Diameter

Rupture much larger

May deform plastically

Burst (Internal Pressure)

Leak the coupling

Barlow (API allows 87.5% of thickness)

Pbr = pipe body burst pressure

Compute the body burstpressure for a

The following factors are important:

(Empirical Formulation from API)

Yield Strength Collapse Pressure

Plastic Collapse Pressure

Transition Collapse Pressure

Elastic Collapse Pressure

Pcr = pipe body collapse pressure

F1, F2, F3, F4, F5

(Fs depend on Yield Stress)

Upper Limit for Yield Strength Collapse

Upper Limit for Plastic Collapse

Upper Limit for Transition Collapse

Calculate the Collapse pressure rating for a 7 in,

N-80 3.071 0.0667 1,955 1.988 0.0434

Linear Interpolation for Fs

For A < e < B interpolate using (linear)

F1 = 2.8762 + 0.10679 10 5 Y + 0.21301 10 10 Y2 0.53132 10 16 Y3

For the casing of Example 3, calculate the

F = 2000 ft 23 lbf/ft = 46,000 lbf

Cross Section Area

Effective Yield Stress (biaxial)

(an equivalent N-76.32)

API Fs Formulas (MsExcel Spreadsheet)

Yield Regime U-Limit:

Plastic Regime U-Limit:

76,320 (3.058 1.992 )

Collapse occurs in the Plastic Regime

Plastic Collapse Strength

(compare with 3,830 psi for the unstressed

Effect of Internal Pressure

The triaxial expression must be used:

( ) yield e = 75.800 ksi = 75,800 psi

( pext )max = 3, 764 + 1, 000 = 4, 764 psi

Burst of Surface & Intermediate Csg.:

p p = 0.564 psi/ft Depth next casing < 8000 ft

p p = 0.564 psi/ft Depth casing < 8000 ft

Burst Loading (this is a surface csg.)

po(psi) = 0.052 x 10 lb/gal x D(ft)

pi= 3,546 psi

Burst Pressure contd:

pab= 3,546 0.52D

pab,4000 = 3,546 0.52 x 4000 = 1,466 psi