los CHAPTER 2 Casing Design 2.1 Specifications of Casing Casing is specified according to the following: 2.1.1 Size The size means the outsize diameter of the casing pipe. 2.1.2 Nominal Weight The average weight per unit length adjusted from the true weight to account for the threaded ends and couplings is nominal weight. 2.1.3 Type of Threaded Ends Most of the casing pipes are connected together by means of a coupling. Different types of threads are cut on the ends of the pipes. Depending upon the type of threads, the casing pipes can be specified as under: {@) API Round Thread Casing (i) Short thread coupling (STC) (ii), Long thread coupling (LTC) Both STC and LTC casings have 8 threads per inch cut on them. Strength of LTC couplings is about 30% more than the STC in tension. (b) API Buttress Thread Casing The individual pipes are joined by means of thread couplings having but- tress threads. Buttress threads allow the transmission of very high axial loads. Number of threads per inch in buttress threads is 5. (c) API Extreme Line Casing In such casings the pipe ends are slightly upset where box and pin threads are cut. In addition the box is provided at its bottom with a slightly tapered sealing surface. Against this, a mating sealing surface with a slight curva- ture, and extending beyond the threaded pin is pressed under radial stres- ses during make up. The thread profile is trapezoidal. Due to the type of thread and the special design of the sealing surface, the extreme line casingis excellentlyCasing Design 109 suited for high service loads. The joint is gas tight and can transmit ex- treme axial tension and compression forces. Number of threads per inch in extreme line casing is 6 upto 7.5/8" dia and 5 from 8.5/8" to 10.3/4”. Apart from the standard API connections mentioned above, some of the manufacturers have developed different joints suitable for different working conditions. 2.1.4 Grade of Steel The casing pipes are graded on the basis of the minimum. yield strength. Various different types of casing grades are H-40, J-55, K-55, C-75, L-80, N-80, C-95, P-110, Q-125, and V-150. The numerical part of the casing grade designation is actually the minimum yield strength in thousands of psi which is convenient for remembering the strength of various grades. The yield strength for this purpose is defined as the tensile stress required to produce a total elongation of 0.6 and 0.5 per cent of length for P-110 and all the remaining grades respectively. 2.1.5 Thickness and Drift Diameter The. casing pipes are manufactured with different wall thicknesses. An increase in wall thickness is achieved at the cost of corresponding de- Crease in the inside diameter. As the weight per foot of the casing increases, its wall thickness increases and internal diameter decreases. Drift diameter of a casing is the diameter of the largest equipment (bit, packer etc) which can be safely run inside the casing. 2.1.6 Lenght Range Length of the casing pipes manufactured is another criteria by which casings are sometimes specified. The length of pipes for different ranges are as under: Range | from 16 ft. to 25 ft. Range Il from 25 ft. to 34 ft. Range Ill from 34 ft. to 46 ft. 2.2. Forces Acting on Casings When the casing is lowered and set in the hole, it is subjected to three forces (i) Longitudinal or axial loading on the casing, due to its own weight. (i) External pressure is exerted on the casing due to the hydrostatic head of the fluid column which is present outside the casing. These forces are countered by the fluid column present inside the casing. In case the casing is empty or the pressure from outside is more than the one present inside, the net outside pressure tends to flatten the casing. (ii), Casing is subjected to internal pressure during the production of oil or gas from the well. It is also subjected to internal pressure during self flow while drilling.SSS NS INS TAPERED SEAL TYPE THREAD APICasing 8 Round Long & Short Thread API Tubing Non-upset 10 Round Thread Fig. 3.2 ! g a Pee 30 30° Casing & Tubing Round Thread Form API Tubing EVE 8 Round Thread OLSSS Sw >I QP TAPERED SEAL TYPE THREAD API Buttress Casing Thread 5 Threads/Inch _ API Buttress Tubing Thread 8 Threads/Inch Fig. 3.3 irjvcoo oz Buttress Casing Thread Form oz-acAH | af 4g° i Z | Buttress Tubing Thread Form | | |. [7 | oz-rvco°o LEE112 METAL TO METAL SEAL TYPE THREADS NO SEALING BY THREADS € 5 & so 3 8 E 3 = Hydril 2 Step Thread eS APMMETAL TO METAL SEAL TYPE THREADS METAL TO METAL ‘SEAL LOW CLEARANCE CASING SHS HS HSH NNT LLLDOLLIID oz-rvcoo | | | API Extreme Line Armco Seal-lock Armco Seal-lock Casing Threads Casing Thread Casing 5 Threads/ 6 Threads/Inch Form Inch elt114 GST Tubing Thread Atlas Bradford Zegz NN TEFLON SEAL 7) Ee eZ ESSSUNSSSSUSSSSSSNSSS SERRE Lorre ERENT TST TS SSSI TTY OLLI ULL Fig. 3.6 KW QW hr RESILIENT SEAL TYPE THREADS Atlas Bradford DSS Tubing ThreadMETAL TO METAL SEAL TYPE THREADS A N Aerte N 2h HA nN THREAD PROFILE N? THREAD PROFILE EN CN XN A SS DIDDY SSSDA DS S) METAL-TO-METAL SEAL PROFILE METAL-TO-METAL SEAL PROFILE DY. WIZTLLIILE LLL. 36° Primary Seal kre 7z ELEN EEK KLE CESK w KSSSSS IOUS Hp UZLZTTZ LK 4 Ke RARE VAM Tubing VAM Casing Fig. 3.7 GLMETAL TO METAL SEAL a, EXTERNAL SEAL \/, 30" 10% Taper CLL LED DON VAM FJL Casing AND SHOULDER 19) THREAD PROFILE Paull Mee \ a METAL-TO-METAL SEAL 20% Taper Fig. 3.8 METAL TO METAL & RESILIENT THREAD PROFILE UR be Re éTao\, 90° 3 i RESILIENT SEAL WITH EXTRUSION RELIEF PROFILE Me METAL SEAL PROFILE Pipe Axis 7 Me A Otis Heavy Wall OLECasing Design 117 2.3 Casing Design Casing design essentially consists of selecting the most economical grades and weights which will withstand wothout failure the three forces to which it will be subjected. Since the forces under consideration are not uniform but vary with depth, it becomes necessary to use a combination string so as to utilise the casing properties to the maximum extent and effect savings in money and material. The principal factors considered in casing design are 1. Collapse; 2. Ten- sion; 3. Burst 2.3.1 Collapse Pressure This is the net external pressure imposed on a pipe. The condition when maximum collapse pressure acts is taken as the basis for design. This happens when the pipe is empty from inside with hydrostatic pressure of mud column exterted from outside. As the hydrostatic pressure of the mud increases in direct proportion to the depth, from the consideration of collapse, the strongest pipe should be placed at the bottom. Another type of collapse failure can be during a squeeze job if the high pressure exerted through the perforations affect casing above the packer. 2.3.2 Tensile Load Tension in casing results from: (i) Weight of the Casing: When a casing string is hanging in a well, each joint supports all the weight of the casing connected below it. Hence the greatest tension occurs at the top of the string. (ii), Pulling through tight sections during reciprocation. (ii) Temperature changes during and after cementing. When casing is cemented, the heat of hydration causes sufficient tempo- rary temperature increase which causes expansion and increased com- pressive stress. When the subsequent cooling occurs, (if the casing is fixed on both top and bottom) shrinking will tend to occur and tension stress will be severe. There is an upward force due to buoyancy which tends to compress the casing at the bottom and thus reduce the tension load at the surface. This force is generally neglected and the design calculations are made as though the casing were hanging freely in the air. The consideration of tension load would require that the strongest pipe be made up near the surface. 2.3.3 Burst Pressure Burst pressure is the net internal pressure i.e. the difference between the internal and the external pressure acting ona pipe. For maximum internal pressure the casing is considered to be filled completely with gas at the bottom hole pressure. For minimum extemal pressure, the hydrostatic head of salt water is supposed to act from outside. Thus the casing is sub- jected to the maximum burst pressure near the surface, where the exter- nal pressure is minimum.118 Drilling Operations Manual The maximum surface pressure is calculated by determining the forma- tion pressure at the shoe and deducting from this pressure the weight of the gas column from shoe to the surface. 2.3.4. Effect of Tension on Collapse Strength of Casing Thelisted values of collapse resistance for a particular size of casing are at zero axial load. The axial or longitudinal tension in casing reduces its resis- tance to collapse. Similarly, the compression improves collapse resis- tance. Easy way of finding the effect of axial tension on collapse resistance is by referring to the collapse curve factors. To determine the collapse strength under a given tensile load: Divide the tensile load by the pipe body yield strength, to obtain load factor (X). Read collapse rating factor (Y) against load factor (X) from tables. Multiply rated collapse strength with collapse rating factor (Y) to find collapse strength under tensile load. Example: 514", 17.00 ppf, N-80 has a collapse rating of 6280 psi what will be collapsrating with an axial tensile load of 94,486 Ibs. 94486 397000 Collapse strength Rating Factor Y = 0.911 So, 0.911 x 6280 psi = 5721 psi collapse strength with a tension load of 94486 Ibs. The X and corresponding Y factors are tabulated on page 119-120 Solution: Axial Load Factor X =, = 0.238; therefore, 2.3.5 Design Factors Design factor is defined as the ratio of allowable stress to the actual stress. Casing strings are designed on the basis of certain assumed conditions and there is always a possibility of exceeding those conditions. The design factors provide margin of safey to make allowance for well condi- tions which can not be accurately predicted. |Following design factors are commonly used: 2.0 un-cemented portion in cemented portion For worst possible loading condition the following assumptions are made: 1. The casing is lowered empty. 2. The effect of buoyancy is neglected. 3. Formation pressure minus gas gradient acts at the surface.Casing Design 119 Collapse Curve Factor The X and Y Factors120 Drilling Operations Manual Collapse Curve Factor (Contd.)Casing Design 121 2.3.7 Collapse Pressure Considerations. When designing a casing string for tension, the pipe should be strong at the top and weaker at the bottom. While designing for collapse the pipe should be strong at the bottom and weaker at the top and for burst the pipe must be strong in areas where it is unsupported. by cement, normally near the top of the hole. Obvioulsy the design demand of these three forces is in conflict with one other. It is necessary, therefore, that a string of casing be designed to pro- videa satisfactory margin of safety for every operating condition expected to be encountered, and still use the lightest weight casing possi- ble. The combination string i.e. casings of different thickness and grade is the most satisfactory method of attaining this objective. The starting point for designing a combination string is the bottom of the casing. Collapse pressure exerted by the hydrostatic head of mud column present outside the casing pipe is calculated using the relation: Hydrostatic head = Mwx H in Kg/cm? 10 where Mw = sp. gr. of mud H = Height of mud column in mts. After knowing the hydrostatic pressure of mud acting outside the casing, this value is multiplied by safety factor for collapse i.e. 1.125. From the tables of casing properties the lightest weight and least expensive grade of casing is selected which will withstand this collapse pressure. The value of collapse pressure goes on decreasing as the height of the mud column is decreased. As such, casing of lower grades capable of holding collapse pressure can be utilised. 2.3.8 Burst Pressure Considerations For calculating the burst pressure proceed as follows: Step No.1 (i) Calculate the surface pressure considering a kick from the next casing shoe depth. (ii) Calculate the surface pressure considering a pressure equivalent to fracture pressure at the casing shoe depth. The least of the above two values is considered as burst pressure. Surface Pressure is found by the relation: Surface Pressure 1 Bottom Hole Pressure GLOMUS Where D — Depth,m GG — Gas Gravity Usually 0.65122 Drilling Operations Manual Step No. 2 Calculate external pressure due to the hydrostatic pressure column of salt water. It will be zero at the surface and maximum at the bottom. Step No.3 On a graph, lines of internal pressure and external pressure due to salt water are drawn and net burst line is plotted. From the net burst line, burst pressure at any point can be calculated. The procedure given in detail in the solved example. 2.3.9 Tensile Load If Wis the weight per unit length of casing (kg/m) and D(m) is the length of the casing used, tensile load in tonnes is as follows: WxD 1000 Tensile load is multiplied by the safety factor and the casing which fulfils the requirement is chosen. tons Note: — As stated earlier, collapse is checked at the bottom of the section while burst and tension are checked at the top of the section. — If two casings having different grades and weights are available (having nearly equal collapse resistances), casing having lower weight should be preferred. — For gas wells, XL joints or Premium joints should be used for pro- duction casing. — For exploratory/deep wells, BTC should be used in Isolation/Inter- mediate casings. — Availability of casing grades/weights should be checked before designing. 2.3.10 Special Considerations for Casing Design — Severely corrosive areas must be given special consideration.In areas where H,S is expected, casings having longitudinal yield strength in the range 80,000-95,000 psi and hardness controlled to maximum of Rockwell hardness No. 22 should be used. — Arctic locations or sub-zero temperatures. — When a packer is set in casing the most severe burst condition arises if tubing leak occurs and gas rises through mud to surface. The maximum burst pressure at any point in the casing is, the forma- tion fluid pressure plus the mud column pressure from the surface to that point less the pressure of mud in annulus from surface to the point. —High burst pressure may develop during squeeze cementing in some cases. This problem is largely eliminated by applying aCasing Design 123 balancing external casing pressure to the annulus. Care should be taken for selecting the point where packer is to be set during squeezing — In cases where pressure regression is encountered or expected to be encountered, casing design in collapse becomes more critical. — Inair/gas/under balanced drilling a high factor of safety in collapse should be maintained. The true value of stresses imposed on oil well tubulars is difficult if not impossible to predict. Therefore, any design procedure must be a com- promise between overly simplified and hopelessly complicated situa- tions, where possible design procedure should be based on actual condi- tions with design or safety factors being altered to fit the uncertainties which exist in a given area. 2.4 Casing Design Example The whole casing design procedure would be clear from the example given below: DATA 1. Size = 9-%" 2. Depth 2500 M 3. Mud Weight = 1.30 gm/cc 4, Depth of next phase = 4000 M 5. Formation Pressure gradient in next phase = 1.50 gm/cc (Mud Weight equivalent) 6. Fracture Pr. grdient at 2500 M = 2.20 gm/cc (Mud weight equivalent) 7. Design factor desired (Minimum) Collapse = MEER Burst — 1.10 Tension — 1.80 8. Next hole size to be drilled—8.5” SOLUTION Buoyancy factor = —2-85—1.30 _ 9 994 7.85 WwW. Mud weight = 1.30 gm/cc D Depth = 2500M Sp. Gravity of steel = 7.85 Collapse Collapse Pressure = eae = 2200 0 1:30 = 325 kg/cm? For DFC = 1.125, Collapse Pressure Resistance required = 325 x 1.125 =365.63 kg/cm? Burst Step 1 Burst Pr. (surface pressure) assuming kick from bottom of next phase is calculated:124 Drilling Operations Manual Formation Pr. = 1.50 x 4000 — 99K o/om? 10 Surface Pr. = _ Formation Pr. (0001138 x 0.65 x D (GG) Gas Gravity = 0.65 Therefore Surface Pr. 600 0001138 x 0.65 x 4000 - 1.344 = 446.3 kg/cm? Burst pressure at surface from second consideration i.e. surface pr. required to fracture casing seat is also calculated:— Fracture Pr. = 2:20 X 2500 _ seq kg/cm? 1 Therefore Surface Pr. = —____550_ {0001738 x 0.652500 = 350 1.203 | As surface pressure in first consideration is less, burst pressure assum- ing complete gas kick from bottom of next phase is considered. Therefore Surface pr. = 446.3 kg/cm? Step No.2 Assuming sp gr. of saline water to be 1.05 External Pr. at 4000 M = 1.07 x 4000 10 = 428 kg/om? External Pr. at surface = 0 Therefore Burst Pr. at 4000 M = 600 — 428 = 172 kg/cm? Burst Pr. at surface = 446.3 — 0 = 446.3 kg/cm? (Graph on Page 123) Casing is normally designed on the basis of collapse, but internal yield and tension are checked. So casing design is started from bottom as col- lapse pressure is maximum at the bottom. The collapse resistance required at the bottom = 325 x 1.125 (For DFC = 1.125) = 365.63 kg/cm? Casing having collapse Resistance equal or greater than 365.63 kg/cm? is selected and its properties are noted down. Further, as next hole to be drilled is 8.500”, casings having drift dia equal or more than 8.500” are selected. P-110, 47 ppf (70 kg/M), BTC is selected as Section I. Its properties are Collapse Resistance = 373.4kg/cm?, Burst Pressure Rating = 663.9 kg/cm* (or internal yeild pressure)Casing Design 125 Burst Load Profile Pressure (kg/cm? 200 300 Resultant Burst Pressure 1000 Depth (M) 2000 External Prressure Internal Pressure126 Drilling Operations Manual Pipe body yeild = 672 tonnes Joint Strength 680 tonnes Dre; = 3734 =4.149> 1.125 325 Hence safe. Above this casing, a casing having lower collapse resistance can be used. P-110, 43.5 ppf (64.6kg/M) BTC is selected as Section. Its properties are: CollapsePressure Resistance = 311.1 kg/cm? Burst Pressure Rating = 612.0 kg/cm? Pipe Body Yield = 625.3 tonnes Joint Strength = 629.3 tonnes Depth to which Section Il can be used with DFC = 1.125 is calculated. DFo = 1.125 = 5 Dp =.311.1x10 = 9127M 1.125 x 1. Length of section | = 2500 — 2125 M = 375 Mts Wt. of BuoyedSection | = SEXO X 0886 — 2190 Tonnes a [Ps Body gta] = 83g} -0.035 Pipe body yield of section II is considered as section | hangs on section II From Table on page 117 X4 = 0.035 Y1 = 0.991 Collapse Pr Resistance of = 0.991 x 311.1 Section II with tensile load of section! = 308.3 kg/cm? Revised depth to which = 308.3 x 10 1.125 x 1.3 section Il can be used 2108M Length of section! 500 — 2108 92M Weight of section | = 392 x70 X 0.834 1000 2.88 T 2.88/625.3 .036 For X2 = 0.036 Y2=0.990 _(fromtable page 117 & 118) Collapse Pr. resistance of section Il =0.990 x 311.5 Depth to which section Il can be used = 308.4 x 10 1.125 X 1.3 = = 5108m Length of section Il = 2500 —2108 = 392MCasing Design 127 Weight of section | = 392 x 70x 0.834 — 29.88Tonnes 1000 Xg = 22.88 625.3 = 0.036 As X2 = X3 Therefore Depth to which section Il can be used is 2108 M or 2100 M (Rounded off) Therefore length of section | = 400 M Check in Tension of Section | Weight of section! = 400 x 70_ 1000 28 Tonnes Therefore DFt = 680 _24.3>1.8 28 Hence safe. Above section II, another casing having still lower collapse resistance can be used. Section II], N-80, 43.5 ppf (64.6 kg/m) BTC is selected. The properties are: Collapse pressure resistance 268 kg/cm? Burst Pr. Rating Pipe body yield Join strength Depth towhich section II can be used Lenath of section Il Combined load of Section 1&ll = 445 kg/cm? 455.8 tonnes 487 tonnes 268 x 10 1.125 X 1.3 1832M 2500 — 400 — 1832 268M (400 (400 x 70) + (268 x Ho 0.834 1000 37.8 Tonnes x, = 378 = 0.083 455.8 ForX1 = 0.083Y1 = 0.975 Collapse Pr. resistance of Section Ill = 268 x 0.975 = 261.6 kg/cm? Depth to which Section III can be used = 261.6 x 10 1.125 X 1.3 = 1788.7 Length of section II 2500 — 400 — 1788 = 312M Combined wt. of Section 1&ll = (400 X 70 +312 x 64.6) 0.834 1000 40.16128 Drilling Operations Manual = 40.16 = 0.088 455.3 Y2 = 0.974 Colapse resistance of Section Ill = 0.974 x 268.3 : = 261.3kg/em? Deeth anita whieh Section Ill _ 261.3 x10 1.3 X 1.125 = 1787M Length of Section Ill 2500 — 400 — 1787 = 313M Combined wt. of Section Nail = (400 x 70+ 313 x 64.6) 0.834 1000 40.2 Tonnes. Xq =—40.2.= 0.088 455.8 As X2 = X3 Depth to which Section III can be used is 1787 or 1785 M (say) Length of Section II Check in Burst for Section Il From Burst Pr. graph Burst at 1785M = 325 kg/cm? DFbi = 611.8 kg/cme 325 = 1.88>1.1 Hence safe. Check in Tension for Section II Wt. of Section! =28 Tonnes Wt. of Section II = 846X315 1000 = 20.35 DFtil =—_487 __ 28 + 20.35 = 10.07>1.8 Hence safe. Any casing having collapse resistance still lower than Section Ill can be used, but is not preferred due to: — Not more than three different weights or grades are preferred as stated earlier. — Burst and tension would increase and. as such heavier sections would be required. So let us design Section III on the basis of burst and see whether it can be extended up to surface.Casing Design 129 DFolll = _445 446.3 = 0.997 <1.1 Hence section Ill cannot be extended to the surface. Depth to which Section III can be used is to be calculated. Burst pressure strength of Section III = 445 kg/cme ForDFb = 1.1 Usable Burst pressure strength of Section Ill = “ = 404.5 kg/eme From Burst pressure graph, 404.5 kg/cm? is at = 650M So Section III can be used upto 650 M Length of Section III = 2500 — 400 — 315 — 650 = 1135M weight of section III = 1135 x 64.6 —73.32 Tonnes 1000 Check in Tension TensileLoad = 400704315 x 64.6 + 1135 x 64.6 1000 = 121.67 Tonnes. DF tI = 38! i 121.67 = 400>1.8 Hence safe. So top 650 M, a casing having burst strenth higher than Section Ill is tobe used. Section IV P-110, 43.5 ppf (64.6 kg/ema) BTC Properties same as Secton II. DFbI = jaa 446.3 = 137>11 Hence safe. Check in Colapse Since collapse pressure of Section IV is greater than Section Ill and is being used above Section III, hence it will be safe in collapse. Check in Tension Tensile Load = (400 X 70 + 315 x 64.6 + 1135 x 64.6 + 650 x 64.6) x 0.834 1000 = 163.6 Tonnes Therefore DFt jy = 629.3 163.6 = 3.85 Hence safe.130 Drilling Operations Manual SUMMARY Interval Length | Casing specifications |DFc | DFb| DFt 0-650M 650M, P-110, 43.5 ppf, BTC |SAFE | 1.37] 3.85 650-1785M | 1135M | N-80,43.5ppf,BTC |1.125|1.10| 4.00 1785-2100M | 315M P-110,43.5ppf, BTC |1.125 | 1.88 | 10.07 2100-2500M 400M P-110, 47 ppf, BTC 2.26 | 24.3 NOTE:— Another important factor to be kept in view while designing a casing String is the availability of casing pipes, grades and weights availa- ble in the project-should be taken into consideration while design- ing a particular casing.