Drilling Engineering - Casing Design

akincraig 64,246 views 95 slides Oct 23, 2014
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About This Presentation

Petroleum Engineering, Drilling Engineering, Casing Design


Slide Content

JAMES A. CRAIG

Table of Contents
Functions of Casing
Types of Casing Strings
Classification of Casing
Mechanical Properties of Casing
Casing Design Criteria
Corrosion Design Considerations

Functions of Casing
Isolate porous formations with different
fluid-pressure regimes and also allow
isolated communication with selectively
perforated formation(s) of interest.
Isolate troublesome zones (high-
pressured zones, weak and fractured
formations, unconsolidated formations,
and sloughing shales) and to allow
drilling to the total depth.
Prevent the hole from caving in

Serve as a high- strength flow conduit to
surface for both drilling and production fluids.
Prevent near-surface fresh water zones from
contamination with drilling mud.
Provide a connection and support of the
wellhead equipment and blowout preventers.
Provide exact dimensions for running testing,
completion, and production subsurface
equipment.

Types of Casing Strings
There are different types of casing for different
functions and drilling conditions.
They are run to different depths and one or
two of them may be omitted depending on the
drilling conditions. They are:
Cassion pipe
Conductor pipe
Surface casing
Intermediate casing
Production casing
Liners

Cassion pipe (26 to 42 in. OD)
For offshore drilling only.
Driven into the sea bed.
It is tied back to the conductor or surface
casing and usually does not carry any load.
Prevents washouts of near-surface unconsolidated
formations.
Ensures the stability of the ground surface upon
which the rig is seated.
Serves as a flow conduit for the drilling mud to the
surface

Conductor pipe (7to 20in. OD)
The outermost casing string.
It is 40 to 500 ft in length for onshore and up
to 1,000 ft for offshore.
Generally, for shallow wells OD is 16 in. and
20 in. for deep wells.
Isolates very weak formations.
Prevents erosion of ground below rig.
Provides a mud return path.
Supports the weight of subsequent casing
strings.

Surface casing (17-1/2 to 20 in. OD)
The setting depths vary from 300 to 5,000 ft
10-3/4 in. and 13- 3/8 in. being the most
common sizes.
Setting depth is often determined by
government or company policy and not
selected due to technical reasoning.
Provides a means of nippling up BOP.
Provides a casing seat strong enough to safely
close in a well after a kick.
Provides protection of fresh water sands.
Provides wellbore stabilization.

Intermediate casing (17 -1/2 to 9-5/8 in.
OD)
Also called a protective casing, it is purely a
technical casing.
The length varies from 7,000 to 15,000 ft.
Provides isolation of potentially troublesome zones
(abnormal pressure formations, unstable shales,
lost circulation zones and salt sections).
Provides integrity to withstand the high mud
weights necessary to reach TD or next casing seat

Production casing (9 -5/8 to 5 in. OD)
It is set through the protective productive
zone(s).
It is designed to hold the maximal shut-in
pressure of the producing formations.
It is designed to withstand stimulating
pressures during completion and workover
operations.
A 7-in. OD production casing is often used

Provides zonal isolation (prevents migration of
water to producing zones, isolates different
production zones).
Confines production to wellbore.
Provides the environment to install subsurface
completion equipment.
Provides protection for the environment in the
event of tubing failure during production
operations and allows for the tubing to be
repaired and replaced.

Liners
They are casings that do not reach the surface.
They are mounted on liner hangers to the
previous casing string.
Usually, they are set to seal off troublesome
sections of the well or through the producing
zones for economic reasons (i.e. to save costs).
Drilling liner
Production liner
Tie-back liner
Scab liner
Scab tie- back liner

Drilling Liner –Same as intermediate/protective casing. It
overlaps the existing casing by 200 to 400 ft. It is used to
isolate troublesome zones and to permit drilling below these
zones without having well problems.
Production Liner –Same as production casing. It is run to
provide isolation across the production or injection zones.
Tie-back Liner – it is connected to the top of the liner with a
specially designed connector and extends to the surface, i.e.
converts liner to full string of casing.
Scab Liner –A section of casing used to repair existing
damaged casing. It may be cemented or sealed with packers
at the top and bottom.
Scab Tie-back Liner–A section of casing extending upwards
from the existing liner, but which does not reach the surface
and normally cemented in place. They are commonly used
with cemented heavy-wall casing to isolate salt sectons in
deeper portions of the well.

Classification of Casing
There are two types of casing standardization:
the API
non-API
Some particular engineering problems are
overcome by specialist solutions which are not
addressed by API specifications:
drilling extremely deep wells
using ‘premium’ connections in high pressure high
GOR conditions.
Nevertheless, we will stick to the API methods

Classifications to be considered are:
Outside diameter (OD).
Inside diameter (ID), wall thickness, drift
diameter.
Length (range)
Connections
Weight
Grade

Outside diameter (OD)
Casing manufacturers generally try to
prevent the pipe from being undersized to
ensure adequate thread run- out when
machining a connection.
Most casing pipes are found to be within ±
0.75% of the tolerance and are slightly
oversized.

Inside Diameter (ID), Wall Thickness,
Drift Diameter
The ID is specified in terms of wall thickness
and drift diameter.
The maximalID is controlled by the
combined tolerances for the OD and the
wall thickness.
The minimal permissible pipe wall thickness
is 87.5% of the nominal wall thickness,
which in turn has a tolerance of -12.5%.

The minimalID is controlled by the
specified drift diameter.
The drift diamater refers to the diameter of
a cylindrical drift mandrel that can pass
freely through the casing with a reasonable
exerted force equivalent to the weight of the
mandrel being used for the test.
A bit of a size smaller than the drift
diameter will pass through the pipe.
Casing & Liner OD (in.)Length (in.)Drift Diameter (in.)
≤ 8-5/8 6 ID –1/8
9-5/8 –13-3/8 12 ID –5/32
≥ 16 12 ID –3/16
API recommended
dimensions for drift
mandrels

Length (range)
The lengths of pipe sections are specified in
three major ranges:
R1, R2 and R3.
Range Length (ft)Average Length (ft)
1 16 –25 22
2 25 –34 31
3 > 34 42

Connections
API provides specifications for four types of
casing connectors:
CSG –Short round threads and couplings –offer
no pressure seal at internal pressure, threaded
surfaces get further separated.
LCSG –Long round threads and couplings –
same basic thread design as CSG but offers
greater strength and also greater joint efficiency
(though less than 100%). Often used because it is
reliable, easy and cheap.

BCSG –Buttress threads and couplings –offers a
nearly 100% joint efficiency. Not 100% leakproof.
XCSG –Extreme line threads – design is an
integral joint, i.e. the coupling has both box and pin
ends. Much more expensive.
CSG and LCSG are also called API 8- Round
threads because they have eight threads per
inch

API
Round Thread
Connector

API
Buttress Thread
Connector

API
Extreme-Line
Connector

Weight
Pipe weight is usually expressed as weight
per unit length in lb/ft. The three types are:
Nominal Weight
Plain-end Weight
Threaded and Coupled Weight or Average Weight

Nominal weight
Based on theoretical weight per foot for a 20- ft
length of threaded and coupled casing joint.
○OD= outside diameter (in.)
○t= wall thickness (in.)
The nominal weight is not the exact weight of the
pipe, but rather it is used for the purpose
identification of casing types.
( )( )( )
2
10.68 0.0722
n
W OD t t OD= −+ ×

Plain-end weight
The weight of the joint of casing without the
threads and couplings.
Threaded and Coupled Weight or Average Weight
The weight of a casing joint with threads on both
ends andcoupling at one end when in the power
tight position.
The variation between nominal weight and
average weight is generally small, and most
design calculations are performed with the nominal
weight.
( )10.68
pe
W OD t= −

○L
c= length of coupling (in.)
○J= distance between the end of the pipe and center
of the coupling (in.)
21
20
20 24
Weight of coupling

20
Weight removed in threading two pipe ends

20
c
tc pe
LJ
WW
 +
= − 

+

Grade
The steel grade of the casing relates to the
tensile strength of the steel from which the
casing is made.
The steel grade is expressed as a code
number which consists of a letter and a
number.
The letter is arbitrary selected to provide a unique
designation for each grade of casing.
The number deisgnates the minimal yield strength
of the steel in thousands of psi. For example, K-55
has a yield strength of 55,000 psi

Mechanical Properties of Casing
Casing is subjected to different loads during
landing, cementing, drilling, and production
operations.
The most important loads which it must
withstand are tensile, burst and collapse
loads.
Other important loads include wear,
corrosion, vibration and pounding by drillpipe,
the effects of gun perforating and erosion

Tension
Under axial tension, pipe body may
suffer 3possible deformations:
Elastic–the metallurgical properties of the
steel in the pipe body suffer no permanent
damage and it regains its original form if the
load is withdrawn
Elasto-plastic–the pipe body suffers a
permanent deformation which often results
in the loss of strength)
Plastic

The strength of the casing string is expressed
as pipe body yield strength and joint strength.

Pipe body strengthis the minimal force required
to cause permanent deformation of the pipe.
a ys
FAσ= ( )
22
4
s oi
A dd
π
= − ( )
22
4
a yo i
F dd
π
σ
= −
F
a= axial force to pull apart the
pipe, lbf
A
s= cross- sectional area of the
pipe, in.
2
σ
y= minimum yield strength, psi
d
o= pipe outer diameter, in
d
i= pipe inner diameter, in

Joint strengthis the minimal tensile force
required to cause the joint to fail.
For API round threads, joint strength is defined
as the smaller of minimal joint fracture forceand
minimal joint pullout force.
0.95
aj up jp
FA σ=For fracture force,
joint strength:
For pullout force,
joint strength:
0.59
0.74
0.95
0.5 0.14 0.14
o up y
aj jp et
et o et o
d
F AL
LdLdσσ


= +

++

( )
2
2
0.1425
4
jp o i
Ad d
π
=−−

σ
up= ultimatestrength, psi
A
jp= area under last perfect
thread, in.
2
L
et= length of engaged thread, in.

Bending force–Casing is subjected to bending
forces when run in a deviated wells. The lower
surface of the pipe stretches and is in tension.
The upper surface shortens and is in
compression.

Other tensional forces include:
○Shock load (the vibrational load when running
casing and the slips are suddenly set at the
surface)
○Drag force (frictional force between the casing
and the borehole walls)
63
b on
F dW= Θ
W
n= nominal weight, lb/ft
ϴ= dogleg severity, degrees (
o
)/100 ft

Burst pressure
Minimum expected internal pressureat
which permanent pipe deformation could
take place, if the pipe is subjected to no
external pressure or axial loads.
The API burst rating is given as:
2
0.875
y
br
o
t
P

=

Collapse pressure
Minimum expected external pressureat
which the pipe would collapse if the pipe
were subjected to no internal pressure or
axial loads.

There are different types of collapse
pressure rating depending on thed
o/t ratio:
Yield strength
Plastic
Transition
Elastic
Grade
Yield
strength
collapse
Plastic
collapse
Transition
collapse
Elastic
collapse
F
1 F
2 F
3 F
4 F
5
H-40 16.40 27.01 42.64 2.950 0.0465 754 2.063 0.0325
J-, K-55 14.81 25.01 37.212.991 0.0541 1,206 1.989 0.0360
C-75 13.60 22.91 32.053.054 0.0642 1,806 1.990 0.0418
L-, N-80 13.38 22.47 31.023.071 0.0667 1,955 1.998 0.0434
C-90 13.01 21.69 29.183.106 0.0718 2,254 2.017 0.0466
P-110 12.44 20.41 26.223.181 0.0819 2,852 2.066 0.0532
Ranges
of d
o/t
when
axial
stress is
zero

Yield Strength Collapse Pressure
Plastic Collapse Pressure
2
1
2
o
cr y
o
d
t
P
d
t
σ


−
=




1
23cr y
o
F
P FF
d
t
σ


= −−





Transition Collapse Pressure
Elastic Collapse Pressure
4
5cr y
o
F
PF
d
t
σ


= −




6
2
46.95 10
1
cr
oo
P
dd
tt
×
=





Combined stresses
The performance of casing is examined
in the presence of other forces.
axial load
z
s
A
σ=
2
,
1 0.75 0.5
y eff i zz
y yy
Pσ σσ
σ σσ
 +
=−−  
 
 

2
,
1 0.75 0.5
zz
y eff y i
yy
P
σσ
σσ
σσ

 

= − − ×− 
 
 

σ
z= axial stress, psi(+ve for tension, -
ve for compression)
P
i= internal pressure, psi
σ
y,eff= effective yield strength, psi

Casing Design Criteria
Casing costs is one of the largest cost
items of a drilling project.
It is imperative to plan for proper
selection of casing strings and their
setting depths to realise an optimal and
safe well at minimal costs.

Casing points selection
Initial selection of casing setting depths is
based on the pore pressure and fracture
pressure gradients for the well.
Information on pore pressure and fracture
pressure gradients is usually available from
offset well data.
This information should be contained in the
geotechnical information provided for
planning the well.

Other factors affecting casing points
selection include:
Shallow gas zones
Lost circulation zones, which limit mud weights
Well control
Formation stability , which is sensitive to
exposure time or mud weight
Directional well profile
Sidetracking requirements
Isolation of fresh water sands (drinking water)
Hole cleaning
Salt sections

High pressured zones
Casing shoes should where practicable be set in
competent formations
Casing program compatibility with existing
wellhead systems
Casing program compatibility with planned
completion program
Multiple producing intervals
Casing availability
Economy

Design factors
API design factors are essentially “safety
factors” that allow us to design safe, reliable
casing strings.
Each operator may have his own set of design
factors, based on his experience and the
condition of the pipe.

The design factors are necessary to cater for:
Uncertainties in the determination of actual loads
that the casing needs to withstand.
Reliability of listed properties of the various steels
used in the industry and the uncertainty in the
determination of the spread between ultimate
strength and yield strength.
Uncertainties regarding the collapse pressure
formulas.
Possible damage to casing during transport and
storage.
Damage to the pipe body from slips, wrenches or
inner defects due to cracks, pitting, etc.
Rotational wear by the drill string while drilling.

The use of excessively high design factors
guarantees against failure but provides
excessive strength and, therefore, increased
cost.
The use of low design factors requires
accurate knowledge about the loads to be
imposed on the casing as there is less
margin available.
The company values selected for design
factors are a compromise between safety
margin and economics.

The API design factors are:
Tension and Joint Strength:DF
T= 1.8
Collapse: DF
C= 1.125
Burst: DF
B= 1.1
Example
Required Design factor
Design
Tension: 100,000 lbf 1.8 180,000 lbf
Collapse: 10,000 psi 1.125 11,250 psi
Burst: 10,000 psi 1.1 11,000 psi

Worst possible conditions
Tension Design
Assume there is no buoyancy effect.
Design is based on the weight of the entire
casing string.
Collapse Design
Assume that the casing is empty on the inside,
that is, no pressure inside the casing and no
buoyancy effect.
Design is based on the maximum mud weight at
the casing depth

Burst Design
Assume no backup fluid on the outside of the
casing.
Design is based on maximum pressure on the
inside of the casing.
The pressure is to design for is the estimated
formation pressure at TD for production casing, or
estimated formation pressure at the next casing
depth.
The casing string must be designed to
withstand the expected conditions in tension,
burst and collapse.

Graphical design method
Casing design itself is an optimization
process to find the cheapest casing string
that is strong enough to withstand the
occuring loads over time.
The design is therefore depended on:
Loading conditions during life of well (drilling
operations, completion procedures, production,
and workover operations)
Strength of the formation at the casing shoe
(assumed fracture pressure during planning and
verified by the formation integrity test.
Availabilty and real price of individual casing
strings

○Burst:Assume full reservoir pressure all along the
wellbore.
○Collapse:Hydrostatic pressure increases with depth.
○Tension:Tensile stress due to weight of string is highest
at the top

Analytical design method
Burst requirements
Casing must withstand the maximum anticipated
formation pressure that the casing string could
possibly be exposed to.

Collapse requirements
We start at the bottom of the string and work
our way up.
Our design criteria will be based on
hydrostatic pressure resulting from the mud
weight that will be in the hole when the
casing string is run, prior to cementing.

Worst possible conditions
Burstdesign: assume no “backup” fluid on the
outside of the casing
Collapsedesign: assume that the casing is
empty on the inside.
Tension design: assume no buoyancy effect.

Corrosion Design Considerations
Corrosion “eats” through casing string
This reduces the wall thickness
It then affects the collapse resistance, burst
resistance and the yield strength, among others.
Forecasting the presence and concentration of
corrosion is essential for a choice of a proper
casing grade and wall thickness and for
operational safety purposes.
Casing can also be subjected to corrosive attack
opposite formations containing corrosive fluids

Factors causing corrosion
Most corrosion problems in oilfield
operations are due to the presence of water.
Corrosive fluids can be found in water-rich
formations and aquifers as well as in the
reservoir itself.
Factors initiating and perpetuating corrosion
can either act alone or in combination.

Oxygen (O
2)
Oxygen dissolved in water drastically increases its
corrosivity potential.
It can cause severe corrosion at very low
concentrations of less than 1.0 ppm.
The solubility of oxygen in water is a function of
pressure, temperature and chloride content.
Oxygen is less soluble in salt water than in fresh
water.
Oxygen usually causes pitting in steels.

Hydrogen Sulphide (H
2S)
H
2S is very soluble in water and when
dissolved, behaves as a weak acid and
usually causes pitting.
This type of attack is called sour corrosion.
Other problems from H
2S corrosion include
hydrogen blistering and sulphide stress
cracking.
The combination of H
2S and CO
2is more
aggressive than H
2S alone.

Carbon Dioxide (CO
2)
CO
2is soluble in water and forms carbonic acid,
decreases the pH of the water and increase its
corrosivity.
It is not as corrosive as oxygen, but usually also
results in pitting.
Corrosion by CO
2is referred to as sweet corrosion.
Partial pressure of CO
2is used as a yardstick to
predict corrosion.
○Partial pressure < 3 psi:generally non corrosive.
○Partial pressure 3 –30 psi:may indicate high corrosion
risk.
○Partial pressure > 30 psi:indicates high corrosion risk.

Temperature
Like most chemical reactions, corrosion rates
generally increase with increasing temperature.
Pressure
The primary effect of pressure is its effect on
dissolved gases.
More gas goes into solution as the pressure is
increased, this may in turn increase the corrosivity
of the solution.

Velocity of Fluids
Stagnant or low velocity fluids usually give low
corrosion rates, but pitting is more likely.
Corrosion rates usually increase with velocity as
the corrosion scale is removed from the casing
exposing fresh metal for further corrosion.
High velocities and/or the presnce of suspended
solids or gas bubbles can lead to erosion,
corrosion, impingement or cavitation.

Corrosion control measures
Corrosion control measures may involve
the use of one or more of the following:
Cathodic protection
Chemical inhibition
Chemical control
Oxygen scavengers
Chemical sulphide scavengers
pH adjustment
Deposit control

Determine the collapse strength for a 5 1/2” O.D.,
14.00 #/ft, J-55 casing under axial load of 100,000 lbf
The axial tension will reduce the collapse pressure as
follows:
( )
22
axial load 100,000
24,820 psi
5.5 5.012
4
z
s
A
σ
π= = =

2
,
1 0.75 0.5
zz
y eff y
yy
σσ
σσ
σσ

 

=×− −  
 
 

72

Here the axial load decreased the J- 55
rating to an equivalent “J- 38.2” rating.
,
38216 psi
y eff
,σ=
2
,
24,820 24,820
55,000 1 0.75 0.5
55,000 55,000
y eff
σ


= ×− −

 

73

Design a 9- 5/8-in., 8,000- ft combination
casing string for a well where the mud weight
will be 12.5 ppgand the formation pore
pressure is expected to be 6,000 psi.
Only the grades and weights shown are
available (N-80, all weights).
Use API design factors.
Design for “worst possible conditions.”
74

Burst requirement
Depth
Pressure
B
P Pore pressure Design Factor= ×
B
P 6,000 1.1= ×
B
P 6,600 psi=
The whole casing string must be
capable of withstanding this internal
pressure without failing in burst.

Collapse requirement
For collapse design, we start at the bottom of the
string and work our way up.
Our design criteria will be based on hydrostatic
pressure resulting from the 12.5 ppg mud that
will be in the hole when the casing string is run,
prior to cementing.

C
P 0.052 Mud weight Depth Design Factor=× ××
C
P 0.052 12.5 8,000 1.125= ×× ×
C
P 5,850 psi=
Further up the hole the collapse
requirement are less severe.
Depth
Pressure

Req’d:Burst:6,600 psiCollapse:5,850 psi

Note that two of the weights of N-80 casing
meet the burst requirements
But only the 53.5 #/ft pipe can handle the
collapserequirement at the bottom of the
hole (5,850 psi).
The 53.5 #/ft pipe could probably run all the
way to the surface (would still have to
check tension), but there may be a lower
cost alternative

To what depth might we be able to run N-80,
47 #/ft?
The maximum annular pressure that this
pipe may be exposed to, is:
c
Collapse pressure of pipe 4,760
P= = =4,231 psi
design factor 1.125

First Iteration
At what depth do we see this pressure
(4,231 psig)in a column of 12.5 #/gal
mud?
c1
P=0.052×12.5×h
c
1
P 4,231
h = = = 6,509 ft
0.052×12.5 0.052×12.5

This is the depth to which the pipe
could be run if there were
noaxial stress in the pipe…
But at 6,509’ we have (8,000 -6,509) =
1,491’ of 53.5 #/ft pipe below us.
The weight of this pipe will reduce the collapse resistance of the 47.0 #/ft pipe!
8,000’
6,509’

This weight results in an axial stress
in the 47 #/ft pipe.
The API tables show that the above stress will reduce
the collapse resistance from 4,760 to somewhere
between:
4,680 psi (with 5,000 psi stress)
and 4,600 psi (with 10,000 psi stress)
1
Weight,W 53.5 #/ft 1,491 ft= ×
1
W 79,769 lbf=
1 2
weight 79,769 lbf
5,877 psi
end area 13.572 in
σ= = =

Interpolation between these values shows
that the collapse resistance at 5,877 psi axial
stress is:
With the design factor:
( )
1
c1 1 1 2
21
σσ
P P PP
σσ
−
=−−


( )
c1
5,877 5,000
P 4,680 4,680 4,600 4,666 psi
10,000 5,000
−
=− ×−=

−
c1
4,666
P 4,148 psi
1.125
= =

This (4,148 psig) is the pressure at a depth:
Which differs considerably from the initial
depth of 6,509 ft, so a second iteration is
required.
2
4,148
h 6,382 ft
0.052 12.5
= =
×

86

87

Second Iteration
Now consider running the 47 #/ft pipe to the
new depth of 6,382 ft.
( )
2
Weight,W 53.5 #/ft 8,000 6,382 ft= ×−
2
W 86,563 lbf=
2 2
weight 86,563 lbf
6,378 psi
end area 13.572 in
σ= = =

Interpolation again:
With the design factor:
( )
1
c1 1 1 2
21
σσ
P P PP
σσ
−
=−−


( )
c2
6,378 5,000
P 4,680 4,680 4,600 4,658 psi
10,000 5,000
−
=− ×−=

−
c2
4,658
P 4,140 psi
1.125
= =
3
4,140
h 6,369 psi
0.052 12.5
= =
×

This is within 13 ft of the assumed value. If
more accuracy is desired (generally not
needed), proceed with the:
Third Iteration
3
3
3
h 6,369 ft
W (8,000 6,369) 53.5 87,259 lbf
87,259
σ 6,429 psi
13.572
=
= − ×=
= =

Interpolation again:
With the design factor:
( )
1
c1 1 1 2
21
σσ
P P PP
σσ
−
=−−


( )
c3
6,429 5,000
P 4,680 4,680 4,600 4,658 psi
10,000 5,000
−
=− ×−=

−
c3
4,658
P 4,140 psi
1.125
= =
c3 c2
PP≅

This is the answer we are looking for:
Run 47 #/ft N-80 pipe to a depth of 6,369 ft
Run 53.5 #/ft N-80 pipe between 6,369 and
8,000 ft.
Perhaps this string will run all the way to the
surface (check tension).

Tension requirement
The weight on the top joint of casing would
be:
With the design factor, the pipe strength
required is:
(6,369 ft 47.0 #/ft) (1,631 ft 53.5 #/ft)
386,602 lbf
=× +×
=
386,602 1.8 695,080 lbf ×=

The Halliburton cementing tables give a
yield strength of 1,086,000 lbf for the pipe
body and a joint strength of 905,000 lbf for
LT & C.
Then 47 #/ft can be run to the surface.

N-80
47.0 #/ft
N-80
53.5 #/ft
6,369 ft
1,631 ft
Surface
8,000 ft