1

Casing Design
Why Run Casing?
Types of Casing Strings
Classification of Casing
Wellheads
Burst, Collapse and Tension
Example
Effect of Axial Tension on Collapse Strength
Example
2
Casing
Cement
What is casing?
Why run casing?
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
Casing Design
3
Why run casing?
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)
4
Example Hole and String Sizes (in)
Structural casing
Conductor string
Surface pipe
Intermediate String
Production Liner
Hole Size
30
20
13
3/8
9 5/8
7
Pipe Size
36
26
17
1/2
12
1/4
8 3/4
e.g., you need 14 ppg to control a lower zone, but an upper zone
will fracture at 12 lb/gal.
What do you do?
5
Diameter Example
16-60 30
16-48 20
8 5/8-20 13 3/8
1. Drive pipe or structural pile
{Gulf Coast and offshore only}
150-300 below mudline.
2. Conductor string. 100 -
1,600 (BML)
3. Surface pipe. 2,000 - 4,000
(BML)
Types of Strings of Casing
6
Types of Strings of Casing
4. Intermediate String
5. Production String (Csg.)
6. Liner(s)
7. Tubing String(s)
Diameter Example
4. Intermediate String
5. Production String (Csg.)
6. Liner(s)
7. Tubing String(s)
7 5/8-13 3/8 9 5/8
4 1/2-9 5/8 7
7
Example Hole and String Sizes (in)
Structural casing
Conductor string
Surface pipe
Intermediate String
Production Liner
Hole Size
30
20
13 3/8
9 5/8
7
Pipe Size
36
26
17 1/2
12 1/4
8 3/4
8
Example Hole and String Sizes (in)
Structural casing
Conductor string
Surface pipe
Intermediate String
Production Liner
250
1,000
4,000
Mudline
9
Classification of Casing
1. Outside diameter of pipe (e.g. 9 5/8)
2. Grade of material (e.g. N-80)
3. Nominal weight (Avg. wt/ft incl. Wt. Coupling)
(e.g. 47 lb/ft)
4. Type to threads and couplings (e.g. API LCSG)
5. Length of each joint (RANGE) (e.g. Range 3)
10
o
c
11
Length of Casing Joints
RANGE 1 16-25 ft
RANGE 2 25-34 ft
RANGE 3 > 34 ft.
12
Casing Threads and Couplings
API round threads - short { CSG }
API round thread - long { LCSG }
Buttress { BCSG }
Extreme line { XCSG }
Other
See Halliburton Book...
13
API Design Factors (typical)
Collapse 1.125
Tension 1.8
Burst 1.1
Required
10,000 psi
100,000 lbf
10,000 psi
Design
11,250 psi
180,000 lbf
11,000 psi
14
Normal Pore Pressure Abnormal Pore Pressure
0.433 - 0.465 psi/ft g
p
> normal
Abnormal
15
Design from bottom
16
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 top
Casing Design
STRESS
Tension
Burst
Collapse
Collapse
Tension
Depth
Burst
17
Casing Design
Collapse (from external pressure)
Yield Strength Collapse
Plastic Collapse
Transition Collapse
Elastic Collapse
Collapse pressure is affected by axial stress
18
Casing Design - Collapse
19
Casing Design - Tension
20
Casing Design - Burst
p
p
Internal
Pressure
Internal Yield Pressure for pipe
Internal Yield Pressure for couplings
Internal pressure leak resistance
21
Casing Design - Burst
Example 1
Design a 7 Csg. String to 10,000 ft.
Pore pressure gradient = 0.5 psi/ft
Design factor, N
i
=1.1
Design for burst only.
22
Burst Example
1. Calculate probable reservoir pressure.
2. Calculate required pipe internal yield pressure rating
23
Burst Example
3. Select the appropriate csg. grade and wt. from the
Halliburton Cementing tables:
Burst Pressure required = 5,500 psi
7, J-55, 26 lb/ft has BURST Rating of 4,980 psi
7, N-80, 23 lb/ft has BURST Rating of 6,340 psi
7, N-80, 26 lb/ft has BURST Rating of 7,249 psi
Use N-80 Csg., 23 lb/ft
24
25
23 lb/ft
26 lb/ft
N-80
26
Collapse Pressure
The following factors are important:
The collapse pressure resistance of a
pipe depends on the axial stress
There are different types of collapse
failure
27
Collapse Pressure
There are four different types of collapse
pressure, each with its own equation for
calculating the collapse resistance:
Yield strength collapse
Plastic collapse
Transition collapse
Elastic collapse
28
Casing Design
Y
PA
= yield strength of axial stress
equivalent grade, psi
Y
P
= minimum yield strength of pipe, psi
S
A
= Axial stress, psi (tension is positive)
Collapse pressure - with axial stress
1.

|
|
.
|

\
|

(
(

|
|
.
|

\
|
=
P
A
P
A
P PA
Y
S
Y
S
Y Y 5 . 0 75 . 0 1
2 / 1
2
29
Casing Design
2. Calculate D/t to determine proper equation
to use for calculating the collapse pressure
Yield Strength
Collapse :
Plastic Collapse:
(
(
(
(
(

|
.
|

\
|

|
.
|

\
|
=
2
1
2
t
D
t
D
Y P
p YP
C B
t
D
A
Y P
p p

(
(
(
(

|
.
|

\
|
=
30
Casing Design
Transition
Collapse:
Elastic
Collapse:
(
(
(
(

|
.
|

\
|
= G
t
D
F
Y P
p T
2
6
E
1
t
D
t
D
10 X 95 . 46
P
(

|
.
|

\
|
|
.
|

\
|
=
31
Casing Design - Collapse
If Axial Tension is Zero:
Yield Strength Plastic Transition Elastic
J-55 14.81 25.01 37.31
N-80 13.38 22.47 31.02
P-110 12.44 20.41 26.22
32
Example 2
Determine the collapse strength of 5 1/2
O.D., 14.00 #/ft J-55 casing under zero axial
load.
1. Calculate
the D/t ratio:
33
Example 2
2. Check the mode of collapse
Table on p.35 (above) shows that,
for J-55 pipe,
with 14.81 < D/t < 25.01
the mode of failure is plastic collapse.
54 . 22 =
t
D
34
Example 2
The plastic collapse is calculated from:
psi 117 , 3 P
p
=
Halliburton Tables
rounds off to 3,120 psi
35
Example 3
Determine the collapse strength for a 5 1/2 O.D.,
14.00 #/ft, J-55 casing under axial load of 100,000
lbs
The axial tension will reduce the collapse pressure as
follows:
P
p
A
2
p
A
PA
Y
Y
S
5 . 0
Y
S
75 . 0 1 Y
(
(
(

|
|
.
|

\
|

|
|
.
|

\
|
=
36
Example 3
Here the axial load decreased the J-55 rating
to an equivalent J-38.2 rating
P
p
A
p
A
PA
Y
Y
S
Y
S
Y
(
(
(

|
|
.
|

\
|

|
|
.
|

\
|
= 5 . 0 75 . 0 1
2
The axial tension will reduce the collapse pressure rating to:
37
Example 3
psi 550 , 2 P
p
~
compared to 3,117 psi with no axial stress!
38
Casing Design Example
Example Problem
API Design Factors
Worst Possible Conditions
Effect of Axial Tension on Collapse Strength
Iteration and Interpolation
Design for Burst, Collapse and Tension
39
Casing Design Example
Design a 9 5/8-in., 8,000-ft combination
casing string for a well where the mud wt.
will be 12.5 ppg and 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.
40
Casing Design
Before solving this problem is it necessary to
understand what we mean by Design
Factors and worst possible conditions.
API Design Factors
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.
41
Casing Design
Well use the design factors recommended by the
API unless otherwise specified.
These are the API design Factors:
Tension and Joint Strength: N
T
= 1.8
Collapse (from external pressure): N
c
= 1.125
Burst (from internal pressure): N
i
= 1.1
42
Casing Design
What this means is that, for example, if we
need to design a string where the maximum
tensile force is expected to be 100,000 lbf,
we select pipe that can handle 100,000 * 1.8 =
180,000 lbf in tension.
Note that the Halliburton Cementing Tables list
actual pipe strengths, without safety factors
built in.
43
Casing Design
Unless otherwise specified in a particular
problem, we shall also assume the following:
Worst Possible Conditions
1. For Collapse design, assume that the casing is
empty on the inside (p = 0 psig)
2. For Burst design, assume no backup fluid on
the outside of the casing (p = 0 psig)
44
Casing Design
Worst Possible Conditions, contd
3. For Tension design,
assume no buoyancy effect
4. For Collapse design,
assume no buoyancy effect
The casing string must be designed to stand up to the
expected conditions in burst, collapse and tension.
Above conditions are quite conservative. They are also
simplified for easier understanding of the basic
concepts.
45
Casing Design
Burst Requirements (based on the expected pore pressure)
The whole casing string must be capable of withstanding this
internal pressure without failing in burst.
D
e
p
t
h
Pressure
46
Casing Design
Collapse Requirements
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.
47
Casing Design
Collapse Requirements, contd
severe less are
ts requiremen collapse the hole the up Further
bottom the at d req psi P
factor design depth weight mud P
c
c


. ' 850 , 5
125 . 1 * 000 , 8 * 5 . 12 * 052 . 0
* * * 052 . 0
=
=
=
D
e
p
t
h
Pressure
48
Casing Design
Reqd: Burst: 6,600 psi Collapse: 5,850 psi
49
Casing Design
Note that two of the weights of N-80 casing
meet the burst requirements, but only the
53.5 #/ft pipe can handle the collapse
requirement 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.
50
Casing Design
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:
D
e
p
t
h
Pressure
51
Casing Design
First Iteration
At what depth do we see this pressure (4,231 psig)
in a column of 12.5 ppg mud?
52
Casing Design
This is the depth to which the pipe
could be run if there were
no axial 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
53
Casing Design
Weight, W
1
= 53.5 #/ft * 1,491 ft
= 79,769 lbf
This weight results in an axial stress in
the 47 #/ft pipe
54
Casing Design
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)
55
Casing Design
Interpolation between these values shows that the
collapse resistance at 5,877 psi axial stress is:
With the design factor,
( )
2 1
1 2
1
1 c1
P P P
S S
S S
P
|
|
.
|

\
|

=
56
Casing Design
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.
57
58
59
Casing Design
Second Iteration
Now consider running the 47 #/ft
pipe to the new depth of 6,382 ft.
60
Casing Design
Interpolating again,
This is the pressure at a depth of
( )
(
(

|
|
.
|

\
|

=
2 1
1 2
1
1 c1
D.F.
1
P P P
S S
S S
P
61
Casing Design
This is within 13 ft of the assumed value. If more
accuracy is desired (generally not needed), proceed
with the:
Third Iteration
P
cc3
= ?
62
Casing Design
Third Iteration, contd
63
Casing Design
Third Iteration, contd
This is the answer we are looking for, i.e., we can
run 47 #/ft N-80 pipe to a depth of 6,369 ft,
and 53.5 #/ft pipe between 6,369 and 8,000 ft.
Perhaps this string will run all the way to the
surface (check tension), or perhaps an even more
economical string would include some 43.5 #/ft
pipe?
64
Casing Design
At some depth the 43.5 #/ft pipe would be
able to handle the collapse requirements,
but we have already determined that it will
not meet burst requirements.
65
N-80
53.5 #/ft
N-80
47.0 #/ft
N-80
43.5 #/ft?
Depth = 5,057?
5,066?
5,210?
Depth = 6,369
6,369
6,382
6,509
8,000
Burst?
Casing Design
66
Tension Check
The weight on the top joint of casing would be
With a design factor of 1.8 for tension, a pipe
strength of
67
Tension Check
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.
68
Casing Design Review
We have 4 different weights of casing available to
us in this case:
1. Two of the four weights are unacceptable
to us everywhere in the string because
they do not satisfy the burst
requirements.
2. Only the N-80, 53.5 #/ft pipe is capable of
withstanding the collapse requirements
at the bottom of the string
69
Casing Design Review
3. Since the 53.5 #/ft pipe is the most
expensive, we want to use as little of it
as possible, so we want to use as
much 47.0 #/ft pipe as possible.
4. Dont forget to check to make sure the
tension requirements are met; both for
pipe body, and for threads and
couplings (T&C).
70
Casing Design Review
The collapse resistance of N-80, 47 #/ft will
determine to what depth it can be run. Two
factors will reduce this depth:
Design Factor
Axial Stress (tension)
Halliburton collapse resistance: 4,760 psi
Apply design factor:
71
Casing Design Review
To determine the effect of axial stress
requires an iterative process:
1. Determine the depth capability without
axial stress
2. Determine axial stress at this point
72
Casing Design Review
3. Determine corresponding collapse resistance
4. Determine depth where this pressure exists
5. Compare with previous depth estimate
6. Repeat steps 2-6 using the new depth estimate
7. When depths agree, accept answer
(typically 2-4 iterations) (agreement to
within 30 ft will be satisfactory)
73
Linear Interpolation
74
Linear Interpolation
75
Linear Interpolation
With design factor:
( )
(

|
|
.
|

\
|

=
2 1
1 2
1
1 cc
P P
S S
S S
P
. F . D
1
P
76
77
78
Question
A combination production casing string is to
consider of 15.5 #/ft and 17 #/ft, J-55
casing to a total depth of 6300 and is to
be run in 12 ppg mud. Determine the depth
at which the casing weight per foot should
change because of collapse-pressure
considerations with a design factor of
1.125, assuming that the fluid level could
fall down as low as 6300 in subsequent
drilling operations.