Petroleum Engineering Summer Course 2015

PE DESIGN, PART A - DRILLING ENGINEERING: Casing Design
PETROLEUM ENGINEERING
SUMMER COURSE
2015

Petroleum Engineering Design

PART A

Drilling Engineering
CHAPTER 4

Casing Design
Chair of Drilling Engineering - University Leoben
Content
Introduc.on
Design Factors, Design Scenarios
API Pipe Body Internal Yield Pressure (Burst)
API Collapse
API Biaxial Design
Introduc.on
Casing Design
There are two dierent jobs that casing must
be designed for:
1. To allow to drill safely the well and resist any forces or
condi.on.
2. To act throughout the life of the well to meet the
objec.ves of the well without requiring a work-over.
Ref: Lecture Notes Drilling Engineering 2, MUL, 2000
Casing Pipe Specica.ons
Cost
Grade of Material - Casing Quality:

API has adopted a casing grade
designa.on to dene the strength
or quality of casing steel. A leWer
is followed by a number that
indicates the minimum yield
strength. This minimum
(longitudinal) yield strength is
dened as the stress required to
produce a total elonga.on of the
0.5% of the test specimen. It is
determine by an extensometer
during a tensile test.
Extensometer Test
Extensometer Test
0,5%
Casing Cost per Unit Weight

Casing Price per Unit Weight for Dierent QualiPes, STC and
LTC Couplings
Price per unit weight compared to H40 (%)
250
200
150
100
50
Q125 LTC/STC
P110 LTC/STC
C95/C90/L80 LTC/STC
Casing Pipe Prices

for 7 OD, 2003
1,000 meters 7 inch 23lb/ft (34.23 kg/
m) N80 LTC costs 62,000 US$ in 2003
N80 LTC/STC
lb/^
J55/K55/H40
LTC/STC
H40 LTC/STC

kg/m
PRICE ($/m)
PRICE ($/ton)
H-40/17 - STC
17
25,30
28,23
1116
H-40/20 - STC
20
29,76
33,22
1116
J-55/20 - STC
20
29,76
33,63
1130
J-55/23 - BTC
23
34,23
47,58
1390
J-55/23 - LTC
23
34,23
39,36
1150
J-55/23 - STC
23
34,23
38,68
1130
N-80/23 - BTC
23
34,23
65,38
1910
N-80/23 - LTC
23
34,23
61,61
1800
J-55/26 - BTC
26
38,69
53,78
1390
J-55/26 - LTC
26
38,69
44,50
1150
J-55/26 - STC
26
38,69
43,72
1130
N-80/26 - BTC
26
38,69
73,90
1910
N-80/26 - LTC
26
38,69
69,65
1800
P-110/26 - BTC
26
38,69
89,38
2310
P-110/26 - LTC
26
38,69
83,58
2160
N-80/29 - BTC
29
43,16
82,43
1910
N-80/29 - LTC
29
43,16
77,68
1800
P-110/29 - BTC
29
43,16
99,69
2310
P-110/29 - LTC
29
43,16
93,22
2160
N-80/32 - BTC
32
47,62
90,96
1910
N-80/32 - LTC
32
47,62
85,72
1800
P-110/32 - BTC
32
47,62
110,01
2310
P-110/32 - LTC
32
47,62
102,86
2160
N-80/35 - BTC
35
52,09
99,48
1910
N-80/35 - LTC
35
52,09
93,75
1800
P-110/35 - BTC
35
52,09
120,32
2310
P-110/35 - LTC
35
52,09
112,51
2160
N-80/38 - BTC
38
56,55
108,01
1910
N-80/38 - LTC
38
56,55
101,79
1800
P-110/38 - BTC
38
56,55
130,63
2310
P-110/38 - LTC
38
56,55
122,15
2160
Steel Price Development (2/2)

1000 meters 7 inch 23lb/ft
(34,23 kg/m) N80 LTC costs
110,000 US$ in 2013
Casing costs of total

well costs:
Soft rock 50%
Medium Hard 45%
Hard 35%
Drilling/tripping
Costs
Soft rock 15%
Medium Hard 30%
Hard 40-50%
2014
Cost Comparison of Wells
API and Non-API Casing

Spec 5CT, Casing and Tubing
Covers seamless and welded casing and tubing, couplings, and
connectors in all grades. Process of manufacture; chemical and
mechanical property requirements; methods of tes.ng; and
dimensions are included.

1/3 of worldwide installa.ons are according API specica.ons.

1/3 of installa.ons have size, steel grade and wall thickness of API
casing but have special non API connectors, such as VAM connec.ons.
1/3 are of non API steel grade and may have non API connectors.
Note: Non-API casing, tubing and connec.ons generally have manufacturing

tolerances equal to or superior API specica.ons
Standard API
Casing Connec.ons
API Round threads in short
(STC) and long (LTC) design
API BuWress squared
threads (BTC) are longer
and stronger connec.ons
API Integral joint (extreme
line, XL) with smaller ID,
OD are strong connec.ons
but expensive
VAM Big Omega Connec.on

Big Omega is a large diameter
connection with improved running
performances, for conductor pipes,
surfaces and intermediate casings, up
to 26". Big Omega is a very strong
coupled connection. The pin thread is
cut directly into the pipe. Standard
coupling ODs are identical with API;
they may be increased for higher
grades and larger wall thickness if
matched internal pressure resistance is
required. The standard coupling length
is 10 5/8" (269,9 mm)as with API.
A make-up arrestor positions the
coupling accurately on the mill end.
Pin to pin torque shoulder for positive
torque stop on the field end allows overtorque and compression resistance.
Ref: www.vam-usa.com
Design Steps
Decide on objec.ves
Iden.fy life.me loads
Load means anything ac.ng upon pipe such as a force like

tension, compression, bending, pressures, torsion, weight,
fric.on, corrosion, dynamic forces during opera.ons, or
environment like temperature, H2S, CO2 => discuss design
scenarios
Sa.sfy management guidelines
Size and number of tubulars, poten.al for drilling beyond

planned total depth, semng depths, failure consequences
Economics, risk versus cost
Create criteria
Make computa.ons
Select casing
Simple Calcula.on Principles
Es.mate loads (pipe internal, external pressures,

tensional load, bending load, torsional load)
Dene design factors (DF)
Compare:
Pipe Property (from API Tables) DF ( Load Backload )
Uni-axial
Bi-axial
Tri-axial
Design Factors
Design Scenarios
Principal Mechanical Loads on Casing

External pressure (collapse)
pressure of mud or forma.on uids on the empty casing, pressure
of expanding salts
Tension
weight of the casing string in empty hole
Biaxial stress (collapse plus tension)

reduc.on of yield strength due to tensional load (above TOC)
Bending
bending stress at dog-legs
Internal pressure (burst)

pressure of uids inside the casing when the annulus is empty (e.g.
above TOC)
Maximum Loads Versus Depth
Depth
Tension- Tensile stress due to

weight of string is highest at top
Burst - Assume full reservoir

pressure all along the
wellbore (may subtract the
gas gradient if known)
Collapse - Hydrostatic
pressure increases with
depth
Stress
10
API Design Factors (typical)

Required

10,000 psi

100,000 lbf

10,000 psi
Collapse 1.125
Tension 1.8
Burst 1.1
Design

11,250 psi

180,000 lbf

11,000 psi
Worst Case Collapse Loads on Casing
Assume evacuated casing.

Apply mud hydrosta.c outside of the casing.
Conserva.ve design does not account for
uid hydrosta.c inside the casing (par.ally
lled). However, this assump.on can be true
under some circumstances.
Collapse design factor, DFe = 1 - 1,125
On the other hand, collapse resistance is
reduced in bent sec.ons and under
tensional load. Thus, worst-case design
would give addi.onal safety.
Pi = 0?
Pe
11
Worst Case (Conserva.ve) Burst Load

on Casing
Assume forma.on pressure (e.g. a shut-in gas

kick while drilling next sec.on) exerted over
the length of the casing string.
Conserva.ve design does not account for
external uids or fracturing of the forma.on
while a kick migrates upwards along the open
hole sec.on (compare the discussed
scenarios).
Burst design factor, SFi = 1 - 1,33
On the other hand, burst resistance capability
may be reduced by casing wear and
longitudinal defects. Thus, conserva.ve
design would give addi.onal safety.
Pi = Pf?
Pe = 0?
Conserva.ve Tensile Load on Casing
Assume full air weight of the casing.

But conserva.ve design does not account for a wellbore
containing uid. In mud, air weight can be reduced by
mul.ply it with a buoyancy factor.
Buoyancy Factor , BF = 1 mud

steel
Also, in inclined wells the casing string lays at the low side of
the wellbore which reduces its weight.
Tension design factor SFt = 1,6 1,8
On the other hand, tensile strength may be signicantly
reduced by bending loads created by crooked wellbores or by
improper connec.on make-up.
12
Worst-Case Design Scenario for

Surface/Intermediate Casing Collapse
Assume: Lost Circula.on
Pe = Pform
Air
Pe
Pi
(Pe = Pmud hyd@casing point)
Cement
Pi = 0
Mud
Lost
Circulation
Alterna.ve Design Scenario for

Surface Casing Burst
BOP
Assume: Kick
Pe
Pe = 0
Pi
Pi
Pi = frac g Dshoe - gas g Dshoe
Cement
Kick
Frac
Next Mud
13
Alterna.ve Design Scenario for

Intermediate Casing Collapse
Air
Assume: Lost Circula.on
H1
Pe = Pform
(Pe = Pmud hyd@casing point)
Pi = Pmud hyd (H2)
H2
Pe
Cement
Pi
Next Mud
Lost
Circulation
Alterna.ve Design Scenario

Intermediate Casing Burst
BOP
Assume: Kick
Pe
Pi
Gas
Pe = 0
Pi = frac g Dshoe - gas g Dshoe
Cement
Frac
Next Mud
Kick
14
Worst Case Design Scenario

Produc.on Casing Collapse
Extremes: Floa.ng, par.ally lled
casing, plugged perfora.ons
Pe = Pform
(Pe = Pmud hyd@casing point )
Pi = 0
(Pi = Pgas hyd inside casing )
Mud
Cement
Completion
Fluid
Tubing
Packer
Gas
Pe
Pi
Plugged
Perforations
Worst Case Design Scenario

Produc.on Casing Burst
Pe
Assume: Tubing Leakage
Pi
Leaky
Tubing
Pe = 0
Mud
Pi = Pform-Phydrostatic gas
Completion
Fluid
Cement
Tubing
Packer
Gas
15
API Pipe Body Internal Yield

Pressure (Burst)
API Pipe Body Internal Yield

According to API, the following formula is used
to calculate pipe body internal yield pressure
at minimum yield strength:
2Ypt
P = 0.875
D
YP = minimum yield strength of pipe, psi
t = wall thickness, in.
D = Outside diameter, in.
Internal
Pressure
For example: 7 in., 23 lb/^, N80

! 2 *80, 000 * 0.317 $
P = 0.875#
&% = 6340 psi
"
7
16
API Internal Yield (Burst) Pressure
Example 1: Design For Burst
Design a 7 Casing string to 10,000 ^.

Pore pressure gradient = 0.5 psi/^
Design factor, SFi = 1.1
Design for burst only, assume a worst case
scenario. For the selected casing quality,
check the safety for tension (SFt=1.8), neglect
buoyancy.
17
Example 1: Solu.on
1. Calculate probable reservoir pressure.
psi
pres = 0.5 ft * 10,000 ft = 5,000 psi

2. Calculate required pipe internal yield pressure ra.ng
p i = p res * SFi = 5 ,000 * 1 . 1 = 5 ,500 psi

3. Select the appropriate csg. grade and wt. from Casing tables
7 in., 23 lb/^, N80 has minimum required burst resistance, however, weight
in air is 230.000 lb, with a safety of 1.8 the tensional load is 414.000 lb, joint
strength o.k. Note that a L-80, with same pressure data, is a slightly beWer
choice for H2S environment.
API Collapse
Resistance
18
Collapse Failure
API Collapse Resistance

There are four dierent types of collapse
pressure, each with its own equa.on for
calcula.ng the collapse resistance according
to API:
1.
2.
3.
4.
Yield strength collapse

Plas.c collapse
Transi.on collapse
Elas.c collapse
19
4 API Collapse Pressures

If axial tension is zero:
PlasPc
Yield Strength
TransiPon
ElasPc
J-55
14.81
25.01
37.31
N-80
13.38
22.47
31.02
P-110
12.44
20.41
26.22
D/t RaPo
API Collapse Pressure Formulas (1/2)

Calculate D/t to determine proper equaPon
to use for calcula.ng the collapse pressure, P
Yield Strength
Collapse, PYP:
Plas.c
Collapse , PP:
(! D $ +
* # & 1"t % PYP = 2Yp *
* ! D $2 * # & ) "t % ,
Pp = Y p
B C
D
20
API Collapse Pressure Formulas (2/2)
PT = Y p
G
D
Transi.on
Collapse, PT:
Elas.c
Collapse, PE:
PE =
46.95 10 6
D D
1
t t
A, B, C, F, G
2
A = 2.8762 +1.0679 10 3 Yp + 2.130110 5 (Yp) 5.3132 10 8 (Yp)
B = 0.026233+ 5.0609 10 4 Yp
2
C = 30.867Yp 1.048310 2 (Yp) + 3.6989 10 5 (Yp) 465.93
F=
3,17 108 * ( B / A)
Yp *1000 * (1 B / A)
G = F ( B / A)
21
Use Yield Pressure Formula if

Condi.on is True
Use Plas.c Collapse Formula if

Condi.on is True
22
Use Transi.on Collapse Formula if

Condi.on is True
Use Elas.c Collapse Formula if

Condi.on is True
23
Example 2: Uniaxial Collapse

Determine the collapse strength of a 5 1/2 O.D., 14.00 lb/^
J-55 casing under zero axial loads.
D
5.500
1. Calculate the D/t ra.o:

=
= 22.54
t 0.244

2. Check the mode of collapse: For J-55 casing with 14.81 < D/t
< 25.01 the mode of failure is

plasPc collapse.

3. The plas.c collapse is calculated from:
" A
%
( 2.990
+
Pp = Yp $
B ' C = 55,000 *
0.0541- 1, 205 =3,115psi
) 22.541
,
#D/t
&
Note, tables rounds o to 3,120 psi
API Collapse Resistance
24
API Biaxial Design
The Biaxial Load

The biaxial load concept is necessary to inves.gate the
combined loads of tension/compression and collapse.
This combined load is of special importance in the area
above the cement head.
When the casing is empty and a tensional stress exists
between surface and cement head, there must be an
correc.on of the collapse resistance.
25
Collapse and Axial Stress

4 The collapse pressure resistance of a
pipe depends on the axial stress
4 The collapse resistance of a pipe is
reduced when tensional loads are
present
4 The collapse resistance of a pipe is
increased when compression loads
are present
Collapse and Axial Stress

Yield strength - with axial stress: use this equa.on to
correct the yield strength Yp (API collapse equa.ons)
Tension - collapse
2 1/ 2
YPA = YP 1 0.75 0.5 a

YP
YP
Compression - collapse
2 1/ 2
YPA = YP 1 0.75 + 0.5 a

YP
YP
YPA = yield strength of axial stress equivalent grade, psi

a = axial stress, psi (tension is posi.ve)
26
Burst and Axial Stress

4 The burst pressure resistance of a
pipe depends on the axial stress
4 The burst resistance of a pipe is
increased when tensional loads are
present
4 The burst resistance of a pipe is
reduced when compression loads
are present
Biaxial Stress Equa.ons - Summary
27
Example 3: Biaxial Collapse (1/3)

Determine the collapse strength for a 5 1/2 O.D., 14.00
lb/^, J-55 casing under axial load of 100,000 lbs.
The axial tension will reduce the collapse pressure as follows:
YPA
a =

= 1 0.75 a
Y
0.5 a
YP
Fa
100,000
=
= 24,820 psi
Area 5.52 5.0122
4
YPA = yield strength of axial stress equivalent grade, psi

a = axial stress, psi (tension is posi.ve)

The axial tension reduces the collapse pressure ra.ng to:
2
(
+
"
%
"
%
24,820
24,820
YPA = * 1 0.75 $
' 0.5 $
'- 55, 000
*
# 55, 000 &
# 55, 000 &-,
)
= 38,216 psi
Here the axial load decreased the J-55 ra.ng to an equivalent J-38.2 ra.ng
(less than H-40!)
28

The plas.c collapse is then:
# A
&
Pp = YPA %
B( C
$D/t
'
Quality A
38,216 2,9452 0,0456 701,43
) 2.9452
,
= 38, 216 +
0.0456. 701.43 = 2, 551 psi
* 22.54
Pp 2, 551 psi
compared to 3,117 psi with no axial stress!
Appendix API Casing Tables
29
API 5CT 5 1/2 in. Casing Performance Properties (1/2)
30
API 5CT 7 in. Casing Performance Properties (1/3)
31
32
Conversion
Table
Meters
Centimeters (cm)
Millimeters (mm)
Metric Tons
Decanewtons (daN)
3,2808
0,3937
0,03937
2204,6
0,22481
Feet
Inches
Inches
Pounds
Wt Indicator (Lbs)
Newton
Kilograms (Kg)
0,224809
2,2046
Pounds
Pounds
Kilogram/cubic meter
Kg/M
3
Kg/M
Liters
Cubic Meters
Liters
Cubic Meters
Liters/Stroke
Cubic Meters/Stroke
Liters/Minute
Liters/Minute
Cubic Meters/Minute
Liters/Meter (L/M)
Cubic Meters/Meter
Liters/Meter (L/M)
Cubic Meters/Meter
KPa/M
Bar/M
Kilograms/Liter (Kg/L)
Kilograms/Cubic Mtr
Specific Gravity (SG)
3
Kg/M
Celsius Degrees
Pascals (Pa)
Kilopascals (KPa)
Bar
16,0184633
0,67196
0,3505
0,00629
6,2898
0,2642
264,173
0,00629
6,2898
0,2642
0,00629
6,2898
0,0019171
1,917
0,0019171
1,9171
0,044207
4,4207
8,3454
0,0083454
8,3454
6,24279
1.8 + 32
0,000145
0,14504
14,50377
Pound/Cubic Foot
Weight (Lb/Ft)
Pounds per Barrel
Barrels
Barrels
Gallons
Gallons
Barrels/Stroke
Barrels/Stroke
Gallons/Minute
Barrels/ Minute
Barrels/Minute
BBL/ Ft Capacity
BBL/Ft Capacity
BBL/ Displacement
BBL/Displacement
Gradient PSI/Ft
Gradient PSI/Ft
Mud Weight PPG
Mud Weight PPG
Mud Weight PPG
3
Mud Weight (Lb/Ft )
Farenheit Degree
PSI
PSI
Psi
33
Ni-Based Alloys
Duplex Stainless Steel
API 5CT Sour Services
hZp://www.sumitomo-tubulars.com/materials/index.htm
34

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PE DESIGN, PART A - DRILLING ENGINEERING: Casing Design

Petroleum Engineering Design

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Casing Design

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Casing Design

Ref: Lecture Notes Drilling Engineering 2, MUL, 2000

Casing Pipe Specica.ons

Chair of Drilling Engineering - University Leoben

Grade of Material - Casing Quality:

PE DESIGN, PART A - DRILLING ENGINEERING: Casing Design

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Casing Design

Casing Cost per Unit Weight

Casing Pipe Prices

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Casing Design

Steel Price Development (2/2)

Casing costs of total

Cost Comparison of Wells

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Casing Design

API and Non-API Casing

1/3 of worldwide installa.ons are according API specica.ons.

Note: Non-API casing, tubing and connec.ons generally have manufacturing

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Casing Design

VAM Big Omega Connec.on

Iden.fy life.me loads

Load means anything ac.ng upon pipe such as a force like

Sa.sfy management guidelines

Size and number of tubulars, poten.al for drilling beyond

Economics, risk versus cost

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Casing Design

Simple Calcula.on Principles

Es.mate loads (pipe internal, external pressures,

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Casing Design

Principal Mechanical Loads on Casing

Biaxial stress (collapse plus tension)

Internal pressure (burst)

Maximum Loads Versus Depth

Tension- Tensile stress due to

Burst - Assume full reservoir

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Casing Design

API Design Factors (typical)

Worst Case Collapse Loads on Casing

Assume evacuated casing.

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Casing Design

Worst Case (Conserva.ve) Burst Load

Assume forma.on pressure (e.g. a shut-in gas

Conserva.ve Tensile Load on Casing

Assume full air weight of the casing.

Buoyancy Factor , BF = 1 mud

Chair of Drilling Engineering - University Leoben

PE DESIGN, PART A - DRILLING ENGINEERING: Casing Design

Worst-Case Design Scenario for

(Pe = Pmud hyd@casing point)

Alterna.ve Design Scenario for