WELL CONSTRUCTION COURSE

Section 3 : Casing Design

1

WELL CONSTRUCTION

CASING DESIGN

FUNCTIONS
OF CASING

WELL CONSTRUCTION

CASING DESIGN

1. To KEEP the hole open and prevent collapse

2. To ISOLATE porous different pressure regimes so that
production or injection may be controlled from a
specific section
3. To PROTECT formations from contamination and
fracture
4. To CONTROL any pressures encountered in the well
5. To provide structural SUPPORT for the BOPs on the
wellhead
6. To ALLOW the passage of testing and completion
equipment
3

WELL CONSTRUCTION

CASING DESIGN

Q.

Why not just drill to TD ?

A.

Due to the nature of sedimentary basins :

Unstable formations and differing pressures necessitate

casing off the open hole at certain depths to enable the
final well objective to be met

Too long an open hole will collapse and pack off possible SIDETRACK or REDRILL

Exposed High and Low Pressure Zones - BLOWOUT

WELL CONSTRUCTION

CASING DESIGN

1. Largest tangible cost on any well

2. Performs critical functions - support, stability
3. Errors in calculations can impact cost, safety
4. Every design has two areas in common

Subjective assumptions have to be made concerning

maximum loads

After the loads are calculated a design factor will

apply
5

WELL CONSTRUCTION

CASING DESIGN

1. Data is taken from offset wells or local geological

knowledge - but actual lithologies may differ
2. LOT data may be different from the predicted values
- need to be able to adjust the wellplan while drilling
3. The controllable kick size must be known at all times
while drilling the well - KICK TOLERANCE
4. Inter-relationships MUST be known between LOT, PP,
potential drilling problems and KT
6

WELL CONSTRUCTION

CASING DESIGN

WELL CONSTRUCTION

CASING DESIGN

WELL CONSTRUCTION

CASING DESIGN

1. Shoe depth chosen so that next

hole section will not be
fractured with higher mud
weights
2. North Sea the average 30
setting depth 340 below sea
bed.
bed
3. Returns to seabed.
4. Cemented back to sea bed
5. Conductor analysis determines
minimum height of cement to
avoid a top up job
6. Can be pile driven on land often called STOVE PIPE
9

WELL CONSTRUCTION

CASING DESIGN

1. Combats weak
formations found at
shallow depths
2. Usually set in competent
rock - hard limestone etc
3. Usually the first casing
that the BOP stack is set
on
4. Normally 20 in the North
Sea or 18-5/8 in the
Middle East
10

WELL CONSTRUCTION

CASING DESIGN

1. Usually set to case off a

potentially unstable formation Eocene Shales
2. Good cementation must be
ensured - multi-stage cement
jobs or multi-stage collars
3. Traditionally 13-3/8 or 9-5/8
casing
4. Connectors are usually Buttress
- not premium sealing

11

WELL CONSTRUCTION

CASING DESIGN

1. Production Casing represents

the last casing string
2. Run to isolate producing
zones, to provide reservoir
fluid control and to permit
selective production of specific
reservoir zones
3. This is the size through which
the well will be completed
4. Usual size is 9-5/8 or 7
12

WELL CONSTRUCTION

CASING DESIGN

Does not reach the surface

Hung off using a liner hanger

As set on bottom, main criteria

is max collapse pressure

Advantages - lower costs,

less pipe, faster running times

Disadvantages - any leaks,

tie-back packer, small bore difficult to always get a good
cement job
13

WELL CONSTRUCTION

CASING DESIGN

Casing is usually described in terms of :

1.

Outside Diameter

2.

Nominal unit weight and wall thickness

3.

The grade of the steel

4.

The type of Connection

5.

The Range and length of joint

6.

The Manufacturing Process

14

WELL CONSTRUCTION

CASING DESIGN

1.

The diameter referred to is the pipe body

2.

The diameter of the coupling is larger

3.

OD tolerance permitted for casing is +1, -0.5%

4.

Wall thickness tolerance is +0, -12.5%

5.

More specific requirements are set for upset

ends of pipe and tubing

15

WELL CONSTRUCTION

CASING DESIGN

Mechanical and physical properties dependent on

chemical composition and heat treatment
API has defined 8 grades [see API specs 5A, 5AC,
5AX]
H40 J55 K55 L80 N80 C95 and P110
The numbers indicate MINIMUM YIELD STRENGTH in
thousands of psi.
The letters serve to prevent oral confusion, although
some have additional meaning
K : > minimum ultimate tensile strength than J
C and L : Restricted Yield Strength
P : High Strength material
16

WELL CONSTRUCTION

CASING DESIGN

PHYSICAL PROPERTIES: defined in terms of Min

and Max Yield Strength and Min Tensile Strength

MINIMUM Yield Strength: most important in casing

design - used to calculate minimum performance
properties

P110: can now be used in most normal operations.

API TESTING; Limited, thus clients may require extra

inspection of critical strings whose failure could have
serious consequences [i.e., HPHT, sour gas wells]

17

WELL CONSTRUCTION

CASING DESIGN

Standardised at API Convention in 1924 - they are:

1. API Short Round ThreadSTC
2. API Long Round Thread LTIC
3. Buttress Thread
BTC
4. Extreme Line
XL

BUTTRESS THREADS: surface and intermediate casing

PREMIUM THREADS: for production casing strings.

PREMIUM SEALS metal to metal sealing, > cost.

Estimated 86% of LEAKS occur on CONNECTIONS

18

WELL CONSTRUCTION

CASING DESIGN

Not equal lengths, API specify the range

Range
1
2
3

Length (ft)
16 - 25
25 - 34
> 34

Average (ft)
22
31
42

RANGE 3 PIPE; is longer and minimises the number

of connections (hence the possible leak areas).

19

WELL CONSTRUCTION

CASING DESIGN

Normally specified as

1.

YIELD STRENGTH
1. Pipe Body and Coupling

2.

COLLAPSE STRENGTH

3.

BURST STRENGTH

Pipe Body and Coupling

20

WELL CONSTRUCTION

CASING DESIGN

PRELIMINARY
CASING DESIGN

21

WELL CONSTRUCTION

CASING DESIGN

1.

Casing is designed to support

three different loads
1. Collapse
2. Burst
3. Tension

2. A standard design process is as

follows
22

WELL CONSTRUCTION

CASING DESIGN

23

WELL CONSTRUCTION

CASING DESIGN

1.

COLLAPSE is calculated first

2.

calculations based on pore pressure or mud weight

that the casing is set in, with the pipe evacuated.

BURST Loads are then calculated

At shoe the lessor of PP at next setting depth

minus the gas column to the shoe or the FP at the
shoe

At surface a/a + gas column to surface, minus

the decreasing PP (or salt water column) to
surface

24

WELL CONSTRUCTION

CASING DESIGN

4.

Design Factors are then applied

5.

Initial Casing Selected

6.

See WC manual
Advise maximum three sections per string

TENSILE Loads are then calculated

Based on selected casing weights

Buoyed tension compared to pipe body

strength and connector strength to ensure
design factors OK
25

WELL CONSTRUCTION

CASING DESIGN

Load cases are

calculated in the order
that they appear

1. Installation

Casing Running

Casing cementing

Plug bump etc

3. Production

2. Drilling
1.

Pressure Testing after WOC

1.

Completion / Kill Fluids

2.

Maximum Mud Weight

2.

Tubing Leaks

3.

Lost Circulation, Well Control

3.

Functioning DST Tools etc

26

WELL CONSTRUCTION

CASING DESIGN

Load Component

Installation Drilling

Production

Weight in Air

Buoyancy

Bending (Fb)

Shock Load (Fs)

Weight of Cement

Pressure Testing

Total
27

WELL CONSTRUCTION

CASING DESIGN

1.

2.

Casing properties
are downrated by
a design factor to
ensure a margin of
safety.
Note : Local

legislation and
individual Operators
may have different
design factors

MANUAL
DESIGN FACTORS

Collapse

1.00

Burst

1.10

Tension

1.30

Triaxial

1.25
28

WELL CONSTRUCTION

CASING DESIGN

CASING SETTING
DEPTH SELECTION

29

WELL CONSTRUCTION

CASING DESIGN

30

WELL CONSTRUCTION

CASING DESIGN

D epth
Lith ology
0

1000

1500

2000

2500

3000

3500
4000
4500
5000

5500

6000

6500

7000

7500

8000

8500

9000

9500

31

WELL CONSTRUCTION

CASING DESIGN

D epth
Lith ology
0

1000

1500

2000

2500

3000

3500
4000
4500
5000

5500

6000

6500

7000

7500

8000

8500

9000

9500

32

WELL CONSTRUCTION

CASING DESIGN

D epth
Lith ology
0

1000

1500

2000

2500

3000

3500
4000
4500
5000

5500

6000

6500

7000

7500

8000

8500

9000

9500

33

WELL CONSTRUCTION

CASING DESIGN

Construct
1.

2.

3.
4.

5.

Mean Pore
Pressure gradient
curve
Mud Weight curve
(+ 200 - 400 psi or
0.5ppg)
Fracture Gradient
curve
Add Safety Margin
Line (0.3
0.5ppEMW less)
Check Offset Mud
weights and LOT
data results
34

WELL CONSTRUCTION

CASING DESIGN

1.

Check the mud

weight curve at
point A

2.

Move up vertically
to point B

B is the setting
depth for
PRODUCTION
casing
35

WELL CONSTRUCTION

CASING DESIGN

3.

4.

Move to point C the mud weight

at this depth
Move up
vertically to point
D.

D is the estimated
setting depth
for
INTERMEDIATE
casing
36

WELL CONSTRUCTION

CASING DESIGN

5.

Move to point E
to check the mud
weight required.
As the pore
pressure is
normal at this
depth casing is
not required for
mud weight.

37

WELL CONSTRUCTION

CASING DESIGN

38

WELL CONSTRUCTION

CASING DESIGN

1.
2.
3.
4.
5.
6.
7.
8.

Shallow gas zones

Lost circulation zones
Lithologies
Unstable formations
Well profile
Hole cleaning
Salt sections or high pressure zones
Kick Tolerance

39

WELL CONSTRUCTION

CASING DESIGN

KICK TOLERANCE
CONSIDERATIONS

40

WELL CONSTRUCTION

CASING DESIGN

TWO TYPES
1.

Kick Intensity

2.

Kick Volume

WE WILL
DO THIS ONE

41

WELL CONSTRUCTION

CASING DESIGN

1.

Look at the problem in Section 3

2.

Draw a brief Well Schematic

We will then work through the
problem together

42

WELL CONSTRUCTION

CASING DESIGN

SCHEMATIC

8,842 ft
4281ft

TD = 13,123 ft
43

WELL CONSTRUCTION

CASING DESIGN
MAASP

MAMW = 14.3 ppg

KICK
INTENSITY

506 psi

MW = 13.2 ppg
KI = MAASP - ( MW x .052 x Hi )
.052 x TVD
MAASP = 8,842 x (14.3 - 13.2) x .052

* Assumes gas has no weight

so it is not included in the
formulae.

Dwp = 8,842 ft
TD - Dwp
= 4281ft

TD = 13,123 ft
44

WELL CONSTRUCTION

KICK
INTENSITY

CASING DESIGN
MAASP

KI = MAASP - ( MW x .052 x Hi )
506 psi

.052 x TVD

MW = 13.2 ppg

KI = 506 - ( MW x .052 x 300 )

.052 x TVD
Dwp = 8,842 ft

TD = 13,123 ft

= 0.44 ppg
Height of influx based
on a 25 bbl kick

TD - Dwp
= 4281ft

300 ft
45

WELL CONSTRUCTION

CASING DESIGN

KICK INTENSITY

MAASP

SO WHAT DOES IT
MEAN ?

506 psi
MW = 13.2 ppg

KI = 506 - ( 13.2 x .052 x 300 ) = .44 ppg

.052 x 13,123
8,842 ft
13,123 ft

Height of influx based

on a 25 bbl gas kick

4281ft

This is the maximum mud weight

increase to circulate out a 25bbl kick
without fracturing the weak point.

Mud weight to balance the formation

pressure is 13.2 ppg + 0.44 ppg

= 13.64ppg

300 ft

46

WELL CONSTRUCTION

CASING DESIGN

Dep th
Lith olog y
0

1000

1500

2000

2500

3000

3500
4000
4500
5000

5500

6000

6500

7000

7500

8000

8500

9000

9500

Use the Offset

Well Data +
your Pore
Pressure and
Fracture
Gradient Plot
information to
select the 133/8 and 9-5/8
setting depths
47

WELL CONSTRUCTION

CASING DESIGN

Calculate the Kick Intensity for your selected casing depths for the
12-1/4 and 8-1/2 Sections
KI = MAASP - ( MW x .052 x Hi )
.052 x TVD

Example: for the 12-1/4 hole you need:

1. Your selected setting depth for the 13-3/8 shoe
2. LOT at the 13-3/8 shoe (from your plot)
3. Mud Weight for the 12-1/4 (from your plot)
4. Your selected 12-1/4 TD
5. 8 Collars (Assume 600ft length)
6. Assume 25bbl kick and 0.5ppg minimum KI
48

WELL CONSTRUCTION

CASING DESIGN

HOWEVER !!
As we have offset data we need to use it to plan
our well. Recalculate the KI using offset well data
1. Your selected 13-3/8 setting depth
2. The LOT at the 13-3/8 shoe (from your plot)
3. 12-1/4 Mud Weight (estimate from your offset
data)
4. Your selected 12-1/4 TD
5. 8 Collars (estimate from the offset data BHAs)
6. Use 25bbl kick and 0.5ppg minimum KI
49

WELL CONSTRUCTION

CASING DESIGN

WORKED EXAMPLE

50

WELL CONSTRUCTION

CASING DESIGN

1. Calculate for COLLAPSE

1. Collapse drilling Load
2. Selecting casing based on collapse

2. Calculate for BURST

1. Burst drilling Load
2. Selecting casing based on burst

3. Check Tensile Loads

51

WELL CONSTRUCTION

CASING DESIGN

Draw a Schematic

The summary well data for the

worked casing design is:
13 casing set at

9,750 ft

External Mud weight (outside) 11 ppg

Internal Mud Weight (inside)
ppg

11.2

Next Section TD (12)13,360 ft

52

WELL CONSTRUCTION

CASING DESIGN

BASIC
WELL
DATA

9,750 ft MD

Mud
Weight
Inside

Mud
Weight
Outside

11.2 ppg

11.0 ppg

13,360 ft MD

53

WELL CONSTRUCTION

CASING DESIGN

The worst case collapse load during

drilling occurs if lost circulation is
encountered and the internal
hydrostatic pressure decreases. Let us
assume Lost Circulation while drilling
12 Hole below 13 Casing. The
well information is:
13 casing

Schematic

9,750 ft

External Mud weight

11 ppg

Internal Mud Weight

11.2 ppg

Drilling ahead,12 hole

13,360 ft
Losses and fluid drop to

2,528 ft
54

WELL CONSTRUCTION

CASING DESIGN

MUD LEVEL
INSIDE
DROPS
TO
2528 ft

MUD LEVEL
DROPS
2,528 ft MD

9,750 ft MD

Mud
Weight
Inside

11.2 ppg

Mud
Weight
outside

11.0 ppg

13,360 ft MD
55

WELL CONSTRUCTION

CASING DESIGN

Calculate the INTERNAL Pressure Profile

at surface
at 2528 ft
at casing shoe

=
=
=
=

This is the pressure

Acting inside the casing

psi

Calculate the EXTERNAL Pressure Profile

at surface
at casing shoe

=
=
=

This is the pressure

Acting outside the casing

psi

Calculate the NETT Collapse Load at the Casing Shoe

Nett collapse at shoe = ________psi
56

WELL CONSTRUCTION

CASING DESIGN

13-3/8 casing
Mud weight
Internal Mud Wt
Drilling ahead12-1/4
Fluid drop to

9,750 ft
11 ppg
11.2 ppg
13,360 ft
2,528 ft

Internal pressure profile

at surface
=0
at 2528 ft
=0
at casing shoe
4,206 psi

= (9750 - 2528) x 11.2 ppg x 0.052 =

External pressure profile

at surface
=0
at casing shoe

= 9750 x 11.0 ppg x 0.052 = 5,577 psi

Nett collapse at shoe

1,371 psi

= 5,577 psi - 4,206 psi

=
57

WELL CONSTRUCTION

CASING DESIGN

0 ft

2528 ft

9750 ft

58

WELL CONSTRUCTION

CASING DESIGN

1.
2.
Size

The following casings are available 13-3/8,

68lb/ft K55 and 13-3/8, 72lb/ft, N80.
The Transocean design factors for collapse is 1.0
Grade

ins

Wt
per
foot
lbs

Inside
Diameter

Collapse
Resistance

Body Yield
Strength

Burst
Pressure

Downrated Burst
Pressure

Coupling
Buttress Thread

ins

psi

x1000 lbs

psi

(Transocean DF
= 1.1)

psi

13-3/8

K55

68

12.415

1,950

1,069,000

3,450

3,450

13-3/8

N80

72

12.347

2,670

1,661,000

5,380

5,380

59

WELL CONSTRUCTION

CASING DESIGN

Casing Wear
reduces wall thickness
Fill-up of casing strings while running
inadequate fill-up can result in casing
collapse

60

WELL CONSTRUCTION

CASING DESIGN

The worst case Burst Load occurs

either during pressure testing or
during a well control event. Let us
assume the 13-3/8 casing is being
pressure tested to 3,000psi
13-3/8 casing
Mud weight

Schematic

9,750 ft
11.5 ppg

Top of Cement (TOC) at 3000

Previous Casing shoe at 1500
Pressure test to 3000 psi
Note: assume that, in the
annulus, the cement has
deteriorated to normal Pore
Pressure at 8.6ppg EMW and
the mud has deteriorated to
brackish water at 8.33ppg
EMW.
61

WELL CONSTRUCTION

CASING DESIGN

3,000 psi

PRESSURE
TESTING
TO
3,000 psi

PRESSURE TEST
Water
(8.33ppg)

Surface
TOC
at 3000

TOC
11.5ppg
Mud

9750

Cement
(8.6ppg)
62

WELL CONSTRUCTION

CASING DESIGN

Calculate the INTERNAL Pressure Profile [psi]

at Surface
=
psi
at Casing Shoe
=
Total =
psi

psi

Calculate the External Pressure Profile [psi]

at Surface
=
__________psi
at TOC
=
______________________________psi
at Casing Shoe =
______________________________psi
Total
=
________psi
Calculate the NETT Burst Load at surface and the casing shoe [psi]
at Surface
=
psi
at Casing Shoe =
psi
63

WELL CONSTRUCTION

CASING DESIGN

at surface
test pressure)

= 3000 (ie, the casing

at casing shoe = 3000 psi + (9750 x 11.5 x .

052)

= 8,831 psi

64

WELL CONSTRUCTION

CASING DESIGN

at surface

=0

at TOC
= 3000ft x 8.33 ppg x 0.052
1299 psi

Between TOC at 3000 ft & the shoe at 9750

ft
= 6750 ft x 8.6 ppg x .052 = 3019 psi

Total

= 4,318 psi

65

WELL CONSTRUCTION

CASING DESIGN

at surface
at shoe
psi

= 3000 psi

= 8831 psi 4318

= 4,513 psi

66

WELL CONSTRUCTION

CASING DESIGN

Production Casing Surface Tubing Leak

Load at shoe

gas at surface + HH of fluid

Development Drilling
Can use oil gradient for invading fluid if no gas present
Pressure Testing
Lowest of Max WH pressure, 80% of burst, WH or
BOP rating
Surface Equipment Limitations
67

WELL CONSTRUCTION

CASING DESIGN

Surface

3000 psi

TOC 3000 ft

DEPTH (ft)
Nett Burst
9750 ft

4513 psi
3000

6000

9000

PRESSURE (psi)

68

WELL CONSTRUCTION

CASING DESIGN

1.
2.

The following casings are available 13-3/8, 68lb/ft K55 and

13-3/8, 72lb/ft, N80.
Note: The Transocean design factors for burst is 1.1, so
downrate the burst pressure accordingly.
Size

Grade

ins

Wt
per
foot
lbs

Inside
Diameter

Collapse
Resistance

Body Yield
Strength

Burst
Pressure

Downrated Burst
Pressure

Coupling
Buttress Thread

ins

psi

x1000 lbs

psi

(Transocean DF
= 1.1)

psi

13-3/8

K55

68

12.415

1,950

1,069,000

3,450

3,136

3,450

13-3/8

N80

72

12.347

2,670

1,661,000

5,380

4,891

5,380

69

WELL CONSTRUCTION

CASING DESIGN

13-3/8 K55 68 ppf

3,000 psi

0 ft

1. Collapse 1950 psi

3. Burst 3450 (3136 downrated for DF)

1446 psi

13-3/8 N80 - 72 ppf

2. Collapse 2670 psi
4. Burst 5380 (4891 downrated for DF)

CONCLUSION
9750 ft

1371 psi

4,271 psi

Both are suitable for Collapse

Only N80 suitable for Burst
RECOMMENDATION

Nett Collapse

Nett Burst

Select 72ppf, N80

70

WELL CONSTRUCTION

CASING DESIGN

Once the casing meets collapse and design criteria, it is necessary to ensure
that it will meet the Tensile design. It needs to withstand installation, drilling
and production loads. It is assume that the casing is fixed at the surface but
free to move at the shoe.. The following loads need to be considered.
Load Component

Installation

Drilling

Production

Weight in Air

Buoyancy

Bending (Fb)

Shock Load (Fs)

X
X

Pressure Testing
Total Load (lbs)

71

WELL CONSTRUCTION

CASING DESIGN

Load cases are calculated

in the order that they appear

Installation

1.

Installation

Casing Running

2.

Drilling

Casing cementing

3.

Production

Plug bump etc

Drilling

Production

1.

Pressure Testing after WOC

1.

Completion / Kill Fluids

2.

Maximum Mud Weight

2.

Tubing Leaks

3.

Lost Circulation, Well Control

3.

Functioning DST Tools etc

72

WELL CONSTRUCTION

CASING DESIGN

Let us assume two load scenarios:

1.

The maximum installation (or running) load when running the 13-3/8 casing
to 9,750ft.

Inside diameter
12.347

Mud weight
11.0 ppg

Instantaneous Velocity
5 ft/sec

2.

The maximum drilling load when cementing the 13-3/8 casing at 9,750ft.

Top of Lead Slurry 3,000 ft

Weight of Lead Slurry

11.6 ppg

Top of Tail Slurry

9,000 ft

Weight of Tail Slurry 15.8 ppg

Plug Bump Pressure

3,000 psi

Calculation:
Use the data above + the attached handout (from the Well Construction Manual,
Section 3, to calculate the tensile loads and fill out the table on the next page.

73

WELL CONSTRUCTION

CASING DESIGN

Load Component

Installation

Drilling

Production

Weight in Air
Fair = W x TVD

Buoyancy (note: needs to be subtracted)

Fbuoy = (Pe x Ao) (Pi x Ai)

Bending (Fb)
Fbend = 64 x DLS x OD x W

Shock Load (Fs)

Fshock = 1,780 x V x As

Pressure Testing
Fptest = Pptest x Ai

Total Tensile Load (lbs)

74

WELL CONSTRUCTION

CASING DESIGN

Load Component

Installation Drilling

Production

Weight in Air

702,000

702,000

702,000

Buoyancy (subtract)

115,821

168,425

115,821

Bending (Fb)

61,632

61,632

61,632

Shock Load (Fs)

184,832
359,198

359,198

954,405 lbs

954,405

Pressure Testing
Total Tensile (lbs)

832,643 lbs

75

WELL CONSTRUCTION

CASING DESIGN

13-3/8 N80 Tensile

Load Component

Installation

Drilling

Production

Weight in Air

702,000

702,000

702,000

Buoyancy

115,821

168,425

168,425

Bending (Fb)

61,632

61,632

61,632

Shock Load (Fs)

184,832
359,198

359,198

954,405

954,405

Pressure Testing
Total [lbs]

832,643

From tables =
1,661,000 lbs
Design Factor = 1.3
1.3 x 954,405 lbs
= 1,277,923 lbs
Thus Tensile Design
is OK

76

WELL CONSTRUCTION

CASING DESIGN

77