Casing Design

Vamegh Rasouli

Casing Design - Introduction

What is casing?
Why run casing?

Casing

Cement

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,
2

Casing Design - Why run casing - contd

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).
e.g., you need 14 ppg to control a lower zone, but an
upper zone will fracture at 12 lb/gal.
What to do?
3

Typical Sequence of
Csg. Strings

Functions of Casing Individually

Drive pipe
Driven & cemented to
shallow depth in predrilled or pre-dug holes
Provides a mud return
path to surface,
Prevents erosion of
ground below rig.

Conductor pipe
Same as Drive pipe,
Supports the weight of next
casing strings,
Isolates very weak
formations.
Diverter installed to shale
shaker
Corrosion barrier

Functions of Casing Individually

Surface casing

Intermediate casing

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.

Usually set in the first

abnormally pressured
zone,
Provides isolation of
potentially troublesome
zones,
Provides integrity to
withstand the high mud
weights necessary to
reach TD or the next csg.
Seat.
6

Functions of Casing Individually contd

Production casing

Liners

Provides zonal isolation

(prevents migration of
water to producing zones
and isolates different
production zones)
Confines production to
wellbore
Provides the environment
to install subsurface
completion equipment

Drilling liners
Same as Intermediate
casing

Production liners
Same as production casing

Tieback liners
Tie back drilling or
production liner to the
surface. Converts liner to
full string of casing

Types of Strings of Casing

Diameter

Example

1. Drive Pipe or Structural Pile

(Gulf Coast and offshore
only)
150-300 BML

16-60

30

2. Conductor String
100 - 1,600 BML

16-48

20

3. Surface Pipe
2,000 - 4,000 BML

85/8-20

133/8

Types of Strings of Casing contd

4. Intermediate String
5. Production String

Diameter

Example

75/8-133/8

9 5/8

4-95/8

Casing Programs

10

Casing Programs contd

11

Casing Selection
Chart

12

Example Hole and String Sizes (in)

Hole Size

Pipe Size

36

Conductor casing

30

26

Surface string

20

17

Intermediate pipe

133/8

12

Intermediate String

95/8

77/8

Production Liner

51/2
13

Classification of CSG.

Outside diameter of pipe (e.g. 95/8)

Wall thickness (e.g. )
Grade of material (e.g. N-80)
Type to threads and couplings (e.g. API LCSG)
Length of each joint (e.g. Range III)
Nominal weight (e.g. 47 lb/ft)

14

Most Common Grades

Minimum Yield
Strength (KPSI)

Ultimate Tensile
Strength (KPSI)

H-40

40

60

J-55

55

75

K-55

55

95

C-75

75

95

L-80

80

95

N-80

80

100

C-90

90

100

C-95

95

105

P-110

110

125

V-150

150

160

15

Length of Casing Joints

RANGE

LENGTH
(ft)

16 - 25

II

25 - 34

III

> 34
16

Casing Threads and Couplings

API round threads short

API round thread - long
Buttress
Extreme line
Other

( CSG )
( LCSG )
( BCSG )
( XCSG )

See Halliburton Book...

17

Casing Threads and Couplings contd

Rounded Threads
8 threads per inch
4 to 20

Square Threads
Longer
Stronger
4 to 20

Integral Joint
Smaller ID, OD
Costs more
Strong
5 to 103/4

18

19

20

10

Wellhead & Christmas Tree

Wellhead
Hang Casing Strings
Provide Seals
Christmas Tree
Control Production
from Well

21

Wellhead & Christmas Tree contd

22

11

Casing Performance - Uniaxial

Loadings
Axial Tension (couplings & body)
Burst Pressure
Collapse Pressure
Bending
Buckling
23

Casing Performance - Uniaxial

Tension Strength/Failure

24

12

Tension Strength
Tension Strength
Couplings: API Tables
for various couplings
Body (perm. deform.)

Fy =

2 2
D
d YP
4

Fy = pipe body yield strength

D = external diameter (nominal)
d = internal diameter
YP = yield stress

25

Tension Strength Example 1

Compute the body-yield strength for a 7, N-80,
23 lb/ft casing.
Solution:
From API Table (1 & 2)

D = 7 in
d = 6:366 in
YP = 80; 000 psi
2
2
Fy =
7
6:366 80; 000 = 532 ksi
4
26

13

Tension Strength Formula

Uses Nominal Diameter
API minimum Thickness 87.5% of original
(nominal) thickness
Yield Strength
Rupture much larger
May deform plastically

27

Casing Performance - Uniaxial

Burst (Internal Pressure)
Yield the body
Yield the coupling
Leak the coupling

28

14

Burst (Internal Pressure)

Barlow (API allows 87.5% of thickness)
Thin Wall Assumption

Pbr = 0:875

2 YP t
D

Pbr = pipe body burst pressure

D = nominal diameter
YP = yield stress

29

Burst (Internal Pressure) Example 2

Compute the body burst pressure for a 7, N80, 23 lb/ft casing.
Solution:
From API Table
D = 7 in
7 6:366
d = 6:366 in ! t =
= 0:317 in
2
YP = 80; 000 psi

2 80; 000 0:317

Pbr = 0:875
= 6; 340 psi
7
30

15

Collapse (External Pressure)

31

Collapse (External Pressure) contd

The following factors are important:
The collapse pressure resistance of a pipe
depends on the axial stress (biaxial stress)
There are different regimes of collapse failure
(depends on ratio D/t)

Yield Strength Collapse (thick wall)

Plastic Collapse
Transition Collapse
Elastic Collapse

(Empirical Formulation from API)

32

16

Collapse (External Pressure) contd

Yield Stress Collapse Pressure (thick wall)

r2 r2 + po r2 r2 r2
o
o
i
i
r (r) =
2
r2 (ro2 ri )

pi r2 r2 + r2 po r2 r2 + ri2
o
o
i
t (r) =
r2 (r2 r2 )
pi r2

33

Collapse (External Pressure) contd

Yield Strength Collapse Pressure

PY = 2 YP
P

(D=t) 1
(D=t)2

PYp = pipe body collapse pressure

D = nominal diameter
t = wall thickness
YP = yield stress (effective for biaxial stress)

34

17

Collapse (External Pressure) contd

Plastic Collapse Pressure

P P = YP

A
D =t B

PP = pipe body collapse pressure

D = nominal diameter
t = wall thickness
YP = yield stress (effective for biaxial stress)
A, B, C, F, G, Material (and stress) dependent coefficients
35

Coef.s Formulas (API Bull. 5C3)

36

18

Collapse (External Pressure) contd

Transition Collapse Pressure

PT = YP

F
G
D=t

PP = pipe body collapse pressure

D = nominal diameter
t = wall thickness
YP = yield stress (effective for biaxial stress)
A, B, C, F, G, Material (and stress) dependent coefficients
37

Collapse (External Pressure) contd

Elastic Collapse Pressure
6

46:95 10
PE =
2
(D=t) [(D=t) 1]
PE = pipe body collapse pressure
D = nominal diameter
t = wall thickness

38

19

Collapse (External Pressure) contd

A, B, C, F, G
These values are for the
uniaxial stress
Different values for
effective yield stress
For Biaxial calculate the
effective Yield Stress
and interpolate the
coefficients
(Coef.s depend on Yield Stress)
39

Collapse (External Pressure) contd

(D=t)Y P

p
(A 2)2 + 8(B + C = YP ) + (A 2)
=
2 (B + C = YP )

40

20

Collapse (External Pressure) contd

Upper Limit for Plastic Collapse

(D=t)P T =

YP (A F )
C + YP (B G)

41

Collapse (External Pressure) contd

Upper Limit for Transition Collapse

(D=t)T E =

2 + B =A
3 B =A

42

21

Collapse (External Pressure) contd

Boundaries for Axial Stress = 0

43

Collapse (External Pressure) Example 3

Calculate the Collapse pressure rating for a 7 in, N-80, 23
lb/ft casing.
Solution: 7 in, N-80, 23 lb/ft t = 0.317 in
Grade

N-80

3.071

0.0667

1,955

1.988

0.0434

(D=t) =

7
= 22:08 !
0:317

Plastic collapse for N80

44

22

Collapse (External Pressure) Example 3

PP = Y P

PP = 80; 000

A
B
D =t

3:071
0:0667 1; 955 = 3; 836 psi
22:08

45

Triaxial Collapse
Effect of Axial Stress in the Collapse
Resistance Effective Yield Stress
Von Mises Criteria (Distortion Energy)
Material fails (ductile yield failure) when total
distortion energy equals uniaxial test distortion
energy
2

(a t ) + (t r ) + (r a ) = 2 Y
2

46

23

Triaxial Collapse contd

Triaxial s

Ye =

Biaxial

Y 3
P

a + pi
2

a pi
2

r

2

2
Ye = YP 3 a a
2
2

Ye = effective yield stress

YP = uniaxial stress t
sa = axial stress
pi = internal pressure (pi << po)

47

Triaxial Collapse contd

Linear Interpolation for the coefficients
Coef.s depend on Yield Stress
For YL < Ye < YU interpolate using (linear)

Xe = X +

Ye YL
(X XL )
YU YL U

48

24

Coef.s Formulas (API Bull. 5C3)

A = 2:8762 + 0:10679 105 YP + 0:21301 1010 Y 2 0:53132 1016 Y 3
P

B = 0:026233 + 0:50609 106 YP

C = 465:93 + 0:030867 YP 0:10483 107 Y 2 + 0:36989 1013 Y 3
P

F =
YP

46:95 106
3B =A
2 + B =A

3 B =A
2 + B =A

B =A

ih

3B =A
2 + B =A

G = F B =A
49

Triaxial Collapse Example 4

For the casing of Example 3, calculate the
corrected critical collapse pressure if a section of
2,000 ft, 7 in, N-80, 23 lbm/ft casing is
suspended below it (assume linear weight of 23
lbf/ft and empty borehole - no buoyancy effect).
What is the corrected collapse pressure if the
internal pressure is 1,000 psi?

50

25

Triaxial Collapse Example 4

Solution:
Weight of Casing Below Point in Question

F = 2; 000 23 = 46; 000 lbf

Cross Section Area

Ac =
Axial Stress

2
2
7
6 :36 6 = 6 :6 55 5 i n 2
4

a =

4 6; 0 0 0
= 6 ; 9 1 2 ps i
6 :6 5 5 5
51

Triaxial Collapse Example 4

Effective Yield Stressr
(biaxial)

Ye =

Ye =

Y2
P

80 ; 0 00 3

3 a 2 a
2
2

6; 912
2

6; 912 = 76; 320 psi

2

(an equivalent N-76.32)

52

26

Triaxial Collapse Example 4

Interpolated Coef.s
Grade

C-75

3.054

0.0642

1,806

1.990

0.0418

N-76.32

3.059

0.0649

1,845

1.992

0.0422

N-80

3.071

0.0667

1,955

1.998

0.0434

API Fs Formulas (MsExcel Spreadsheet)

Yp

76320

3.058

0.0649

1845

1.992

0.0422

53

Triaxial Collapse Example 4

( D =t) =

7
= 2 2 :0 8
0 :3 1 7

Collapse Regime
Yield Regime U-Limit:
p
(A 2)2 + 8(B + C = YP ) + (A 2)
(D = t )Y P =
2 (B + C = YP )
q

( 3 : 0 58 2 ) 2 + 8 ( 0 : 0 64 9 + 1 ; 8 4 5 ) + ( 3 : 0 5 8 2 )
7 6 ;3 2 0
= 13:54 < 22:08
2 ( 0 :0 6 4 9 + 1 ; 8 4 5 )
76;32 0

54

27

Triaxial Collapse Example 4

Plastic Regime U-Limit:

( D =t ) P T =

22 : 0 8 <

YP (A F )
C + YP ( B G )

7 6 ; 3 2 0 ( 3 :0 5 8 1 :9 9 2 )
= 2 2: 7 9
1 ; 8 4 5 + 7 6 ; 3 2 0 ( 0 :0 6 4 9 0 : 0 4 2 2 )

Collapse occurs in the Plastic Regime

55

Triaxial Collapse Example 4

Plastic Collapse Strength

PP = Y P

PP = 76; 320

A
B
D =t

3:058
0:0649 1; 845 = 3; 772 psi
22:08

(compare with 3,830 psi for the unstressed casing)

56

28

Triaxial Collapse Example 4

Effect of Internal Pressure
Critical pressure expressions are for pressure differential.
However, the effective yield stress should account for
the internal pressure, since the yield will start at the
internal wall.
The triaxial expression must be used:

Ye =

Y2
P

a + pi
2

a pi

2
57

Triaxial Collapse Example 4

Ye =

80; 0002 3

6; 912 + 1; 000
2

6; 912 1; 000
2

Ye = 76; 750 psi

sy ield

76750

3.060

0.0651

1858

1.992

0.0424

PP = 76; 750

3 :0 6 0
0 :0 6 5 1 1 ; 8 5 8 = 3 ; 7 8 2 p s i
2 2:0 8

(Po )max = 3; 782 + 1; 000 = 4; 782 psi

58

29

Pressure Collapse Table

59

Casing Design Criteria

Biaxial Method or Uniaxial Method
Burst
Conductor
Surface and Intermediate Casing
Production Casing

Collapse
Tension
60

30

Casing Design Criteria contd

Burst Conductor:
External pressure is zero
The maximum internal pressure is the formation
fracture pressure at the depth of the conductor set
depth. If the fracture pressure is unknown, assume
pff=1 psi/ft
F.S.=1.1
Neglect the gas density inside the conductor

61

Burst of Conductor

62

31

Casing Design Criteria contd

Burst of Surface & Intermediate Csg.:
External pressure: hydrostatic pressure of the heaviest mud used to
drill the hole and set the casing
Internal pressure: based on pore pressure at the final depth of the
next casing. If the pore pressure at the bottom of the next casing is
not known, assume the following:

r
p = 0:564 psi=ft depth < 8,000 ft
rpp = 0:650 psi=ft depth 8,000 ft
p

Assume that a fraction f (usually not less than 40%) of the length is
evacuated by gas and (1-f) fraction of the length remains filled with
drilling fluid.
Neglect the gas density inside the casing.
F.S.=1.1
Worse scenario at the top of string
63

Burst of Surf. & Interm. Csg.

64

32

Casing Design Criteria contd

Burst of Production Casing:

External pressure: hydrostatic pressure due to formation saltwater (SGsw = 1.1542)

Internal pressure: based on pore pressure at the final depth Dc (production depth). If
the pore pressure at the bottom of the casing is not known assume the following:

r
p = 0:564 psi=ft depth < 8,000 ft
rpp = 0:650 psi=ft depth 8,000 ft
p

Assumed the whole internal casing filled with gas (gas lift production)
Pressure inside the casing determined as follows:
g (D D )
M
c

pi = pb e

RT

DD

p e 40;000c
b

F.S.=1.1
Worse scenario at the top of string

65

Burst of Production Casing

66

33

Casing Design Criteria contd

Collapse:
Collapse due to fluid in the annulus between the casing
and the borehole
Considered the heaviest drilling fluid used to drill the
hole and set the casing
Assume casing empty
No buoyancy
F.S.=1.0 (neglect the strengthening effect of cement;
most of the casing will not be empty)
Worse scenario at the bottom of string
67

Collapse of Casing

68

34

Casing Design Criteria contd

Tension:
Corresponds to the weight of the casing
measured in the air (no buoyancy effect)
F.S.:
1.6 for couplings
1.8 for casing body
Worse scenario at the top of string

69

Casing Design Example

Evaluate the burst and collapse pressure loadings
and design an appropriate surface casing using
the biaxial method. Check for axial load.

Setting depth of the casing string: 4000 ft

Mud density as setting the string: 10.0 lb/gal
Setting depth of the next csg. string: 11000 ft
Mud density of the next phase: 10.5 lb/gal
Casing size and coupling: 103/4 Buttress threads,
minimum grade K-55
Assume f = 40%.

70

35

Casing Design Example contd

Burst Loading (this is a surface csg.)
External Pressure:
po(psi) = 0.052 x 10 lb/gal x D(ft)
po = 0.52 x D

71

Casing Design Example contd

Internal Pressure:
pp=0.650 psi/ft (Dnc>8,000 ft)
pp = 11,000 x 0.650 = 7,150 psi
(1-0,4)xDnc = 6,600 ft
p6600= 7,150-0.052x10.5x6,600=3,546 psi
pi= 3,546 psi

72

36

Casing Design Example contd

Burst Pressure contd:
F.S. = 1.1
pab = (pi-po)
pab= 3,546 0.52D

73

Casing Design Example contd

Collapse Loading
External Pressure:
po = 0.52 x D
Internal pressure = 0 psi
F.S. = 1.0
pac = 0.52 x D
74

37

Casing Design Example contd

Design for Burst
Start at bottom (minimum burst pressure)
pab,4000 = 3,546 0.52 x 4000 = 1,466 psi
Cheapest casing: (p.320-321)
K-55, 40.50 lb/ft, Burst Strength 3,130 psi
Minimum depth that can go:
pab,D = 3,546 0.52 x D = 3130 psi / 1.1
Dmin = 1347 ft
75

Casing Design Example contd

Continue with next cheapest Casing
K-55, 45.50 lb/ft, Burst Strength 3,580 psi
Minimum depth that can go:
pab,D = 3,546 0.52 x D = 3,580 psi / 1.1
Dmin = 561 ft

76

38

Casing Design Example contd

Continue with next cheapest Casing
K-55, 51.00 lb/ft, Burst Strength 4,030 psi
Minimum depth that can go:
pab,D = 3,546 0.52 x D = 4,030 psi / 1.1
Dmin = -226 ft (above surface)

77

Casing Design Example contd

Burst Diagram
0 ft

103/4 K-55 51.00 lb/ft

561 ft
103/4 K-55 45.50 lb/ft
1347 ft

103/4 K-55 40.50 lb/ft

4000 ft

78

39

Casing Design Example contd

Design for Collapse (uniaxial)
Start at top (minimum collapse pressure)
pac = 0.52 x D
Cheapest casing:
K-55, 40.50 lb/ft, Collapse Strength 1,580 psi
Maximum depth that can go:
pac,D = 0.52 x D = 1,580 psi / 1.0
Dmax = 3,038 ft
79

Casing Design Example contd

Continue with next cheapest Casing
K-55, 45.50 lb/ft, Collapse Strength 2,090 psi
Maximum depth that can go:
pac,D = 0.52 x D = 2,090 psi / 1.0
Dmax = 4.019 ft

80

40

Casing Design Example contd

Collapse Diagram
0 ft

103/4 K-55 40.50 lb/ft

3038 ft
103/4 K-55 45.50 lb/ft
4000 ft

81

Casing Design Example contd

Combine Two Diagrams
0 ft

103/4 K-55 51.00 lb/ft

561 ft
103/4 K-55 45.50 lb/ft
1347 ft

+
3038 ft

burst
103/4 K-55 40.50 lb/ft
collapse
103/4 K-55 45.50 lb/ft

4000 ft

82

41