Casing Failure Prevention

East Texas Gas Producers Assoc.

9 March 2010
 The Ideal Casing String

For as long as needed, it will:

Safely carry all applied loads,

Until the next string is set
and be free from leaks.
to the life of the well

2
 AThree Stepsinare
breakdown anyRequired to
one of these
Achieve
steps can the
result in Idealfailure!
a casing
Design: The engineer decides casing sizes,
The discussion
Design today will focus
weights, grades and connections for each hole
on:
section (usually choosing from available standard
options).
Common
Manufacturingfailure
Manufacturing modes Someone builds
and Procurement:
the casing (and coupling stock), someone threads the
Underlying
connections, someone causes
buys the casing and someone
delivers it to the rig.
Steps to minimizeInstallation
the risk of failure
Installation: Rig crew and casing crew pick it up one
joint at a time and run it.

3
Casing Failures

4
 Failure Modes
Casing Failures

PRESSURE TENSION BRITTLE FRACTURE

Burst Tube Fracture Environmental
Collapse Connection Fracture Cracking
Connection Connection Jump Naturally Brittle
Leaks Out Material
Buckling

FATIGUE OTHER
Connections Galling
BTC Disengagement

5
 Failure Modes
Casing Failures

PRESSURE TENSION BRITTLE FRACTURE

Burst Tube Fracture Environmental
Collapse Connection Fracture Cracking
Connection Connection Jump Naturally Brittle
Leaks Out Material
Buckling

FATIGUE OTHER
Connections Galling
BTC Disengagement

6
 Failure Modes
Casing Failures

PRESSURE
Burst
TENSION
Tube Fracture
BRITTLE FRACTURE
Environmental
Collapse Connection Fracture Cracking
Connection Connection Jump Naturally Brittle
Leaks Out Material
Buckling

FATIGUE OTHER
Connections Galling
BTC Disengagement

7
Pressure Related
Burst and Collapse
BURST FAILURE

Failure Mechanism
Overload failures where pressure (burst
or collapse) exceeds load capacity
Recognition
Appearance: Plastic deformation
(ductile material)
Orientation: Longitudinal
Location: Sections with highest loads
COLLAPSE FAILURE

8
Remember..
Pressure and Tension are not independent.
Axial and Pressure Loads Interactively Affect One Another
10000
(psi)

8000
Burst Strength

6000

4000

2000
Compression Tension
-700 -600 -500 -400 -300 -200 -100 100 200 300 400 500 600 700
-2000
(psi)

-4000
Collapse Strength

-6000

-8000
Triaxial Ellipse
-10000 for 7"- 23.0 lb/ft
N-80 Casing
Axial Force (1000 lbf)

9
 Why Connections Leak:
1. Inadequate Bearing Pressure

Bearing Pressure (PB)

If bearing pressure (PB) exceeds
internal pressure (PI), then no leak.

Internal Pressure (PI)

If internal pressure (PI) exceeds bearing

pressure (PB), then leak.

Connections
10
 Why Connections Leak:
2. Leak Path Across Seal(s)
A leak path is present on this pin seal. The seal
will leak regardless of how much bearing
pressure is forcing the two components Bearing Pressure (PB)
together.

Connections
11
API Connections Have Built-In (Helical) Leak Paths

PIN

BOX API BUTTRESS

These tortuous paths are plugged with the

solids in thread dope during makeup.

PIN

API ROUND THREAD

BOX

Connections
12
 Preventing Leaks
Leak Paths (other than helical) Found in visual inspection. Removed
from the string.

Inadequate Bearing Adequate Bearing Pressure is assured by:

--Proper dimensions
Pressure --Proper makeup

Connections
13
 Pressure Related Failures
Failure drivers Mitigations Steps
Design error:
Applied load > rated
load capacity
Material problem:
Load capacity < rated
load capacity
Casing wear
Inspection problem:
Manufacturing flaw,
thin wall joint or thread
dimensions
Improper make up
Use appropriate design factors
to account for higher than
anticipated loads.
Inspect material for
manufacturing flaws, thin wall,
grade and thread dimensions.
Minimize casing wear by:
reducing side loads, use of
casing friendly hardbanding and
reducing rotations of drill string.
Make up connections to
generate desired bearing
pressure.
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 Failure Modes
Casing Failures

PRESSURE TENSION BRITTLE FRACTURE

Burst Tube Fracture Environmental
Collapse Connection Fracture Cracking
Connection Connection Jump Naturally Brittle
Leaks Out Material
Buckling

FATIGUE OTHER
Connections Galling
BTC Disengagement

15
 Failure Generally Associated with Tensile Loads

In API tensile tests to Only 9% failed by fracture.

failure, 148 of 162 (91%) of TENSILE
round threaded connections FRACTURE IN THE
PIN THREADS
failed by jumpout.

TENSILE
FRACTURE IN THE
TUBE

THREAD
JUMPOUT

16
 How Jumpout Happens
Many times, jumped-out threads have been successfully
rejoined downhole by setting down and turning right.
BOX BOX
BOX
BOX
BOX

NOT
ENGAGED
PIN ENGAGED-
JUMPED OUT
Much of the thread deformation (strain)
on jumpout is elastic, so only minor
thread damage occurs (at thread crests).

17
Jumpout - The Main Reason API Adopted
the Buttress Thread Form
Vs. 30 degrees for the 3 degrees
round thread form

BOX

PIN

API BUTTRESS THREAD FORM

18
 Stable Casing Buckling Buckled
Sudden, rapid axial collapse of a casing
section that occurs when forces that
destabilize the section exceed forces
that stabilize it.
Factors affecting buckling:
State of tension or compression including
temperature and pressure affects
Stability forces
(PI x AI) - (PO x AO)
Section stable if:
F > (PI x AI) - (PO x AO)
Section buckled if:
F (PI x AI) - (PO x AO)

where:
F is the amount of tension (+) or compression (-) (lbs)
PO is the annular pressure (psi)
AO is the outer circumference of the casing (in)
F (PI x AI) - (PO x AO)
F >(PI x AI) - (PO x AO) PI is the pressure inside the casing (psi)
AI is the inner circumference of the casing (in)

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 Tension Failures
Failure drivers
Design error:
Applied load > rated load
capacity
Material problem:
Load capacity < rated load
capacity
Casing wear
Inspection problem:
Manufacturing flaw, thin wall
joint or incorrect thread
dimensions.
Improper make up
Casing buckling
Mitigation steps
Use appropriate design factors
to account for higher than
anticipated loads
Inspect material for
manufacturing flaws, thin wall
and grade.
Minimize casing wear by
reducing side loads, use of
casing friendly hardbanding and
reducing rotations of drill string.
Gauge connections and make
up properly.
Adjust tension and TOC to
eliminate buckling.
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 Failure Modes
Casing Failures

PRESSURE TENSION
Burst Tube Fracture
BRITTLE FRACTURE
Environmental

Collapse Connection Fracture Cracking
Connection Connection Jump Naturally Brittle
Leaks Out Material
Buckling

FATIGUE OTHER
Connections Galling
BTC Disengagement

21
BRITTLE FRACTURE (Hydrogen Induced)
Free hydrogen ions from the chemical reaction with H2S
Thisand
entered the steel in this coupling brittle
madecoupling fracture
it brittle, occurred
leading to in
the failure. But some materialsanbegin
H2S (hydrogen sulfide) environment.
life brittle
The mechanism is called Sulfide Stress
Cracking (SSC)
Whether or not such a failure will happen
depends on many factors that work
together in complex interrelationships:
H2S concentration
Microscopically, Sulfide Stress Time of exposure
cracks tend to be branched Tensile stress level
and run along grain
boundaries.
Metallurgical properties
Temperature
Other factors

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 BRITTLE FRACTURE
Slip cuts (Naturally Induced)
This N80 casing joint was never
exposed to hydrogen sulfide.
Rather, it came brittle off the
production line due to improper
metallurgy and/or heat treatment.

Under impact loading, the pipe

cracked and parted (much like
laboratory glass piping is cut)
when a crack started at the
bottom of a slip cut, and rapid,
brittle fracture occurred. Such
a material is called NOTCH-
SENSITIVE.

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 Why Tough Material is Better Than Brittle
MATERIAL A - BRITTLE, NOTCH-SENSITIVE

MATERIAL B - TOUGH

In impact loading
Can safely
Tougher RAPID,
materials are safer & more forgiving In fatigue loading
carry a higher BRITTLE
TENSILE STRESS

stress with a FRACTURE In hydrogen sulfide

given defect,

Will fail by tearing

apart like a piece MATERIAL B
of taffy, not
shattering like a SAFE MATERIAL A
piece of glass!

Can safely carry a larger defect at a given stress

DEFECT SIZE

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 Fundamentals!
Fundamentals of Casing Material Selection for
Sour and Corrosive Service
Recall the failure mechanism
Sulfide Stress Cracking (SSC)

Free hydrogen generated in the

H2S-Steel corrosion reaction
causes otherwise ductile metal to
become brittle and crack.

25
 How Hardness and H2S Concentration Affect SSC
(5% NaCl solutrion. Carbon steel specimens @ 130% yield stress)
40
As hardness decreases, time to failure increases.
NACE definition of sour:
As concentration decreases, time to failure increases.
35 H2S Partial Pressure 0.05 psia.
(5 PPM @ 10,000 psi)

90 Six H2S H2S PP @

30 minutes months
HARDNESS (HRC)

0.1 ppm
PPM 10,000 psi
8000 80
25
3000 30
1.0 ppm
15 0.15
20 5 .05
15
1 .01

15 3000 0.1 .001

Curves give H2S concentration

8000
10 in NaCl solution. (After Hudgins,
0.1 1 10 100 1000 10 4 McGlasson, Mehdizadeh, and
DAY WEEK MONTH YEAR Rosborough)

TIME TO FAILURE (HOURS)

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Temperature and SSC
P110 range of
possible YS
For a given grade, as
minimum temperature
increases, liklihood of
SSC decreases.

This explains why P110

(for example) may be fine NO SSC NACE Minimum
Temperature for P110
for a deep liner in sour
service, but be SSC
unacceptable in the same
hole near the surface.

27
 How Hardness and Tensile Stress Affect SSC
(300 ppm H2S in 5% NaCl solutrion. Carbon steel specimens)
45
Why Group 2 sour
service grades
40
(M65,L80,C90,T95)
have restricted
maximum hardness 35

HARDNESS (HRC)
40%

60%
As Tensile Stress 30

decreases, time to
failure increases. 25
80%

Curves give stress as a percent 20

100%
of yield strength. (After Hudgins,
McGlasson, Mehdizadeh, and 130%
Rosborough)
15
0.1 1 10 100 1000
DAY WEEK MONTH
TIME TO FAILURE (HOURS)

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A Corrosion Engineer Selecting a Sour Service Material Will Consider
Many Factors:
a. H2S concentration
b. Chloride levels The analysis is complex and the result
c. CO2 concentration will be a compromise thats very
d. pH dependent on Local Conditions.
e. Temperature
f. Oxygen content of the flowstream
g. Sulfur content of the flowstream
h. Gas/Oil Ratio
i. Water content of the flowstream
j. Fluid velocity
k. Cost of alternatives
l. Anticipated life of the well

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 Typical Chemistry of Steels

Classification
Carbon Low Alloy Stainless Nickel Based
Steels Steels Steels Alloys
Element (% Wt.)
Carbon 0.3 - 0.5 0.3 - 0.5 <0.25 <0.3
Manganese 0.5 - 2.0 <2 <2 <2
Molybdenum ---- <1 <4 <10
Chromium ---- <2 9 - 26 <25
Nickel ---- <1 <25 40 - 70
Iron >97 >95 40 - 85 2 - 40
Typical Cost Ratios
1 1.5 3 - 10 $$$!

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 Not for Material Selection!
(talk to your corrosion engineer)
A Guide for the Application of Corrosion Resistant Alloys (CRA)
$16-20
Higher temperature
benefits SSC, but NIC 62
accelerates weight- $12-14 (C-276)

loss corrosion. NIC 42

(G3, SM2550)

$6-7
400 deg F
475
Temperature (deg F)

22 CR, 25 CR
(DUPLEX SS) Prices will vary widely with
400 300 deg F
conditions in the metal markets.
$2-3 2000
1500
300 $1.5-2 13 CR
(420 MOD SS)
275 800
9 Cr 200

0.15 1.5 10 1000 10000

Partial Pressure H2S (psia)

If L80 Type 1 costs $1

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Questions

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