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Subject: Uprating of 5K Casing Head Spools

Problem: It is possible that more wells in the future around Hassi Messaoud will
encounter virgin pressure. Virgin formation pressures are predicted to be 1.456 SG
(6,969 psi) at a total vertical depth of 3,365m, which results in a 6,029 psi maximum
surface pressure (assuming a gas/oil gradient of .23 SG), which occurs during a tubing
leak (see attached StressCheck results). This would exceed the API Spec 6A (19th
Edition) / ISO 10423 specifications for the 13 5/8” 5K x 11” 5K Casing Head Spool. The
API test pressure for this spool is 7,500 psi (1.5 times the rated pressure). Previous
editions of RP6A called for a 10,000 psi test pressure (2 times rated pressure) for 5K
equipment so most wellheads and spools are constructed to withstand this pressure. If
this is the case, a manufacturer should be able to certify a wellhead to 6,650 psi since
the equipment will test to 10,000 psi (or 1.5 times the working pressure).

Solution: The major suppliers of wellheads should be contacted and it verified that they
can certify a 5K casing head spool to 6,650 psi working pressure. Of course the casing
head spool won’t contain the API or ISO 10423 stamps but RP 6A, API states:

“API standards are published to facilitate the broad availability of proven, sound
engineering and operating practices. These standards are not intended to obviate the
need for applying sound engineering judgment regarding when and where these
standards should be utilized. The formulation and publication of API standards is not
intended in any way to inhibit anyone from using any other practices.

Any manufacturer marking equipment or materials in conformance with the marking


requirements of an API standard is solely responsible for complying with all the
applicable requirements of that standard. API does not represent, warrant, or guarantee
that such products do in fact conform to the applicable API standard.

Standards referenced herein may be replaced by other international or national


standards that can be shown to meet or exceed the requirements of the referenced
standard. Manufacturers electing to use another standard in lieu of a referenced
standard are responsible for documenting equivalency.”
Results:

ITAG was contacted (Martin Scheurer 00-49-51-41-914-267) and the problem was
discussed and Martin informed me that they had already been approached on this and a
letter had been written. They can either supply new 5,000 psi wellhead spools that had
been tested to 10,000 psi or verify that existing wellheads would test to 10,000 psi. That
letter is attached.

FMC was contacted (Martin Frain 029-738-417) and they stated that their 5,000 psi
spools could be tested to 10,000 psi and they would pass once the lockdown screws
and packing materials were upgraded to 10,000 psi specs. Valve components would
also have to be upgraded to withstand the 10,000 psi test. They said they would certify
in writing to this test pressure. A letter from them as well as their design calculations for
6,650 psi. is attached.

Cameron was contacted (Philip 029-737-391) and they also stated their 5,000 spools
should have no problem testing to 10,000 psi and they would document accordingly.

Conclusion:

All three major manufacturers of wellheads stated that they could test and certify their
5,000 psi casing spools to 10,000 psi, which at 1.5 times the working pressure of 6,650
psi follows the testing guidelines in API RP 6A. This will allow 5,000 psi casing spools to
be used on the wells in Hassi Messaoud where virgin formation pressures are being
encountered and a maximum surface pressure of 6,029 psi predicted. Of course
accurate formation pressure measurements and gas/oil gradient calculation will assure
that the 6,650 working pressure of these casing spools is not exceeded.

This concept is not new to Algeria. The wellhead manufacturers have supplied 6,650 psi
working pressure wellhead equipment to operators here for some time. Those operators
include, but are not limited to, El Gassil, RKF, BHP and Talisman.

Note: Time and cost were not taken into consideration for this analysis only the technical
feasibility.

Greg Hamm - Drilling Engineer


Attachments:

1) Ratings from API RP 6A – Nineteenth edition

2) StressCheck Analysis

3) Letter from ITAG

4) Letter from FMC

5) Design analysis from FMC


Attachment 1 - Ratings from API RP 6A :

7.4.9.3.3 Hydrostatic body test — Individual equipment

a) Test method
Subject assembled equipment to a hydrostatic body test prior to shipment from the
manufacturer’s facility. The hydrostatic body test shall be the first pressure test
performed. Do not apply test pressure as a differential pressure across closure
mechanisms of valves. Use water or water with additives as the testing fluid. Complete
tests prior to painting; however if the bodies and other pressure-containing parts have
been made of wrought material, tests may be completed after painting.
Loose connectors, bullplugs and valve-removal plugs do not require a hydrostatic test.

The hydrostatic body test for assembled equipment shall consist of three parts:
the primary pressure-holding period;
the reduction of the pressure to zero;
the secondary pressure-holding period.

Conduct tests prior to the addition of body-filler grease. Lubrication applied during
assembly is acceptable.

Both pressure-holding periods shall not be less than 3 min; do not start the timing until
the test pressure has been reached, the equipment and the pressure-monitoring gauge
have been isolated from the pressure source, and the external surfaces of the body
members have been thoroughly dried.

Determine the hydrostatic body test pressure by the rated working pressure of the
equipment. Hydrostatic test pressures shall be as given in Table 19.
b) Special considerations
For equipment with end or outlet connections having different working pressures, use the lowest working
pressure
rating to determine the hydrostatic body test pressure (except for cross-over connectors and chokes).
Test a cross-over connector at a test pressure based on the pressure rating for the upper connection.
Apply test
pressure inside and above the restricted-area packoff of the lower connection. The lower connection shall
be tested
below the restricted area packoff to a level based on its pressure rating.
For chokes having an inlet connection of a higher pressure rating than the outlet connection, test the body
hydrostatically, from the inlet connection to the body-to-bean seal point of the replaceable seat or flow
bean, to the
appropriate pressure for the inlet connection. Test the remainder of the body, downstream from the seal
point, to
the appropriate pressure for the outlet connection. Temporary seat seals may be used to facilitate testing.
Valves and chokes shall be in the partially open position during testing.
Test each bore of multiple-bore equipment individually.
c) Acceptance criteria
The equipment shall show no visible leakage under the test pressure. Leakage by the thread during the
hydrostatic
testing of a threaded wellhead member when joined with a threaded test fixture is permissible above the
working
pressure of the thread.

 
File: Design #1 Date: May 21, 2008 Page: 1
GENERAL DATA

Description: Wellbore #1
Well Options, Deviated: Yes
Well Options, Offshore: No
Well TD (MD): 4500.00 m
Reference Point: RKB
Air Gap: 0.00 m
Origin N: 0.00 m
Origin E: 0.00 m
Azimuth: 290.00 °

CASING AND TUBING SCHEME

Hole Size Measured Depths (m) Mud at


OD (in) Name Type
(in) Hanger Shoe TOC Shoe (sg)
1 18 5/8" Surface Casing 26.000 0.00 530.00 0.00 1.050
2 13 3/8" Intermediate Casing 16.000 0.00 2280.00 330.00 1.250
3 9 5/8" Production Casing 12.250 0.00 3320.89 2080.00 2.020
4 7" Production Liner 8.375 2630.00 3530.00 2630.00 1.490
5 4 1/2" Production Liner 6.000 3000.00 4500.00 3000.00 1.490

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File: Design #1 Date: May 21, 2008 Page: 2
WELL SCHEMATIC (DEPTH - MD)

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File: Design #1 Date: May 21, 2008 Page: 3

Section View
0
Section View

300

600

900

1200

1500
True Vertical Depth (m)

1800

2100

2400

2700

3000

3300

3600

0 35 70 105 140 175 210 245 280 315 350 385 420
VSection (m)

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File: Design #1 Date: May 21, 2008 Page: 4
PORE PRESSURE

Vertical Pore Pressure/EMW Permeable


Depth (m) (psi) (sg) Zones
1 0.00 0.0 1.000 Yes
2 1000.00 1422.3 1.000 Yes
3 1010.00 1580.2 1.100 Yes
4 1500.00 2560.2 1.200 Yes
5 2500.00 4267.0 1.200 Yes
6 2510.00 6783.1 1.900 Yes
7 3420.00 9242.3 1.900 Yes
8 3425.00 7092.9 1.456 Yes
9 3500.00 7248.2 1.456 Yes

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File: Design #1 Date: May 21, 2008 Page: 5

Pore, Fracture & MW


0
Pore Pressure
Fracture Gradient
350 Mud Weight

700

1050

1400

1750
Measured Depth (m)

2100

2450

2800

3150

3500

3850

4200

4550

4900
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00
Equivalent Mud Weight (sg)

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File: Design #1 Date: May 21, 2008 Page: 6
PRODUCTION DATA

Packer Fluid Density: 1.250 sg


Packer Depth, MD: 3000.00 m
Perforation Depth, MD: 4500.00 m
Gas/Oil Gradient: 0.2300 sg

INITIAL CONDITIONS (9 5/8" Production Casing)

Mix-Water Density: 1.000 sg


Lead Slurry Density: 2.060 sg
Displacement Fluid Density: 2.020 sg
Slackoff Force: 0.0000 tonne
Temperatures: Default
Vertical Depth (m) Temperature (°C)
0.00 m 25.00 °C
3110.00 m 102.13 °C
3179.67 m 103.86 °C
3237.90 m 105.30 °C
3266.10 m 106.00 °C
3293.48 m 106.68 °C
3312.00 m 107.14 °C

WELL SUMMARY

MD Interval Drift Dia. Minimum Safety Factor (Abs) Design Cost


String OD/Weight/Grade Connection
(m) (in) Burst Collapse Axial Triaxial ($)
1 Surface Casing 18 5/8", 87.500 ppf, K-55 BTC, K-55 0.00-530.00 17.567 3.90 1.40 10.32 3.86 92,757
2 Total = 92,757
3
4 Intermediate Casing 13 3/8", 68.000 ppf, L-80 BTC, L-80 0.00-2280.00 12.259 1.50 L 1.25 1.90 F 1.57 321,865
5 Total = 321,865
6
7 Production Casing 9 5/8", 47.000 ppf, P-110 BTC, P-110 0.00-1500.00 8.625 A 1.52 L 1.23 2.45 1.95 143,383
8 9 5/8", 53.500 ppf, P-110 BTC, P-110 1500.00-3320.8 8.500 A 2.09 L * 0.83 4.71 1.32 194,035
9 Total = 337,418
10
11 Production Liner 7", 29.000 ppf, P-110 NEW VAM 2630.00-3530.0 6.059 2.13 1.18 7.76 C 1.71 54,431
12 Total = 54,431
13
14 Production Liner 4 1/2", 13.500 ppf, L-80 NEW VAM 3000.00-4500.0 3.795 ----- N/A (2.06) C 1.85 43,569
15 Total = 43,569
16
17 Total = 850,040
18 * S.F. Below D.F.
19 L Conn Leak
20 F Conn Fracture
21 C Conn Critical
22 A Alternate Drift
23 ( ) Compression

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File: Design #1 Date: May 21, 2008 Page: 7
STRING SUMMARY

MD Interval Drift Dia. Minimum Safety Factor (Abs) Design Cost


String OD/Weight/Grade Connection
(m) (in) Burst Collapse Axial Triaxial ($)
1 Production Casing 9 5/8", 47.000 ppf, P-110 BTC, P-110 0.00-1500.00 8.625 A 1.52 L 1.23 2.45 1.95 143,383
2 9 5/8", 53.500 ppf, P-110 BTC, P-110 1500.00-3320.8 8.500 A 2.09 L * 0.83 4.71 1.32 194,035
3 Total = 337,418
4
5 * S.F. Below D.F.
6 L Conn Leak
7 A Alternate Drift

CONNECTIONS (9 5/8" Production Casing)

Connection Conn Safety Factor (Abs) Pipe + Conn Cost ($)


Pipe Section
Type Grade OD (in) Burst Axial ($/m) 337,418
1 9 5/8", 47.000 ppf, P-110 BTC P-110 10.625 1.52 2.46 95.59 143,383
2 9 5/8", 53.500 ppf, P-110 BTC P-110 10.625 2.09 4.73 106.56 194,035

BURST LOADS DATA (9 5/8" Production Casing)

Drilling Load: Gas Kick Profile


Influx Depth, MD: 4500.00 m
Kick Volume: 100.0 bbl
Kick Intensity 0.060 sg
Maximum Mud Weight: 1.490 sg
Kick Gas Gravity: 0.70
Fracture at Shoe: 11305.8 psi
Fracture Margin of Error: 0.000 sg
Drill Pipe OD: 5.000 in
Collar OD:
Collar Length:
Assigned External Pressure: Fluid Gradients (w/ Pore Pressure)

Production Load: Tubing Leak


Packer Fluid Density: 1.250 sg
Packer Depth, MD: 3000.00 m
Perforation Depth, MD: 4500.00 m
Gas/Oil Gradient: 0.2300 sg
Reservoir Pressure: 7160.0 psi
Assigned External Pressure: Fluid Gradients (w/ Pore Pressure)

External Pressure: Fluid Gradients (w/ Pore Pressure)


TOC, MD: 2080.00 m
Prior Shoe, MD: 2280.00 m
Mud Weight Above TOC: 2.020 sg
Fluid Gradient Below TOC: 0.998 sg
Pore Pressure In Open Hole: No

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File: Design #1 Date: May 21, 2008 Page: 8
BURST LOADS TABLE (9 5/8" Production Casing)

Depth (MD) Gas Kick Tubing Leak Fluid Gradients w/ Pore Press
(m) (psi) (psi) (psi)

1 0.00 2427.9 6029.0 0.0


2 1500.00 5520.7 8695.8 4309.7
3 2080.00 6416.9 9727.0 5976.1
4 2280.00 6725.9 10082.6 6260.0
5 2630.00 7266.7 10704.9 6756.9
6 3000.00 7425.5 11362.7 7282.2
7 3000.00 7425.5 7010.4 7282.2
8 3110.00 7472.7 7046.4 7438.4
9 3180.00 7502.6 7069.2 7537.3
10 3240.00 7527.6 7088.2 7620.0
11 3270.00 7539.7 7097.4 7660.0
12 3300.00 7551.4 7106.4 7698.9
13 3320.89 7559.4 7112.4 7725.2

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File: Design #1 Date: May 21, 2008 Page: 9

Burst Pressure Profiles (9 5/8" Production Casing)


0
Gas Kick (100.0 bbl, 0.060 sg)
Tubing Leak
250
Fluid Gradients w/ Pore Pressure

500

750

1000

1250

1500
Measured Depth (m)

1750

2000

2250

2500

2750

3000

3250

3500

0 900 1800 2700 3600 4500 5400 6300 7200 8100 9000 9900 10800 11700
Pressure (psi)

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ITAG Valves & Oilfield Products GmbH
A Company of the ITAG Group
Valves & Oilfield Products

page 1 of 1

Technical Proposal to Sonatrach - Division Forage


------------------------------------------------------------------------------------------------------

Up-rating of ITAG Casing Spools of Nominal Size 13 5/8"- 5M x 11"- 5M

Technical Request by Sonatrach Division Forage

A technical request has been issued on 23.04.2008 for up-rating the 5.000 psi WP
Casing Spool 13 5/8" x 11" to a maximum working pressure (MWP) of 6.600 psi.

Technical Summary by ITAG Valves & Oilfield Products

Up-rating of 5k Wellhead Equipment to a MWP of 6.500 psi or 6.600 psi is a praciable and economical
solution when just a slightly higher working pressure is required than the standard 5.000 psi.
All dimensions and flange interfaces remain as specified by API 6A for 5M equipment.

We can propose 2 reliable and save ways to supply Sonatrach with up-rated Casing Spools:

1. To supply new Casing Spools, which are manufactured, tested and certified to 6.600 psi MWP.

2. To upgrade already supplied Casing Spools from 5.000 psi to 6.600 psi - this has to be done
by a 2-step-program:

A – First, to check each individual Casing Spool Assembly for material properties and, if passed
B – Second, re-testing (pressure testing) according to API 6 A standard FAT procedure but with
increased test pressures (shell test 10.000 psi / closure test 6.600 psi)

Reasons and Procedure

API 6A as the framework for Wellhead Equipment standardizes basic dimensions as e.g. flange interfaces,
inner and outer diameters and also the corresponding pressure classes. In cooperation with dimensions and
pressures, API 6A has also specified the minimum material properties and has classified 4 standard strength
classes (material designations).
For 5.000 psi flange connections, it is possible to use material of the next higher strength class (designation)
which gives the necessary increase of yield strength to withstand a MWP of 6.600 psi.

By experience, most ITAG Wellhead Equipment has higher mechanical properties than the specified
minimum values. When performing an up-rating of previously delivered 5k equipment, we can not guarantee
that all parts will pass, but empirically it will be a figure of 70 - 90%.
It is mandatory that each spool assembly needs to be checked and has to pass a pressure test for getting
uprated and recertified.

2008-04-29/MS

Head Office: Itagstrasse, 29221 Celle, Germany · Telephone +49 / 51 41 / 9 14-0 · Telefax +49 / 51 41 / 9 14-2 34 · E-mail ivop@itag-ce.de
FMC Technologies SA

Surface Wellhead
Route des Clérimois
BP 705
89107 Sens Cedex France
Phone +33 3 86 95 87 18
Fax +33 3 86 95 89 87

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BHP Algeria ROD 6650 psi

DESIGN CALCULATIONS

The design calcs referenced within this document relate to the wellhead referred to
as ROD-R-031, FMC Reference TF 00527 and cover the upgrade of the system to 6650
psi

N.B. The casing program is 18-5/8” (conductor) x 13-3/8” x 9-5/8” x 7” x 4-1/2”


(Tubing) The system employed is a 5K System with the tubing spool, adapter
and production annulus valves upgraded to 6650 psi (see drawing below).
Calculations highlighted in blue represents loading acting down, while
calculations in red represent loading acting upwards.

Calculation 7
Latch Ring
Calculation 8
6650 psi
Lockdown Screws

6650 psi
Tubing Spool can be Calculation 1
uprated to 6650 without Tubing Hanger load
changes to equipment shoulder

To uprate Casing Spool 5000 psi


Calculation 2
to 6650 psi the annulus
7” Hanger to 9-5/8”
valves require to be
Hanger load shoulder
changed from M101 to
M120

Calculation 3
To uprate 9-5/8” Hanger
9-5/8” Packoff to 9-5/8”
to 6650 psi, the type of
Hanger load shoulder
hanger requires to
change (from flutes to
thru’ holes)
Calculation 4
9-5/8” Hanger load
Calculation 5 shoulder
13-3/8” Hanger weakest
point Calculation 6
Landing Ring
BHP Algeria ROD 6650 psi

LOAD SHOULDER CALCULATIONS

The following table defines the limitations of each load shoulder. The calculations
are in accordance with API 6A and follow the guidelines laid out in the John
Fowler "Design Handbook for API 6A/16A/17D"

Component Load Actual Percenta FMC


Capacity Loading ge of Calculation
Allowable Reference
Tubing Hanger load
980,000 lbs 960,000 lbs 97 % Calculation 1
shoulder (Refer to
Note 1)
7” Hanger to 9-5/8”
1,900,000 lbs 869,000 lbs 45 % Calculation 2
Hanger load shoulder
9-5/8” Packoff to 9-
1,380,000 lbs 677,100 lbs 45% Calculation 3
5/8” Hanger load
shoulder
9-5/8” Hanger load
1,062,000 lbs 1,016,640 lbs 95 % Calculation 4
shoulder (Refer to
Note 2)
13-3/8” Hanger
1,000,000 lbs 724,893 lbs 72% Calculation 5
weakest point
Landing Ring
1,000,000 lbs 814,130 lbs 81% Calculation 6
Latch Ring
680,000 lbs 502,900 lbs 73% Calculation 7
Lockdown Screws
Applied Pressure Applied Pressure 83% Calculation 8
Capacity Capacity
6650 psi 7999 psi

Note 1 The Tubing Spool load shoulder should not be loaded with a pressure greater than 6650 psi
applied across the bore. If testing above 6650 psi a high strength load ring requires to be fitted.

Note 2 This hanger has 4-off flowby slots which has the effect of greatly reducing the bearing area and
as a consequence the capacity of the hanger. The alternative hanger has thru’ holes instead of
slots thus maximizing the bearing area and increasing the hanger capacity, This type of hanger
is used in 10K applications.

Note 3 The calculations are based on the following casing loadings (mud buoyancy is not taken into
account)

13-3/8” 400 metres @ 68 lb/ft


9-5/8” 2200 metres @ 47 lb/ft
7” 2750 metres @ 29 lb/ft
4-1/2” 3000 metres @ 12.6 lb/ft
CASING HANGER LOAD SHOULDER ANALYSIS, BHP
To API 6A/16A/17D 4-1/2" TUBING HANGER
This set of calculations considers a hoop stress induced failure and a shear stress induced failure.

Worst Case loading


on shoulder is due to
BOP Test at 6650 psi.
The load shoulder is
designed for a
maximium rating of
6650 psi. If pressure
testing above 6650 psi
(e.g. 10,000 psi) a
high strength load ring
requires to be fitted.

N.B. On no account
should a pressure
greater than 6650 psi
be applied to the plug

Input Data
Maximum ID of shoulder surface
ID := 13.130
Minimum OD of mating part
(in inches)
OD := 13.453
OD of shoulder (in inches)
DT := 13.505
OD of head (in inches)
ODH := 19.094
Wall thickness at large end
of shoulder (in inches)
ODH − DT
T1 := T1 = 2.795
2
Wall thickness at small end
of shoulder (in inches)
ODH − ID
T2 := T2 = 2.982
2

Diameter to point of contact (in inches) BOP Test Plug situated at Tub Hgr load shldr
OD ID
D := + D = 13.291 PT := 13.505 THOD := 0
2 2

04/09/2002 Page 1 of 4 Calculation 1.mcd


Angle from vertical in degrees (input range of angles to be considered) θ Where θ := 45
Worst Case Total Loading is BOP Test, no Tubing
Angle from vertical in radians

π
θ r := θ ⋅
180
Test Pressure (In psi)
p := 6650

Pressure End Load (in lb-f)


( ) ⋅p Fc := 0 lbs
2 2
π⋅ PT − THOD
PED :=
4
Axial force (in lb-f) acting on taper
Fa := PED + Fc Fc = 0
Coefficient of friction (dimensionless)
PED = 952578 lbs
f := 0.15
Fa = 952578
Minimum Yield Strength of Material (psi)
Sy := 60000
Minimum Tensile Strength of Material (psi)
St := 85000
Calculated Data

Effective angle, summing the friction angle and the taper angle, up to 90 deg max.

0 (
A := arctan( f ) + θ r ) A = 0.934
0
π
A := A = 1.571
1 2 1

Aeff := min( A ) Aeff = 0.934


Bearing Stress

−Fa
Sb :=
(
 π⋅ OD2 − ID2 
 
)
 4 

Sb = −141255.156 Fc = 0

Allowable Limit = 1.7 x Min.Tensile Strength - Justification FMC Design Documentation on


UWD-15 Wellhead Housing, Section D, Bearing Stresses.

Sbmaxy := −1.7⋅ St Sbmaxy = −144500 psi


Sb
%age of allowable %All := ⋅ 100
Sbmaxy

%All = 97.754 %

04/09/2002 Page 2 of 4 Calculation 1.mcd


Hoop force in wall due to axial force acting on taper.

Fa
Fh :=
( 2⋅ π⋅ tan( Aeff ) )

Metal Area Resisting Hoop Stress - Based on the 45 deg rule which assumes that the
horizontal reaction force in a support shoulder is carried by the material within a 45 deg
cone of the support surface.

A1 := 0⋅ ( T1)
2

( )
Lt := ( DT − ID) ⋅ cotan θ r ⋅ 0.5

A2 := 0.5⋅ ( T1 + T2) ⋅ Lt
2
A3 := 0.5⋅ T2

Ah := A1 + A2 + A3
Ah = 4.988

Membrane Hoop Stress

Fh
Sh :=
Ah

Metal Area Resisting Radial Stress - Based on the 45 deg rule which assumes that the
radial reaction force in a support shoulder is carried by the material between the centre lines
of the thick and thin section with load acting at diameter D (Point of contact between hanger
and head).

T2
h := + Lt
2

Membrane Radial Stress

−Fa
Sr :=
h ⋅ π⋅ D⋅ tan( Aeff )

04/09/2002 Page 3 of 4 Calculation 1.mcd


Local Membrane Stress Intensity

Pl := Sh − Sr Pl = 32512.396 psi θ = 45 Fc = 0

Allowable Limit = Yield Strength of Material


Allowable Limit SLM SLM := Sy
SLM = 60000 psi

Pl
%age of allowable %All := ⋅ 100
SLM

%All = 54.187 %

Maximum Half-Angle Shear Stress

2
 θr 
sin  
Ss := ( −Sb ) ⋅
 2 θ = 45 Fc = 0
( )
sin θ r

Ss = 29254.901 psi

Allowable limit = 0.577 x Yield Strength of Material

Ssmax := 0.577⋅ Sy

Ssmax = 34620 psi

Ss
%age of allowable %All := ⋅ 100
Ssmax

%All = 84.503 %

04/09/2002 Page 4 of 4 Calculation 1.mcd


CASING HANGER LOAD SHOULDER ANALYSIS, BHP
To API 6A/16A/17D 7" CASING HANGER TO PACKOFF
This set of calculations considers a hoop stress induced failure and a shear stress induced failure.

Worst case loading on this shoulder will be when


the packoff above is installed and a pressure of 6650
psi acts across the packoff combined with the
7"Casing Weight (ROD 7" Casing Load - 2750 m of
29 lb/ft casing = 261,647 lbs) Load Shoulder
supporting 7" Casing
Total loading with 6650 psi across the packoff and
casing weight of 261,647 lbs is 869,000 lbs.
Capacity of load shoulder is 1,900,000 lbs
however capacity of main 9-5/8" load shoulder is
only 1,062,000 lbs

Input Data
Maximum ID of shoulder surface
ID := 12.000
Minimum OD of mating part
(in inches)
OD := 12.740
OD of shoulder (in inches)
DT := 13.086
OD of head (in inches)
ODH := 19.094
Wall thickness at large end
of shoulder (in inches)
ODH − DT
T1 := T1 = 3.004
2
Wall thickness at small end
of shoulder (in inches)
ODH − ID
T2 := T2 = 3.547
2

Diameter to point of contact (in inches) Area under loading at packoff


OD ID
D := + D = 12.37 PT := 13.092 THOD := 7.423
2 2

04/09/2002 Page 1 of 4 Calculation 2.mcd


Angle from vertical in degrees (input range of angles to be considered) θ Where θ := 45
Worst Case Total Loading is 7" Casing
Angle from vertical in radians
7" Casing Load Fc := 261647 lbs
π
θ r := θ ⋅
180
Test Pressure (In psi)
p := 6650

Pressure End Load (in lb-f)

PED :=
(
π⋅ PT − THOD
2 2 ) ⋅p
4
Axial force (in lb-f) acting on taper
Fa := PED + Fc
Coefficient of friction (dimensionless)
PED = 607421 lbs
f := 0.15
Minimum Yield Strength of Material (psi)
Sy := 75000
Minimum Tensile Strength of Material (psi)
St := 95000
Calculated Data

Effective angle, summing the friction angle and the taper angle, up to 90 deg max.

0 (
A := arctan( f ) + θ r ) A = 0.934
0
π
A := A = 1.571
1 2 1

Aeff := min( A ) Aeff = 0.934


Bearing Stress

−Fa
Sb :=
(
 π⋅ OD2 − ID2 
 
)
 4 

Sb = −60441.085 Fc = 261647

Allowable Limit = 1.4 x Min.Tensile Strength

Sbmaxy := −1.4⋅ St Sbmaxy = −133000 psi


Sb
%age of allowable %All := ⋅ 100
Sbmaxy

%All = 45.444 %

04/09/2002 Page 2 of 4 Calculation 2.mcd


Hoop force in wall due to axial force acting on taper.

Fa
Fh :=
( 2⋅ π⋅ tan( Aeff ) )

Metal Area Resisting Hoop Stress - Based on the 45 deg rule which assumes that the
horizontal reaction force in a support shoulder is carried by the material within a 45 deg
cone of the support surface.

A1 := 0⋅ ( T1)
2

( )
Lt := ( DT − ID) ⋅ cotan θ r ⋅ 0.5

A2 := 0.5⋅ ( T1 + T2) ⋅ Lt
2
A3 := 0.5⋅ T2

Ah := A1 + A2 + A3
Ah = 8.069

Membrane Hoop Stress

Fh
Sh :=
Ah

Metal Area Resisting Radial Stress - Based on the 45 deg rule which assumes that the
radial reaction force in a support shoulder is carried by the material between the centre lines
of the thick and thin section with load acting at diameter D (Point of contact between hanger
and head).

T2
h := + Lt
2

Membrane Radial Stress

−Fa
Sr :=
h ⋅ π⋅ D⋅ tan( Aeff )

04/09/2002 Page 3 of 4 Calculation 2.mcd


Local Membrane Stress Intensity

Pl := Sh − Sr Pl = 19805.112 psi θ = 45 Fc = 261647

Allowable Limit = Yield Strength of Material


Allowable Limit SLM SLM := Sy
SLM = 75000 psi

Pl
%age of allowable %All := ⋅ 100
SLM

%All = 26.407 %

Maximum Half-Angle Shear Stress

2
 θr 
sin  
Ss := ( −Sb ) ⋅
 2 θ = 45 Fc = 261647
( )
sin θ r

Ss = 12517.759 psi

Allowable limit = 0.577 x Yield Strength of Material

Ssmax := 0.577⋅ Sy

Ssmax = 43275 psi

Ss
%age of allowable %All := ⋅ 100
Ssmax

%All = 28.926 %

04/09/2002 Page 4 of 4 Calculation 2.mcd


CASING HANGER LOAD SHOULDER ANALYSIS, BHP
To API 6A/16A/17D 9-5/8" PACKOFF FLAT SHOULDER
This set of calculations considers a hoop stress induced failure and a shear stress induced failure.

Load Shoulder supporting 9-5/8" Packoff


Total capacity of load shoulder is 1,380,000 lbs
Worst case loading is BOP Test Plug, where
pressure load is 677,000 lbs

Input Data
Maximum ID of shoulder surface
ID := 11.346
Minimum OD of mating part
(in inches)
OD := 12.591
OD of shoulder (in inches)
DT := 12.591
OD of head (in inches)
ODH := 12.591
Wall thickness at large end
of shoulder (in inches)
ODH − DT
T1 := T1 = 0
2
Wall thickness at small end
of shoulder (in inches)
ODH − ID
T2 := T2 = 0.622
2

Diameter to point of contact (in inches) BOP Test Plug situated at Tub Hgr load shldr
OD ID
D := + D = 11.968 PT := 13.130 THOD := 0
2 2

04/09/2002 Page 1 of 4 Calculation 3.mcd


Angle from vertical in degrees (input range of angles to be considered) θ Where θ := 90

Angle from vertical in radians Worst Case Total Loading is BOP Test Plug, where Fc,
casing load would be zero.
π
θ r := θ ⋅
180
Fc := 0
Test Pressure (In psi)
p := 5000

Pressure End Load (in lb-f)

PED :=
(
π⋅ PT − THOD
2 2 ) ⋅p
4
Axial force (in lb-f) acting on taper
Fa := PED + Fc Fc = 0
Coefficient of friction (dimensionless)
PED = 677001 lbs
f := 0.15
Fa = 677001
Minimum Yield Strength of Material (psi)
Sy := 75000
Minimum Tensile Strength of Material (psi)
St := 95000
Calculated Data

Effective angle, summing the friction angle and the taper angle, up to 90 deg max.

0 (
A := arctan( f ) + θ r ) A = 1.72
0
π
A := A = 1.571
1 2 1

Aeff := min( A ) Aeff = 1.571


Bearing Stress

N.B. There are 4-off 3" slots provided in the casing hanger to cater for drilling returns

−Fa
Sb :=
( )
 π⋅ OD2 − ID2   OD ID 
 − −  ⋅ 4⋅ 3
 4   2 2 
Sb = −42482.243 Fc = 0

Allowable Limit = 1.0 x Min.Tensile Strength

Sbmaxy := −1.0⋅ St Sbmaxy = −95000 psi


Sb
%age of allowable %All := ⋅ 100
Sbmaxy

%All = 44.718 %

04/09/2002 Page 2 of 4 Calculation 3.mcd


Hoop force in wall due to axial force acting on taper.

Fa
Fh :=
( 2⋅ π⋅ tan( Aeff ) )

Metal Area Resisting Hoop Stress - Based on the 45 deg rule which assumes that the
horizontal reaction force in a support shoulder is carried by the material within a 45 deg
cone of the support surface.

A1 := 0⋅ ( T1)
2

( )
Lt := ( DT − ID) ⋅ cotan θ r ⋅ 0.5

A2 := 0.5⋅ ( T1 + T2) ⋅ Lt
2
A3 := 0.5⋅ T2

Ah := A1 + A2 + A3
Ah = 0.194

Membrane Hoop Stress

Fh
Sh :=
Ah

Metal Area Resisting Radial Stress - Based on the 45 deg rule which assumes that the
radial reaction force in a support shoulder is carried by the material between the centre lines
of the thick and thin section with load acting at diameter D (Point of contact between hanger
and head).

T2
h := + Lt
2

Membrane Radial Stress

−Fa
Sr :=
h ⋅ π⋅ D⋅ tan( Aeff )

04/09/2002 Page 3 of 4 Calculation 3.mcd


Local Membrane Stress Intensity

− 11
Pl := Sh − Sr Pl = 3.759 × 10 psi θ = 90 Fc = 0

Allowable Limit = Yield Strength of Material


Allowable Limit SLM SLM := Sy
SLM = 75000 psi

Pl
%age of allowable %All := ⋅ 100
SLM

− 14
%All = 5.012 × 10 %

Maximum Half-Angle Shear Stress

2
 θr 
sin  
Ss := ( −Sb ) ⋅
 2 θ = 90 Fc = 0
( )
sin θ r

Ss = 21241.122 psi

Allowable limit = 0.577 x Yield Strength of Material

Ssmax := 0.577⋅ Sy

Ssmax = 43275 psi

Ss
%age of allowable %All := ⋅ 100
Ssmax

%All = 49.084 %

04/09/2002 Page 4 of 4 Calculation 3.mcd


CASING HANGER LOAD SHOULDER ANALYSIS, BHP
To API 6A/16A/17D 9-5/8" CASING HANGER TO UNIHEAD
This set of calculations considers a hoop stress induced failure and a shear stress induced failure.

Load Shoulder supporting worst case


condition of BOP Test Plug @ 5000 psi
plus 9-5/8" Casing Weight
N.B. Pressure Test Loading equates to 677,000 lbs.
Total capacity of load shoulder is 1,062,000 lbs
leaving a capacity of 385,000 lbs for 9-5/8" Casing,
Actual Casing weight is 339,000 lbs

N.B. When running the 7" Casing, the BOP Test


Plug lands on the separate Tubing Hanger Load
Shoulder. Therefore in the case of having 7" and
9-5/8" casing the total capacity for the 2 Strings is
1,062,000 lbs

Input Data
Maximum ID of shoulder surface
ID := 12.520
Minimum OD of mating part
(in inches)
OD := 13.086
OD of shoulder (in inches)
DT := 13.130
OD of head (in inches)
ODH := 19.094
Wall thickness at large end
of shoulder (in inches)
ODH − DT
T1 := T1 = 2.982
2
Wall thickness at small end
of shoulder (in inches)
ODH − ID
T2 := T2 = 3.287
2

Diameter to point of contact (in inches) BOP Test Plug situated at Tub Hgr load shldr
OD ID
D := + D = 12.803 PT := 13.130 THOD := 0
2 2

04/09/2002 Page 1 of 4 Calculation 4.mcd


Angle from vertical in degrees (input range of angles to be considered) θ Where θ := 45
Worst Case Total Loading is BOP Test Plug + 9-5/8 Casing
Angle from vertical in radians
Worst case 9-5/8" Casing Load, 47 lb/ft @ 2200
π
θ r := θ ⋅
180
Test Pressure (In psi) Fc := 339000 lbs
p := 5000

Pressure End Load (in lb-f)

PED :=
(
π⋅ PT − THOD
2 2 ) ⋅p
4
Axial force (in lb-f) acting on taper
5
Fa := PED + Fc Fc = 3.39 × 10
Coefficient of friction (dimensionless)
PED = 677001 lbs
f := 0.15
Fa = 1016001
Minimum Yield Strength of Material (psi)
Sy := 75000
Minimum Tensile Strength of Material (psi)
St := 95000

Calculated Data

Effective angle, summing the friction angle and the taper angle, up to 90 deg max.

0 (
A := arctan( f ) + θ r ) A = 0.934
0
π
A := A = 1.571
1 2 1

Aeff := min( A ) Aeff = 0.934

Bearing Stress
N.B. There are 4-off 3" slots provided in the casing hanger to cater for drilling returns

−Fa
Sb :=
( )
 π⋅ OD2 − ID2   OD ID 
 − −  ⋅ 4⋅ 3
 4   2 2 

Sb = −127210.466 Fc = 339000

Allowable Limit = 1.4 x Min.Tensile Strength

Sbmaxy := −1.4⋅ St Sbmaxy = −133000 psi


Sb
%age of allowable %All := ⋅ 100
Sbmaxy

%All = 95.647 %

04/09/2002 Page 2 of 4 Calculation 4.mcd


Hoop force in wall due to axial force acting on taper.

Fa
Fh :=
( 2⋅ π⋅ tan( Aeff ) )

Metal Area Resisting Hoop Stress - Based on the 45 deg rule which assumes that the
horizontal reaction force in a support shoulder is carried by the material within a 45 deg
cone of the support surface.

A1 := 0⋅ ( T1)
2

( )
Lt := ( DT − ID) ⋅ cotan θ r ⋅ 0.5

A2 := 0.5⋅ ( T1 + T2) ⋅ Lt
2
A3 := 0.5⋅ T2

Ah := A1 + A2 + A3
Ah = 6.358

Membrane Hoop Stress

Fh
Sh :=
Ah

Metal Area Resisting Radial Stress - Based on the 45 deg rule which assumes that the
radial reaction force in a support shoulder is carried by the material between the centre lines
of the thick and thin section with load acting at diameter D (Point of contact between hanger
and head).

T2
h := + Lt
2

Membrane Radial Stress

−Fa
Sr :=
h ⋅ π⋅ D⋅ tan( Aeff )

04/09/2002 Page 3 of 4 Calculation 4.mcd


Local Membrane Stress Intensity

Pl := Sh − Sr Pl = 28379.461 psi θ = 45 Fc = 339000

Allowable Limit = Yield Strength of Material


Allowable Limit SLM SLM := Sy
SLM = 75000 psi

Pl
%age of allowable %All := ⋅ 100
SLM

%All = 37.839 %

Maximum Half-Angle Shear Stress

2
 θr 
sin  
Ss := ( −Sb ) ⋅
 2 θ = 45 Fc = 339000
( )
sin θ r

Ss = 26346.15 psi

Allowable limit = 0.577 x Yield Strength of Material

Ssmax := 0.577⋅ Sy

Ssmax = 43275 psi

Ss
%age of allowable %All := ⋅ 100
Ssmax

%All = 60.881 %

04/09/2002 Page 4 of 4 Calculation 4.mcd


CASING HANGER LOAD SHOULDER ANALYSIS,
To API 6A/16A/17D 13-3/8" HANGER WEAKEST POINT
This set of calculations considers a hoop stress induced failure and a shear stress induced failure.
Hanger is designed to support a total load in excess of 1,000,000 lbs load
Input Data
Maximum ID of shoulder surface
ID := 13.507
Minimum OD of mating part
(in inches)
OD := 14.200
OD of shoulder (in inches)
DT := 14.200
OD of head (in inches)
ODH := 14.200
Wall thickness at large end
of shoulder (in inches)
Weakest section
ODH − DT
T1 := T1 = 0 of 13-3/8" Hanger
2 supports 1,000,000 lbs
Wall thickness at small end
of shoulder (in inches)
ODH − ID
T2 := T2 = 0.346
2

Diameter to point of contact (in inches)


OD ID
D := + D = 13.854
2 2
Load Shoulder is not affected by Internal Pressure testing
PT := 13.505 THOD := 0

Angle from vertical in degrees (input range of angles to be considered) θ Where θ := 90

Angle from vertical in radians Worst case loading will be 1,000,000 lbs
Fc := 1000000
π
θ r := θ ⋅
180
Test Pressure (In psi)
p := 0

Pressure End Load (in lb-f)

PED :=
( 2
π⋅ PT − THOD ) ⋅p
2

4
Axial force (in lb-f) acting on taper
6
Fa := PED + Fc Fc = 1 × 10
Coefficient of friction (dimensionless)
PED = 0 lbs
f := 0.15
Fa = 1000000
Minimum Yield Strength of Material (psi)
Sy := 75000
Minimum Tensile Strength of Material (psi)
St := 95000

04/09/2002 Page 1 of 4 Calculation 5.mcd


Calculated Data

Effective angle, summing the friction angle and the taper angle, up to 90 deg max.

0 (
A := arctan( f ) + θ r ) A = 1.72
0
π
A := A = 1.571
1 2 1

Aeff := min( A ) Aeff = 1.571

Bearing Stress

−Fa
Sb :=
(
 π⋅ OD2 − ID2 
 
)
 4 

6
Sb = −66311.275 Fc = 1 × 10

Allowable Limit = 1.0 x Min.Tensile Strength

Sbmaxy := −1.0⋅ St Sbmaxy = −95000 psi


Sb
%age of allowable %All := ⋅ 100
Sbmaxy

%All = 69.801 %

04/09/2002 Page 2 of 4 Calculation 5.mcd


Hoop force in wall due to axial force acting on taper.

Fa
Fh :=
( 2⋅ π⋅ tan( Aeff ) )

Metal Area Resisting Hoop Stress - Based on the 45 deg rule which assumes that the
horizontal reaction force in a support shoulder is carried by the material within a 45 deg
cone of the support surface.

A1 := 0⋅ ( T1)
2

( )
Lt := ( DT − ID) ⋅ cotan θ r ⋅ 0.5

A2 := 0.5⋅ ( T1 + T2) ⋅ Lt
2
A3 := 0.5⋅ T2

Ah := A1 + A2 + A3
Ah = 0.06

Membrane Hoop Stress

Fh
Sh :=
Ah

Metal Area Resisting Radial Stress - Based on the 45 deg rule which assumes that the
radial reaction force in a support shoulder is carried by the material between the centre lines
of the thick and thin section with load acting at diameter D (Point of contact between hanger
and head).

T2
h := + Lt
2

Membrane Radial Stress

−Fa
Sr :=
h ⋅ π⋅ D⋅ tan( Aeff )

04/09/2002 Page 3 of 4 Calculation 5.mcd


Local Membrane Stress Intensity

− 10 6
Pl := Sh − Sr Pl = 1.705 × 10 psi θ = 90 Fc = 1 × 10

Allowable Limit = Yield Strength of Material


Allowable Limit SLM SLM := Sy
SLM = 75000 psi

Pl
%age of allowable %All := ⋅ 100
SLM

− 13
%All = 2.273 × 10 %

Maximum Half-Angle Shear Stress

2
 θr 
sin   6
Ss := ( −Sb ) ⋅
 2 θ = 90 Fc = 1 × 10
( )
sin θ r

Ss = 33155.638 psi

Allowable limit = 0.577 x Yield Strength of Material

Ssmax := 0.577⋅ Sy

Ssmax = 43275 psi

Ss
%age of allowable %All := ⋅ 100
Ssmax

%All = 76.616 %

04/09/2002 Page 4 of 4 Calculation 5.mcd


Load Ring Printed: 22/08/2001

Page 1
Load Ring Printed: 22/08/2001

Page 2
Load Ring Printed: 22/08/2001

Page 3
Load Ring Printed: 22/08/2001

Figure 1 - Support Ring

Page 4
Load Ring Printed: 22/08/2001

Page 5
Load Ring Printed: 22/08/2001

Page 6
Load Ring Printed: 22/08/2001

Page 7
Load Ring Printed: 22/08/2001

Page 8
Load Ring Printed: 22/08/2001

Page 9
CASING HANGER LOAD SHOULDER ANALYSIS, BHP
To API 6A/16A/17D CM Latch @ 6650 psi
This set of calculations considers a hoop stress induced failure and a shear stress induced failure.

Input Data
Maximum ID of shoulder surface
ID := 9.000
Minimum OD of mating part
(in inches)
OD := 9.364

Seal Diameter (PT) at CM Latch


PT := 9.813

Test Pressure (In psi)


p := 6650

Pressure End Load (in lb-f)

PED :=
( 2) ⋅p
π⋅ PT
4

Minimum Yield Strength of Material (psi)


Sy := 110000
Minimum Tensile Strength of Material (psi)
St := 130000

Calculated Data

Bearing Stress

−PED
Sb :=


(
 π⋅ OD2 − ID2 

) 5
PED = 5.029 × 10
 4 

Sb = −95798.029

Allowable Limit = 1.0 x Min.Tensile Strength

Sbmaxy := −1.0⋅ St Sbmaxy = −130000 psi


Sb
%age of allowable %All := ⋅ 100
Sbmaxy

%All = 73.691 %

04/09/2002 Page 1 of 4 Calculation 7.mcd


Shear Stress, τ, is given by the following
Thickness of lockring Ds
t := 0.65

Diameter at point of Shear, Ds


Ds := 9.000

Shear Area, Ats


Ats := π⋅ Ds ⋅ t

Ats = 18.378
PED
τ :=
Ats

Allowable Shear Stress, σΑ


σA := 0.6⋅ Sy
σA = 66000 psi

Percentage of Allowable Shear Stress, PAS

PAS := 
 τ  100

 σA 
PAS = 41.463 %

04/09/2002 Page 2 of 4 Calculation 7.mcd


LOCKDOWN SCREW CAPACITY (6650 PSI) ANALYSIS, BHP
To API 6A/16A/17D 4-1/2" TUBING HANGER

Tubing Hanger is held in place by 10-off 1.29" Diameter Lock Down Screws each having a
capacity of 101,945 lbs and 130,000 psi (Reference Calculation below and FMC Guideline
G20.24)

Using H2S Service Lockdown Screws, SYMS, Minimum Yield Strength is 130000 psi

SMYS := 130000 Dr := 1.29

 π⋅ Dr2 
Fr :=   ⋅ SMYS⋅ 0.6
 4 
Fr = 101945
Maximum Capacity of N-off Lockdown Screws (Ft), where N := 10
Ft := N⋅ Fr
Ft = 1019445 lbs

04/09/2002 Page 1 of 4 Calculation 8.mcd


The maximum pressure is established using the following calculation where Pr is maximum
allowable pressure, N is number of engaged lockdown screws, A is area under pressure and
SF is the minimum safety factor

OD := 13.51 in ID := 4.5 in

A :=
( 2
π⋅ OD − ID
2)
4

A = 127.447 in sq SF := 1

N⋅ Fr
Pr :=
( A ⋅ SF)

Pr = 7999 psi

Thus 130,000 psi yield lockdown screws are suitable for 6650 psi applications

04/09/2002 Page 2 of 4 Calculation 8.mcd