Casing Design i.

If only have to consider shut in conditions, use P-Z diagram

ii. If you have to consider circulating out a kick:
General Notes - Solve bubble equation for hinf
API Casing Range - OR, use P-Z diagram for casing setting depth
Length Avg Length Length Avg Length shown above, but have to iterate for different
Range volumes until right shoe depth is found (time
(m) (m) (ft) (ft)
1 4.9-7.6 6.7 16.1-25 22 consuming!!!)
2 7.6-10.4 9.4 25-34.1 30.8
Load Cases
3 >10.4 12.8 >34.1 42
External Pressure Profile - Drilling
 Mixwater: 8.5ppg, or 0.442psi/ft, Freshwater: 0.433psi/ft
 Initial drilling fluid gradient down to TOC
 1 psi = 6.895 kPa, 1 N = 0.2248 lbf, 1 lbf = 4.448 N
 Pore pressure gradient below TOC if opposite rock
 Mix water gradient below TOC if opposite casing
Design Factors
Tensile = 1.3
Cement Quality
Burst = 1.1
 If not stated, use bond quality that gives worst case
Collapse = 1.0
 If stated in question, use it
TriAxial = 1.25
NOTE: Applies for production, but degrade annular fluid to base density!
Weak Pup Joint
- Bentonite and Brine do not deteriorate, only OBM and
 Look to see if triaxial analysis shows that burst capacity of pup joint is
polymer
sufficient
 If it is still not sufficient, some things to consider if you decide to drill
Good/Bad Cement - No Reservoir
ahead:
1) Kick drills with crews to minimize size of influx
 If weak pup joint is not strong enough for full displacement to gas, but Annulus Fluid
is strong enough to withstand a reasonable size kick:
1) Basically, there is no correct answer, although some good TOC
qualifiers should be noted. Evan a compromise of drilling to the Low Perm Form Cmt Mixwater
top of the sand/shale sequence prior to re-assessing the
situation with respect to equipment availability could be
considered justified. Low Perm Form Cmt Mixwater
2) If drilling is suspended immediately and remedial work executed,
this could take several days just to mobilize the equipment and
personnel required, and several more for the actual operations. Low Perm Form Cmt Mixwater
3) The open hole section drilled to this point may be lost due to
formation instability during repair and will have to be re-drilled
4) But can't just say full evacuation to gas is not realistic, have to Good Cement - Low Pressure Reservoir
consider:
a. Is it exploration or development well (quality offset)
Annulus Fluid
b. Rig kick detection equipment
c. Rig crew experience and performance
d. What MW is possible based on formation strength TOC
e. Calculate the max allowable kick volume Low Perm Form Connect Lines
f. If you recommend to drill ahead, clearly state the risks

Casing Seat Selection with Kick High Perm Form Low Pressure Gradient
 If swabbed kick, assume you strip back to bottom and therefore
Po=1D
Low Perm Form Cmt Mixwater
 If drilling kick, kick intensity = Pdp, therefore Po=Pdp+1D

1. Plot formation strength gradient

2. Calculate hkick, kick, and Ptopkick=Po-hkickkick Good Cement - High Pressure Reservoir

 kick  1 
P ann  Pdp , Annulus Fluid
h kick
TOC
Vinf Connect Lines
hkick  Low Perm Form
Cap OH / DC
High Pressure
3. Given Vkick and knowing Po, choose a new depth for kick: High Perm Form Gradient
a) Influx on bottom
b) Bottom of influx at top of drill collars
c) 1000ft intervals above TD Low Perm Form Cmt Mixwater

4. Calculate the new volume of kick

Poor Cement - Low Pressure Reservoir
PBtmKick VNew  Po VKick
5. Calculate new influx density
Annulus Fluid
 V
Inf  Kick Kick TOC
VNew Low Perm Form Cmt Mixwater
6. Calculate new height of bubble, using calculated volume
7. Calculate pressure at top of bubble Low Pressure
PTop  PBtmKick  hNew  New High Perm Form Gradient
8. Repeat steps for every depth.
9. Point where line crosses formation strength line is minimum Low Perm Form Cmt Mixwater
Annulus Fluid
casing depth point.
10. Table: TOC
DBtmBubble PBtm Bubble Vnew InfNew hNew PTopBubble Depth PTop Poor Cement - High Pressure Reservoir
Low Perm Form Cmt Mixwater
Decide Calc Calc Calc Calc Calc/Plot Calc/Plot

Kick Tolerance High Pressure

 Given shoe depth and formation strength, must determine max influx
High Perm Form Gradient
volume allowed (i.e. kick tolerance).
Low Perm Form Cmt Mixwater
 Ai = X-sectional area of inside of pipe (mm2, in2)
Pe = External pressure (kPa, psi)
Pi = Internal pressure (kPa, psi)

Bending Loads (FL)

Internal Pressure Profile - Drilling
Collapse SI Units
 Partial or Total Losses FL = 0.0061 x do x  x As (daN)
a)Use mud weight to balance high pressures in reservoir, but
depleted reservoir encountered instead Field Units
b)Plot pore pressure of reservoir, or weak zone FL = 218 x do x  x As (lbs)
c) Extend MW gradient from top of weak zone until intersect y-axis
FL = Bending Load (+/-) (daN, lbs)
 Cementing do = Outer diameter of casing (mm, in)
 Salt Loading  = Dogleg severity (deg/30m, deg/100ft)
 Air, foam, aerated drilling As = x-sectional area (mm2, in2)
 Blowout
NOTE:
Burst o o
 Always assume at least 2 doglegs, and add 2 to given
 Full displacement to gas (shut-in at surface) 
a)Use pore pressure at TD, not at top of reservoir
b)Check if shoe breaks down Shock Loads (FS)
c) If exceeds shoe strength, de-rate load to breakdown at shoe and
gas gradient to surface SI Units
d)Mention: FS = 6.1x107 x Vav x As (N)
- Shoe may not break down since we only know "leak-off" point

- May not deplete gas (could plug/charge up) Field Units

- Don't know FSG in exploration wells FS = 2700 x Vav x As (lbs)
 Gas kick (if given)
 Do not consider salt loading when calculating burst FS = Shock Load (+/-) (N, lbs)
Vav = Average running speed (m/sec, ft/sec)
Internal Pressure Profile - Production As = x-sectional area (m2, in2)
Collapse
 Evacuation to atmosphere below packer (plugged perforations) NOTE:
 Partial or losses, drop in brine height above packer to pore pressure  Assume average running speeds of 1m/sec, or 3ft/sec
 Blowout, hole bridges, no internal pressure  Average reciprocation speeds of 0.5 m/sec, 1.5ft/sec
 Gas lift - evacuation to gas above packer, no internal pressure
Total Load Force (FTOT)
Burst
 Tubing leak at surface + 10% or 1000psi, whichever is lower RIH: FTOT = Wa - FB + FL + FS (RIH)
 Below packer: Displacement to hydrocarbons, evac to gas Reciprocate: FTOT = Wa - FB + FL + FS (Reciprocate)
 Do not consider salt loading when calculating burst
General Notes
Drag: Installation load with RIH does not use drag
because it works against shock. However, when
reciprocating, if Drag>FS, then use drag in place of FS to
give a higher load. This would be the scenario of pulling
up, not down.
Connections: Make sure you check connections (DF=1.3)
Casing Selection: If tension check proves that the casing
is not sufficient, increase the grade, not weight. If the
weight is increased, then all the tension calcs will have to
be redone.
Wear: If it is localized wear, it has very little effect on
tensile strength, therefore, can be ignored. State
assumption.

Service Loads

1. Immediately after Bumping Plug

 Different densities inside and outside of casing

 Cement, preflush, etc, push up on bottom of casing

Installation Loads  Displacement fluid pushes against any internal upsets

 Displacement fluid pushes against ID at plug depth

 Self Weight in air (WA)  Bending loads are the same
 Pressure (buoyancy) loads (FB)
 Bending loads (FL) 2. Pressure Test after Bump
 Dynamic drag loads (only if given)  Same as above, but internal pressure has test
 Shock loads (FS) pressure

Pressure Loads/Buoyancy (FB) Pressure Testing

SI Units  You always want to test to max anticipated load, but

FB = 0.0001 x [(Pe x Ae) - (Pi x Ai)] (daN) you have to check certain criteria:
 FP-Test + FStatic < FAllowable
Field Units Where: FStatic = WBuoyed + FL
FB = [(Pe x Ae) - (Pi x Ai)] (lbs) FP-Test = PTest (ID2)(/4)

FB = Pressure Force (daN, lbs)

Ae = X-sectional area of outside of pipe (mm2, in2)
 PTest 
FYield 
1.3   WBuoyed  FL  , has  Check if DP will part if packer slips fail

ID  4 
 



ID CSG  ODDP  PTest 
2 2
Load on DP =
tension as limit 4
 Other limiting factors: +Buoyed DP Weight
a) 91% of the casing burst rating (based on 1.1 DF)
b) The burst rating for casing allowing for design factor  If going to run a liner next, the pressure test prior to
(1.1) and wear, when drilled through drilling out the casing will be based on the maximum
c) The tensile rating of the casing when applying the pressure for drilling the next hole section, and this may
pressure test (above equation) be more than the test for the regular casing.
d) The rating of the cement plugs, for Green cmt tests  Casing pressure tests should be carried out for 10
minutes

Pressure Testing Prior to Drilling Out

 Test to max anticipated burst load that will be seen while
drilling the next hole section
 If going to run a liner next, the pressure test prior to drilling
out the casing will be based on the maximum pressure for
drilling the next hole section, and this may be more than the
test for the regular casing.
 Casing pressure tests should be carried out for 10 minutes
Pressure Testing with a Retrievable Packer (RTTS)
Procedure:
1. Test all surface lines prior to any pressure test.
2. Visually check RTTS slips and rubber element.
3. Lock open circulating valve and ensure J slot in locked
position.
4. RIH with no right hand rotation.
5. Run below setting depth by 15ft.
6. Pick up to depth and set packer with right hand rotation.
7. Holding RH torque, slack off until tool takes weight.
8. Release torque and slack off weight onto tool.
9. Open circulating valve by turning to right and picking up to
neutral weight. Apply pump pressure.
10. Inch upwards until circulation established.
11. Close rams and perform test in leak off mode.
12. Monitor pressures and return.
13. Once test completed, slack off until tool takes weight and
release RH torque.
14. To POOH pick straight up.
15. To open tool prior to POOH, lower pipe and turn to right.
16. To back out safety joint, shear tension sleeve and apply 10
right hand turns.
General Notes:
If mud in casing is a high density such that a pressure test
would result in a load that is higher at the bottom of the casing,
a retrievable packer must be used
 Set packer at an intermediate depth (preferable at or below
TOC)
 Open side outlet valves on the next annulus so there is no
pressure build-up in that annulus as a result of the casing
expanding during the test (thus, next annulus fluid would be
compressed if not opened to vent)
Keep DP open - this will allow mud to flow up the DP and

Good Rotary Tubulars Mgmt & Special Drilling
Practices
 Tool joint hardbanding is "casing friendly" and is not
tungsten carbide, but rather Armco XT or something
similar.
 Hardbanding is flush or slightly under that of the actual
tool joint OD.
 Mud motors used to reduce total rotation of drillpipe in
csg.
 Drillpipe rubber protectors (centralizers) are used
 Doglegs are monitored closely while drilling the upper
sections to ensure a smooth as possible well trajectory
 Use of rotary steerable in upper hole sections to
reduce doglegs, but use motor in lower sections to
reduce rotations in the casing that has already been
set.
 Centralize casing properly
 Always check burst and collapse of DP. If it is a
concern, pressure up the other side to compensate
and bleed off in an order that makes sense
 Always check tensile rating of DP (or compression,
buckling, if test being applied from below). DP will be
subjected to this pressure if the slips fail, allowing the
DP to move.
 You can then apply a lower test pressure below the
packer. But you would rather not do this because
pressure testing against hard cement may cause the
cement to crack.
Casing Selection
General Notes
 Design Factors:
- Collapse: 1.00
- Burst: 1.10
- Tension: 1.30
- Triaxial: 1.25
Wear
Collapse:
- Question will likely say to disregard wear for collapse
- If question does not say disregard wear, state that the

out if the packer leaks and pressure is inadvertently exerted reduction in collapse resistance is not directly related to the
below the packer % wall thickness reduction and therefore will not attempt to
 Calculate (estimate) how much volume is expected to be make relationship.
pumped in order to reach test pressure Burst:
Close pipe rams - Burst rating is directly proportional to wall thickness


Apply pressure to annulus - Wear may be only over a certain interval, and there may be


 Always check burst and collapse of DP. If it is a concern, different amounts of wear in different locations
pressure up the other side to compensate and bleed off in
an order that makes sense Biaxial Collapse Design
 Always check tensile rating of DP (or compression, 1. Determine internal and external pressures that will create
buckling, if test being applied from below). DP will be the greatest differential collapse pressure.
subjected to this pressure if the slips fail, allowing the DP to 2. Calculate the axial force on the pipe at that depth (static).
move. 3. Determine the temperature profile
 You can then apply a lower test pressure below the packer. 4. Calculate the effective collapse pressure:
But you would rather not do this because pressure testing
against hard cement may cause the cement to crack.
 If possible, you would prefer to achieve pressure test on the  2t 
lower portion of the casing via the green cement pressure Peff  Pe   1  Pi (SI, Field)
test. Proceed with green  D
 Carried out in stages Peff = Effective collapse pressure (kPa, psi)
 Problems may be experienced when trying to set packer in Pe = External pressure (kPa, psi)
high grade casing due to the problem of getting the slips to Pi = Internal pressure (kPa, psi)
bite. t = Nominal wall thickness (mm, in)
 Always make sure to check for drillpipe collapse D = Nominal outside diameter (mm, in)
5. Calculate the stress at that section Triaxial Burst Design

SA = Static Load/AS
Load = Buoyant weight of pipe + bending (kN, lbs)
AS = X-sectional area (m, in)
SA = Axial stress (kPa, lbs)

6. Calculate the corrected yield strength for collapse formula

 2 
YPA  
 YP x 1  0.75
SA  
 0.5
SA  
  YP   YP 
 
YPA = Axial equivalent grade (kPa, psi)
YP = Nominal Yield Strength of pipe (kPa, psi)
e.g. 80,000psi for L-80 casing
SA = Axial stress (kPa, psi)

 Triaxial stress analysis addresses two key factors:

a) The integration of all stresses in the pipe (VME)
b) Analyses service loads, predominately those
associated with pressure and temperature
changes.
7. De-rate the pipe body yield strength for temperatures effects
- Use temperature at that point in casing
1. Find the maximum burst load, usually bullhead kill after
- De-rate YPA that was just calculated
tubing leak during production.
Table 2.2.3 - DLP
2. Look at TOC for maximum compressive loading (worst
Degree OC Degree OF Relative Strength case).
21 70 1 3. Find the static buoyant load (ignoring bending) at this
66 150 0.98 point.
107 225 0.95 4. Find the stress change in the uncemented length of pipe.
149 300 0.93
191 375 0.91
FTemp  EA S T
232 450 0.89

8. Calculate D/t ratio FTemp = Force due to temp change (lbs)

9. Compare against table  = Thermal expansion coefficient
Table 2.2.6 - DLP = 6.9x10-6 oF-1 OR 1.24x10-5 oC-1
D/t Failure Mode Equation AS = X-sectional area of pipe (in2)
Grade Yield Plastic Transition Elastic T = Average change in temp (oF)
E = 30x106psi OR 2.1x108 kPa
K55 0-14.81 14.81-25.01 25.01-37.21 >37.21
NOTE: Take the average of top & bottom prior to
L80 0-13.38 13.38-22.47 22.47-31.02 >31.02
production, and reservoir temperature for during
C95 0-12.85 12.85-21.33 21.33-28.36 >28.36
production.
P110 0-12.44 12.44-20.41 20.41-26.22 >26.22
NOTE: FTemp will be a negative number

10. API Plastic Collapse Model 5. Determine the total compressive load at TOC.

 A  FComp = Buoyant Load + FTemp

PP  YPA   B  C Temperature de-rated YPA
 D t   NOTE: Should be negative number (FTemp is negative)
Table 2.2.4 - DLP
Grade A B C (psi) C (kPa) 6. Find the compressive stress at this point.
K55 2.991 0.0541 1206 8,315
L80 3.071 0.0667 1955 13,480 Comp = FComp/As
C/X95 3.124 0.0743 2404 16,576
G105 3.162 0.0794 2702 18,630 7. Find the compressive bending stress on the ID of the
P110 3.181 0.0819 2852 19,665 pipe.
Q125 3.239 0.0895 3301 22,760
S135 3.278 0.0946 3601 24,829 a= -(183 x 106 x ID x ) [SI]
a = -(218 x 106 x ID x ) [Field]
11. API Transition Collapse Model
a = Change in axial stress (kPa, psi)
ID = Inner diameter of casing (m, in)
 F 
PP  YPA   G Temperature de-rated YPA  = Dogleg severity (deg/30m, deg/100ft)
  D t  
8. Calculate total compressive stress on ID
Table 2.2.5 - DLP
Grade F G
TotalID= Comp + a
K55 1.989 0.0360
L80 1.998 0.0434 NOTE: Should be both negative, leading even bigger
C/X95 2.029 0.0482 negative
G105 2.053 0.0515
P110 2.066 0.0532 9. Find the compressive bending stress on the OD of the
Q125 2.106 0.0582 pipe.
S135 2.133 0.0615
a= -(183 x 106 x OD x ) [SI]
12. Compare this pressure to the maximum expected collapse a = -(218 x 106 x OD x ) [Field]
pressure at that point. If the pressure PP is lower, the casing is
fine. Remember, design factor for collapse is 1.0.
 a = Change in axial stress (kPa, psi)
OD = Outer diameter of casing (m, in)
 = Dogleg severity (deg/30m, deg/100ft)

10. Calculate total compressive stress on OD

TotalOD = Comp + a

NOTE: Should be both negative, leading even bigger

negative

11. Find the radial stress on the inside of the pipe

rID = -Pi (will usually be pressure during hot kill)

12. Find the tangential stress on the inside of the pipe

Pi  A i  A o   2Po A o
 tID 
Ao  Ai

Pi = Internal pressure (kPa, psi)

Po = External pressure (kPa, psi)
Ai = Total internal x-sectional area (mm2, in2)
Ao = Total external x-sectional area (mm2, in2)

13. Find the radial stress on the outside of the pipe

rOD = -Po (outside pressure during hot kill)

14. Find the tangential stress on the outside of the pipe

2Pi A i  Po  A o  A i 
 tOD 
Ao  Ai

15. Find the Equivalent von Mises stress on the inside of the
pipe.

 VME / ID 
  tID  rID  2    tID   TotalID  2    TotalID  rID  2
2
NOTE: Every group should be double subtracting to get an
addition.

16. Find the Equivalent von Mises stress on the outside of the
pipe.

 VME / OD 
  tOD  rOD  2    tOD   TotalOD  2    TotalOD  rOD  2
2
NOTE: Every group should be double subtracting to get an
addition.

17. De-rate the yield stress of the casing for temperature

Table 2.2.3 - DLP

Degree OC Degree OF Relative Strength
21 70 1
66 150 0.98
107 225 0.95
149 300 0.93
191 375 0.91
232 450 0.89
NOTE: For example, 80,000psi for L80 casing

18. Divide the de-rated yield stress by design factor of 1.25.

19. Compare against the VME/ID and the VME/OD. If OK, then casing
passes Triaxial Burst Design.