Module 1: The Well Construction Process Quiz

Hand out Module 1 Quiz

15 minutes to complete

1
Daily Drilling Report Review: Handout

Each day in class students will briefly (5 minutes) review the Daily Drilling
Report to check on well.
Students will continue to plot the time vs depth chart started earlier.
Students will briefly discuss any changes or concerns.

2
Advanced Drilling Techniques
Module 2: Casing Design
Module 2: Casing Design
Lesson 1: Introduction to Casing Learning Part 1
Daily Drilling Report
Tubular Manufacturing
Review Casing Videos (2)
Learning Aid 2.1: API Pipe Specifications Guide
Learning Aid 2.1: Fundamental Units of Conversion
Learning Aid 2.1: Celsius to Fahrenheit
Assignment 2.1: Unit Conversions Add On Metrics
Lesson 2: Introduction to Casing Learning Part 2
Forces on Casing
Basic Design Criteria Steps
Class Activity and Assignment 2.2: Casing Design

4
Module 2: Casing Design
Lesson 3: Casing Performance
Summary
Daily Drilling Report
Casing Design Criteria
Safety Factors
Assignment 2.3: Read Aadnoy pages
26—52
Review Learning Aid 2.1: All
Conversions
Review Learning Aid 2.1: API
Lesson 5: Casing Design
Calculations Using Excel
Learning
Daily Drilling Report
Steps to Design and Select
Casings
Assignment 2.5: Read Aadnoy
pages 52—83
Assignment 2.5: Build an Excel
Spreadsheet to Calculate
Casing Design

Lesson 4: Casing Problems

Daily Drilling Report
Class Application Activity: Example
Casing Calculations Problems
Assignment 2.4: Casing Calculations
Problems

5
Lesson 1: Introduction to Casing Learning (Lecture 1)

http://apkfun.co/casing-drilling-technology.html

6
Lesson 1 Objectives

In this lesson we will:

Describe three methods for manufacturing tubular goods.
Determine casing safety and environmental considerations.
List types, functions and properties of casings.
Using the API Learning Aid 2.1, describe types of steel.
Review Fundamental Units of Conversion Learning Aid 2.1.
Define requirements and select tubulars (casings) from existing
manufactured products.
Describe design constraints, internal and external forces.
Define safety requirements for applying design constraints.
List considerations when designing casing strings.

7
Manufacturing of Casing

Tubular goods are manufactured by three methods:

Seamless Process: The billet of steel passes through a sequence of
rotary piercing mills, plug mills, reelers, and sizing mills.
Electric-Resistance Welding: Cutting, roll forming into a tube, and welding
the edges together along the length of a flat sheet of steel without the
addition of extraneous metal.
Electric Flash Technique: Cutting a sheet of steel to dimensions, forming
the length to a tube, and flashing and pressing the two edges together to
make a weld.

8
Manufacturing Seamless Casing

Manufacture of Seamless Casing

https://www.youtube.com/watch?v=ztcEyel47Kg
9
Casing Programs

Source: http://www.slideshare.net/alaminia/q922de2l06-v1

Example Casing Programs

10
Class Activity: Casing Videos

Instructions:
Review the casing videos
 Oil and Gas Well (6.03 minutes)
 Actual Casing Drilling (5.32 minutes)
Use quiz on Oil and Gas Well Drilling video as a class activity

11
Oil and Gas Well Casing Video: 6 minutes

Videos\AD2014_2_1_ Oil &

Gas Well Casing_video.mp4

AD2015_2_1_ Oil & Gas Well

Casing_video.mp4

12
Casing Drilling Offshore Video: 5 minutes

13
Class Video Review: Review Oil and Gas Well Drilling Video
Questions and Answers
After watching the video, answer the questions:
1. How many different types of casing can be found?
a. a. 2
b. b. 5
c. c. 4
d. d. 6
e. e. 3
2. The size of the ___ and ___ becomes smaller in diameter as
the crew drills the well deeper.

3. The drilling contractor can begin drilling at the surface and can
drill it to the total depth in the first step.
a. True
b. False
4. What is prevented by conductor casing?
14
Class Video Review Cont.

5. What is the work of surface casing?

6. ______________ seals off troublesome zones.

7. Production casing isolates ________

8. _____________ set the depth of the surface hole.

9. What is often the longest section of well?

10. What is a liner?

15
Types of Casing (I will add pictures … seem removed)

The types of casing are as

follows:
Drive Pipe or Structural Pile
(e.g., 36”) (Structural, not
considered normally part of
casing)
Conductor: Needed to
circulate the drilling fluid (e.g.,
20”) (Structural, not
considered normally part of
casing)
1.Pipe sizes and depths are
for illustration purposes, every
well will be designed with a
slightly different pipe diameter
and setting depth.
Source: http://slovenski-
plin.si/pridobivanje-zemeljskega-
plina.html 16
Types of Casing (I will add pictures … seem removed)
1. 1. Surface: Prevents cave-in of unconsolidated weaker near-
surface sediments and protects shallow freshwater sands from
contamination Surface String (13 3/8”)
2. 2. Intermediate: Required in deeper wells that penetrate
abnormally pressured formations, lost-circulation zones, unstable
shale sections, or salt sections (9 5/8”)
3. 3. Oil or Production: The final casing string set in a well
4. 4. Liners: Casing strings that do not extend to the surface, but
are suspended from the bottom of the next larger casing string

5. Pipe sizes and depths are for illustration purposes, every well will
be designed with a slightly different pipe diameter and setting
depth.
***

17
Classification of Casing
Grade (e.g., N-80, P-110, …)
“Letter” N/P, etc. = impurities + heat treating process. In this example, N means there
are a particular set of impurities and heat treating were performed on the steel to give
the steel a certain set of desired properties.
80 is the resulting tensile strength in units of 1000’s of PSI’s. 80 = 80000 lbs per square
inch (PSI) of tensile strength.
OD (e.g., 13 3/8”, 9-5/8”, …)
Outside Diameter of the Tube (OD) is classically measured in units of inches.
Type of Thread (Buttress, Vam, …)
The connection type
Length of Each Joint (e.g., Range 3)
Range 1, 16-25 ft., 18 ft. Minimum length, 6 ft. maximum variation
Range 2, 25-34 ft., 28 ft. minimum length, 5 ft. Maximum variation
Range 3, over 34 ft., 36 ft. minimum length, 6 ft. Maximum variation
Nominal Weight (e.g., 47 lbs/ft, 68 lbs/ft, …)
The weight of 1 foot in length of pipe in dry air.

18
Functions of Casing

The functions of casing are as

follows:
Prevent caving of the hole
Prevent contamination
(usually fresh water)
Isolates producing
formations http://petroleumsupport.com/
mechanical-sticking-
mechanism-of-stuck-pipe/
Pressure control
Confines production to well
bore
Facilitates installation of
sub-surface equipment
(pumps, etc.)
https://sites.google.com/a/students.hpschools.net/hydraulic-
fracturing/the-solution/disadvantages-and-advantages
19
Learning Aid 2.1: API Pipe Specifications

The properties of casing are as follows:

Outside diameter
Wall thickness (determines inside diameter)
Drift diameter
Grade of material
Type of coupling
Length or range
Nominal weight (includes threads and coupling)

Students: Download AD2015_2_1_API_Pipe

Specifications_learning aid from Sharepoint

20
API Screenshot of Properties of 4.5 inch Casing

21
API Screenshot of Properties of Grades of Steel

22
Controlling Casings Properties (Rui: any more detail needed? OK)

The properties of the casing are controlled by:

Deforming the steel past its elastic limit (increases strength in
direction stressed, reduces strength in perpendicular directions)
Control of the normalizing, cooling, quenching and tempering of
the steel
Wall thickness of the tube
Type of steel: Relatively mild (0.3% carbon) steel with additions of
manganese and other materials (Molybdenum, Chromium, Nickel,
Copper, Phosphorous, Sulfur, Silicon) in small amounts is used in
tubular goods

23
Types of Steel

Types of steel are as follows:

F-25
H-40
K-55*
N-80
P-110
V-150
*K-55 and J-55 are interchangeable, new designation is K-55

(Note: Based on minimum yield strength. The letter “J” describes the grade of
material, and the number, e.g. “55" is the minimum yield strength in 1000's
lb./in2)
Use the API Pipe
Specifications
Learning Aid
24
Standardization of Casing

Internationally, the petroleum industry has adopted the American Petroleum

Institute (API) standards for:
Casing
Tubing
Line pipe
The API standard covers seamless and welded casing and tubing, couplings,
pup joints and connectors in all grades, process of manufacture, chemical
and mechanical property requirements, methods of test and dimensions.

25
The Grade Code

The grade code (a letter followed by a number) defines

strength characteristics of pipe. GRADE

The letter provides a unique designation for each grade

adopted and can be thought to represent the manufacturers
K55*
"recipe" for the steel (special chemical additives, S80*
normalizing, and heat treating if any).
H40*
The number in thousands of psi is the minimum yield S80*
strength (tensile stress required to produce a total
elongation per unit length of 0.005 on a standard test H40*
specimen) of the pipe. K55*
S80*
Some special non-API grades were also included in the
analysis; these grades (manufactured by Lone Star Steel K55*
and Mannesmann Tube Co.) have been used in wells that S80*
required extreme tensile strength, special collapse C75
resistance, or high strength with resistance to hydrogen L80*
N80*
sulfide. C90
The tubulars strengths in collapse, burst, and tension are SS95*
dependent upon the wellbore conditions (temperature, S95*
CYS95*
pressure, CO2, H2S, O2, pH)
C95*
26
Length or Range

Range 1, 16-25 ft., 18 ft. Minimum length, 6 ft. maximum variation

Range 2, 25-34 ft., 28 ft. minimum length, 5 ft. Maximum variation
Range 3, over 34 ft., 36 ft. minimum length, 6 ft. Maximum variation

27
API Casing Connectors

API casing connectors are:

Short round threads and couplings (CSG or ST&C)
Long round threads and couplings (LCSG or LT&C)
Buttress threads and couplings (BCSG or BT&C)
Extremeline threads pin and box (XCSG or XP&B)
The OD of the coupling, bit size and drift ID of the
previous casing are compared by the CASING / BIT
SIZE AI module.
Several premium non API connections are available at
considerable cost from manufacturers (Armco, Atlas
Bradford, Hydrill).

http://www.tenaris.com/en/products/premiumconnections.aspx

28
Design of the Casing String

As we get deeper into the design, we need to start looking at the

environment where we are going to place the casing.

292
Forces on Casing: External
External—Tend to collapse casing
Formation gas or liquids
Hydrostatic head behind pipe
Pump pressure behind pipe
Plastic or creeping formations

http://gekengineering.com/Downloads/Free_Downloads/Casi
ng_Design_Hand_Calculation_Design_Example.pdf

https://encrypted-tbn3.gstatic.com/

http://www.connection-mag.com/?p=2361
30
Equivalent Mud Density

31
Collapse

32
Design Constraints: Collapse or External Force
(Crushing)

Wall thickness (greater weights increase wall thickness)

Yield strength (higher grades increase yield strength)
Axial loading (decreases collapse resistance)

Note: Recommended design safety factors

Safety Factor Collapse (SFC) = 1.125

33
Class Activity: Reasons to Run Casing

Onshore - to prevent contamination of fresh water sands

To control pressures during drilling
To provide an acceptable environment for subsurface equipment in producing
wells
To prevent the hole from caving in
To enhance the probability of drilling to total depth (TD)

Question: You need 14 ppg to control a lower zone, but an upper zone will fracture
at 12 lb/gal.
What do you do?

34
Lesson 1 Wrap Up

What is still unclear?

What questions do you have about the topics we have discussed before we
move on?

Homework
Assignment 2.1 Unit Conversions Add on Metrics Worksheet
Review Advanced Drilling Glossary Terms
Review Learning Aid 2.1: Fundamental Units of Conversion
Review Learning Aid 2.1: Celsius to Fahrenheit
Review Learning Aid 2.1: API Guide

35
Daily Drilling Report Review: Handout

Each day in class students will briefly (5 minutes) review the Daily Drilling
Report to check on well.
Students will continue to plot the time vs depth chart started earlier.
Students will briefly discuss any changes or concerns.

36
Lesson 2: Introduction to Casing Learning Part 2
(Lectures 2 & 3)

37
Lesson 2 Objectives

In this lesson we will:

Determine selection of casing setting depths.
Calculate collapse pressure.
Determine forces on casing.
Calculate burst.
Define design constraints.
Determine tension forces on the pipe.
Determine axial tension using different thread types.
List basic design criteria steps.

38
Forces on Casing

How to Determine Casing Setting Depth

External Forces
Collapse Pressure
Sample Collapse Resistant from API Guide Properties of
Casing
Internal Forces
Burst Pressure
How Burst is Calculated
Tension Forces
Connection Forces
Joint Constraints

39
How to Determine Casing Setting Depth

40
External: Collapse Pressure (Miska p. 395)

ri 2  Pi  r02  Pe ( Pi  Pe )  r02  ri 2
r  
r0  ri
2 2
r 2  (r02  ri 2 )

ri  Pi  r  Pe
2 2
( Pi  Pe )  r  ri 2 2
t  0
 0

r0  r
2
i
2
r  (r0  ri )
2 2 2

 d n / t   1 
Pcr  2   yield   2 

 d n / t  
41
Sample Collapse Resistant from API Guide Properties of Casing

Insert page with dimmed portion

and highlighted column or add picture

42
Forces on Casing: Internal

Internal—Tend to burst casing

Producing formation pressure
Hydrostatic head inside pipe
Pump pressure inside pipe

https://encrypted- http://plumbingproblemstoday.blogspot.com/2013/01/pl
tbn2.gstatic.com/images?q=tbn:ANd9GcQxO7zmXe umbing-problems-pipe-noise.html
cgINL-L6VoIj5aDMJk9rPEdPnJLY4-_8VAEQKfBpvevA
43
Burst

44
How Burst is Calculated

45
Design Constraints: Burst or Internal

Wall thickness
Yield strength
Axial loading (has very little effect on burst
resistance)

Note: recommended design safety factors

Safety Factor Burst (SFB) = 1.000

46
Burst Pressure Formula

• F1 = Pbr L dS = Pbr L (d / 2) dq

• F2 = σs t L sin (dq / 2) = σs t L (dq / 2)

 2   yield 
Pbr  0.875   
 dn 

47
Tension Forces

Tension—Tend to part casing and reduces

collapse resistance by:
Weight of pipe (including buoyancy)
Dynamic or shock loads
Reduced temperature
Increased internal pressure (expansion)
Hole friction
Float equipment

48
Tension Forces on the Pipe

49
Design Constraints: Tension or Axial Loading

Body strength (wall area x yield in psi)

Coupling-pull-out (load to shear threads)
Gage point (area under last fully engaged thread x yield in psi)
Notch effect (decreased gage point resistance due to bending threads)

Note: recommended design safety factors

Safety Factor Tension (SFT) = 1.500

50
Axial Tension at Pipe Body and Joint: Round Thread

Axial tension at pipe body

Ften = (/4) σyield (dn2 - d2)

Axial tension at round thread connector

Ften = 0.95 Ajp σult, for fracture
Ften = 0.95 Ajp Let (X + Y), for joint pull out
Ajp = (/4) [(dn-0.1425)2 - d2]
X = 0.74 dn-0.59 σult / ( 0.5 Let + 0.14 dn)
Y = σyield / (Let + 0.14 dn)

51
Axial Tension at Pipe Body and Joint: Buttress Thread

Axial tension at pipe body

Ften = (/4) σyield ∙(dn2 - d2)

Axial tension at buttress thread connector

Ften = 0.95 Ap σult [1.008 - 0.0396 (1.083 - σyield/σult) ∙dn],
for pipe thread failure
Ften = 0.95 Asc σult, for coupling thread failure
Ap = (/4) ∙(dn2- d2), area of steel in pipe body
Asc = (/4) ∙(dc22 - dc12), area of steel in coupling

52
Axial Tension at Pipe Body and Joint: Extreme Line Connector

Axial tension at pipe body

Ften = (/4) σyield (dn2 - d2)

Axial tension at extreme-line connector

Ften = (∙ σult/4) ∙ (dn2- d2), for pipe failure
Ften = (∙ σult/4) ∙ (dj22 - db2), for box failure
Ften = (∙ σult/4) ∙ (dpin2 - dj12), for pin failure

53
Applying Design Constraints: Force Distribution

Maximum tension at the top; suspended weights are

additive
Maximum collapsing force at the bottom; hydrostatic
head and pump pressures are additive.
Maximum bursting pressure at the bottom; hydrostatic
head and pump pressures are additive. Assuming the
internal pressure is produced gas, the same bursting will
be throughout the string.

Note: recommended design safety factors

Safety Factor Tension (SFT) = 1.500

Safety Factor Burst (SFB) = 1.000
Safety Factor Collapse (SFC) = 1.125

54
Basic Design Criteria Steps

1. Determine the grade and weight of pipe needed in the bottom of the
hole based on the collapse resistance with a safety factor. Assume
the maximum collapse pressure will be the hydrostatic pressure of
the hole fluid (usually mud).
2. Determine if the pipe selected will withstand the bursting pressure
with a safety factor. Assume maximum bursting pressure will be the
hydrostatic pressure of the hole fluid (usually mud).
3. Determine the depth to which the next lighter weight pipe could be
used based on effective collapse resistance (including axial loading)
with a safety factor. Assume collapsing pressure will be hydrostatic
pressure of the hole fluid (usually mud).
4. Determine if the next lighter pipe will withstand the bursting pressure
with a safety factor. Assume the bursting is the maximum hydrostatic
pressure of the hole fluid (usually mud) at the bottom of the hole.

55
Casing Design Sequence: tension and hydrostatic pressure variations

56
Basic Design Criteria Steps (Cont.)

5. Determine if the selected coupling (long or short) joint strength or

coupling-pull-out strength at the top of the previous section (bottom
section) will withstand the load at this point with a safety factor.
Assume load will be the dead weight of all the pipe below this point.
6. Determine if the gage point (including notch effect) resistance will
withstand the load at this point with a safety factor. Assume
maximum load will be the dead weight of all the pipe below this point.
7. Determine the depth to which the next lighter weight pipe could be
used based on effective collapse resistance (including axial loading)
with a safety factor. Assume the collapsing pressure will be the
hydrostatic pressure of the hole fluid (usually mud) and the axial load
will be the dead weight of all the pipe below this point.
8. Determine if the next lighter pipe will withstand the bursting pressure
with a safety factor. Assume the bursting pressure will be the
maximum hydrostatic pressure of the hole fluid (usually mud) at the
bottom of the hole.

57
Basic Design Criteria Steps (Cont.)

9. Determine if the selected coupling (long or short) joint strength or

coupling-pull-out strength at the top of the previous section
(intermediate section) will withstand the load at this point with a
safety factor. Assume load will be the dead weight of all the pipe
below this point.
10.Determine if the gage point (including notch effect) resistance will
withstand the load at this point with a safety factor. Assume
maximum load will be the dead weight of all the pipe below this
point.
11.Determine if the selected coupling (long or short) joint strength or
coupling-pull-out strength will withstand the load at the top of the
hole. Assume load will be the dead weight of all the pipe below this
point.
12.Determine if the gage point (including notch effect) resistance will
withstand the load at the top of the hole with a safety factor. Assume
load will be the dead weight of all the pipe below this point.

58
Class Activity and Assignment 2.2: Casing Design

Instructions: Please use the API Learning Aid and look up the
information below. Start in class and complete as homework
as needed.

1. Burst Resistance
Students: Find the API burst resistance for a 16-in, H40 casing, with
nominal weigh of 65 lbf/ft and a nominal thickness of 0.375-in.

2. Collapse-Pressure
Students: Find the API collapse-pressure for a 16-in, H40 casing,
with nominal weigh of 65 lbf/ft and a nominal thickness of 0.375-in.

3. Axial Stress with Bending

Students: Find the maximum axial stress for a 16-in, H40 casing,
with nominal weigh of 65 lbf/ft and a nominal thickness of 0.375-in.
The casing is subject to a 500 000 lbf axial-tension load in a portion
of a directional wellbore having a dogleg severity of 3/100 ft.
Assume a uniform contact between the casing and the borehole wall.

59
Lesson 2 Wrap Up

What is still unclear?

What questions do you have about the topics we have
discussed before we move on?

Homework
Review Advanced Drilling Glossary Terms
Assignment 2.2: Casing Design

60
Daily Drilling Report Review: Handout

Each day in class students will briefly (5 minutes) review the Daily Drilling
Report to check on well.
Students will continue to plot the time vs depth chart started earlier.
Students will briefly discuss any changes or concerns.

61
Lesson 3: Casing Performance Summary

62
Lesson 3 Objectives

In this lesson we will:

Use the API Learning Aid.
Describe the different effects of different factors on drilling.
Define current safety factors.
Determine selection of casing setting depths.
Explain casing design criteria.
Explain why lost circulation is a worst-case situation.
Explain special design considerations.
Review Unit Conversions Learning Aid 2.1 (F to C; Unit Conversions.)

63
Casing Performance Summary

For this lesson, students will be referencing the API Learning Aid

64
Effect of Combined Stress

65
Effect of Combined Stress Formula

ri2  Pi  r02  Pe ( Pi  Pe )  r02  ri2

r   2 2 2
r0  ri
2 2
r  (r0  ri )

ri2  Pi  r02  Pe ( Pi  Pe )  r02  ri2 Center or picture

t   2 2 2
r0  ri
2 2
r  (r0  ri )

 d n / t   1 
Pcr  2   yield   2 

 d n / t   http://imagefriend.com/thick-wall-cylinder-formula.shtm

66
Effect of Axial Tension on Collapse

67
Effect of Bending

The deviation angle from the true vertical and wellbore curvature
causes the axial tension on the string to change.
On the outside of the bend this tension is dramatically increased, on
inside of bend compression is equally increased. In a straight section
with a large vertical deviation angle the tension due to pipe weight is
reduced.
The increased effect is designed for and the reduced effect is
ignored. Increased wellbore friction during pipe movement, both
running and cementing, causes favorable (downward) and
unfavorable (upward) effects.
The upward increased friction is designed for by adding an overpull
force to the free hanging weight of the pipe.
The recent increase in horizontal well drilling has caused major
disagreements among experts on how to calculate the bending
effect, and as a result, this effect is not considered.

68
Effect of Hydrogen Sulfide

Hydrogen embrittlement is caused by hydrogen sulfide gas in the

presence of water.
The hydrogen atom enters the lattice of the steel in high stress areas.
This reduces the ductility and makes the steel brittle so it breaks
instead of yielding.
This corrosion process is accelerated by higher concentrations of
H2S, low temperatures, low pH, high pressure, and the presence of
other reducing agents like CO2, or O2.
The effect is more pronounced in high strength steels with yields
above 90,000 psi or with Rockwell hardness number (RHN) above
22.
Softer more ductile steels, like H 40, J 55, K 55, L-80 which have
maximum yield strengths of 80,000 psi, are selected in corrosive
environments.

69
Safety Factors Summary

Conservativeness begins when severe, anticipated load conditions

are allowed for and increases when the ratings, such as minimum
internal yield pressure and pipe body yield strength, represent the
start of material yielding and not actual material failure.
API collapse ratings appear to be the least conservative of the casing
properties examined because they are based on actual failure data
rather than material yield.
Both burst and tension strength ratings are based on minimum yield
strength and the onset of yielding.
Tension designs are based on a relatively certain minimum
anticipated load. The result of this awkward design approach is a
large tension design factor that is likely to be excessive.
Current safety factors being used by most of the industry are 1.5
(Tension), 1.125 (Collapse) and 1.0 (Burst).

70
History of Safety Factors Table

Author Date Collapse Burst Tension Method

API 1939 1.500 1.50 1.50

API rating 1945 1.125 1.50 1.50 revise rating

Hills 1951 1.125 1.50-2.00 1.1-1.75 survey

Saye 1954 1.000 1.33 1.6-2.00 survey

Saye 1954 0.85‒1.00 1.33 1.28 tests

Moody 1955 1.00‒1.125 1.00-1.33 1.6-2.00 survey

Greenip 1978 1.125 1.10 1.80 cited

Bourgoyne 1986 1.10 1.10 1.60 cited

Payne 1989 1.125 1.00 1.50 probabilistic

71
Casing Design Criteria

The first step in casing design is determining the size of the deepest casing
string that will be run if the well is completed.
The method of artificial lift, the flow rate of the various produced or injected
fluids and the number and sizes of tubing strings that will be placed in the
well throughout its life determine the drift ID of the production casing string.
In addition the flow area for competent cement placement for cased hole
completions should also be checked to determine appropriate relation
between hole size and casing size.
Once the production casing size has been determined the drilling engineer
selects a program of bit sizes, casing sizes, grades, weights, coupling types,
setting depths and mud densities for the safe drilling and completion of the
well.
Combination strings consisting of multiple sections of the same OD with
different steel grade, wall thickness, and connections are the most
economical designs.
The current trend in ultra deep wells is the use of drilling liners and then a
combination production casing running from the bottom back to the surface.

72
Selection of Casing Setting Depths (Methods to Generate Curve
Follow in next slides)

73
Class Activity: How to Calculate Pore Pressure

Seismic Data
Empirical Correlations using Offset Well Data

Example: Depth=12 000 ft, Equivalent Mud Weight=9.6

ppg, Overburden Stress Gradient=1 psi/ft
Calculate:
a) Pore pressure gradient @12000 ft
b) Pore pressure @12000 ft
c) Matrix stress gradient @12000 ft
d) Matrix stress @12000 ft

74
Solution: How to Calculate Pore Pressure

Solution:
a) Pore pressure gradient= 0.052*9.6 = 0.4992 psi/ft
b) Pore pressure @12000 ft = 0.4992 *12000 = 5990 psi
c) Matrix stress gradient

𝑆 𝑃 σ σ
S=P+σ = + = 1 – 0.4992
𝐷 𝐷 𝐷 𝐷

σ
= 0.5008 psi/ft
𝐷

75
Solution: How to Calculate Pore Pressure

Solution cont.:
d) σ at 12,000 ft = 0.5008 * 12,000 = 6,010 psi

76
How to Calculate Fracture Pressure

Hubbert & Willis Method

1 2𝑃
𝐹𝑚𝑖𝑛 = 1+
3 𝐷
1 𝑃
𝐹𝑚𝑎𝑥 = 1 +
2 𝐷
Where,
F: Fracture Gradient, psi/ft
P: Pore pressure, psi
D: Depth, ft

77
How to Calculate Fracture Pressure (Cont.)

Eaton Method

𝑆−𝑃 ν 𝑃
𝐹= × +
𝐷 1−ν 𝐷
Where,
F: Fracture Gradient, psi/ft
ν: Poisson’s Ratio
P: Pore Pressure, psi
D: Depth, ft

78
Example Hubbert and Willis Method: How to Calculate Fracture Pressure

Example:
Depth=11000 ft
Pore Pressure Gradient=0.64 psi/ft
ν = 0.30
a) Hubbert & Willis Method

1 2𝑃 1 𝑝𝑠𝑖
𝐹𝑚𝑖𝑛 = 1+ = 1 + 2 × 0.64 = 0.76 = 14.6 𝑝𝑝𝑔
3 𝐷 3 𝑓𝑡
1 𝑃 1 𝑝𝑠𝑖
𝐹𝑚𝑎𝑥 = 1 + = 1 + 0.64 = 0.82 = 15.8 𝑝𝑝𝑔
2 𝐷 2 𝑓𝑡

79
Example Ben Eaton Method: How to Calculate Fracture Pressure

Example Cont.:
a) Ben Eaton Method

𝑆−𝑃 ν 𝑃 0.30
𝐹= × + = 1 − 0.64 × + 0.64 =
𝐷 1−ν 𝐷 1 − 0.30

𝑝𝑠𝑖
0.79 = 15.3 𝑝𝑝𝑔
𝑓𝑡

80
How to Determine Fracture Pressure: Leak Off Test

Leak Off Test

Run and Cement Casing
Drill out 10 to 20 ft below casing shoe
Close the BOP (pipe ram)
Pump slowly and monitor the pressure

81
How to Calculate Fracture Pressure: Result of Leak Off Test

Pressure vs. Volume

2000

1800

1600

1400

1200
P (psi)

1000
Pressure vs. Voume
800

600

400

200

0
0 2 4 6 8 10 12 14
Volume Injected (bbl)

82
How to Calculate Fracture Pressure: Using the Leak Off Test Results

Example:
In a leak off test the casing was set at 4000 ft, leak off
occurred when the stand pipe pressure (SPP) was 1000
psi. (MW=9.6 ppg)
What is the fracture gradient?
What is the maximum MW can be used to drill next hole?

83
Solution: Using the Leak Off Test Results

Example Cont.:
𝑃𝑙𝑒𝑎𝑘 𝑜𝑓𝑓 = 𝑃ℎ + 𝑆𝑃𝑃 = 0.052 ∗ 9.6 ∗ 4000 + 1000 = 2997 𝑝𝑠𝑖
Fracture Gradient = 2997/4000 = 0.75 psi/ft
Maximum MW = 0.75/0.052 = 14.4 ppg

84
Now we have generated this Picture: Selection of Casing Setting
Depths

85
Casing Requirements

Casing depth requirements are affected by:

Government regulations
Protection of source drinking water zones and existence of lost-circulation
zones
Previously produced low pressure zones (cause of stuck pipe) and plastic
Flowing salt beds

86
Selection of Casing Sizes

The bit size used to drill the production hole must be larger than the OD of the
casing connectors.
The casing string above must have a drift ID larger than the bit used to drill this
lower part of the well.
The casing size and bit size of successively shallower well segments are selected
until the design reaches the surface.

87
Selection of Weight, Grade, and Coupling

The weight, grade, and connections of strings are determined based on the worst
loading conditions anticipated during the life of the well.
A combination string (the least expensive design) is used rather than a design
containing only one weight, grade and coupling. (storage, running errors, downhole
tool options)
Drilling conditions that apply to surface, intermediate and production casing strings
vary; therefore the design criteria for each varies.

88
Casing Bit Casing

89
Determining Casing Design Criteria
Burst design criteria are based on an assumed well-control condition while
circulating out a large volume of formation influx (gas or liquid) normally defined
as a kick.
If the kick gets out of control, the formation-fracture pressure below the casing
seat should be exceeded before the burst pressure of the casing or surface
equipment is reached.
An underground blow out is preferred to a surface blow out which would
endanger rig personnel.
The casing seat pressure is designed to equal the fracture pressure of the
formation at the casing seat.
Cement or high density mud on the outside of the casing is not used because of
the possibility of a poor cement job and mud solid settling that occurs with time.
After the string design has been completed, burst parameters are checked to
ensure burst rating is never exceeded.

90
Casing Design Sequence

91
Collapse Design Criteria

Collapse design criteria are based on the worst lost-circulation problem or

the worst collapse loading possible when the casing is run.
The design of most surface casing cement operations is to bring cement
returns to the surface. This results in an external pressure due to an entire
column of cement and an internal pressure from a column of displacement
fluid (drilling mud).
Collapse pressure is expressed by:
Pcollapse = 0.052 TVDcsg seat (ρcmt - ρmud)
where:
TVD = True Vertical Depth

92
Collapse Pressure

Collapse Pressure

𝑃𝑐 = 𝑃𝑒 − 𝑃𝑖
Worst Case Scenario: 𝑃𝑖 = 0
So, 𝑃𝑐 = 𝑃𝑒 = 0.052 ∗ MW ∗ TVD

Is it always a realistic assumption? Why?

Where 𝑃𝑐 is maximum? Why?

93
How to Calculate Collapse Pressure

At Surface:
𝑃𝑐 = 𝑃𝑒 − 𝑃𝑖 = 0 − 0 = 0

At Casing Shoe:
𝑃𝑐 = 𝑃𝑒 − 𝑃𝑖 = 0.052 ∗ 𝑀𝑊 ∗ 𝐶𝑆𝐷

Where 𝑃𝑐 is maximum?

94
Burst

Burst Pressure
𝑃𝑏 = 𝑃𝑖 − 𝑃𝑒
Two Case:
a) Unlimited Kick
b) Limited Kick (Kick Tolerance)
What are 𝑃𝑖 and 𝑃𝑒 ?
Which case is more realistic? Why?
Where 𝑃𝑏 is maximum? Why?

95
Burst (Cont.) – Rui? second formula should add pressure of internal
fluid

96
Burst (Cont.)

Casing Tensile Strength must be greater than pipe weight which is hung from.
NOTE: Safety factor MUST also be taken into account!
What is worst scenario for tension calculation?
Where in the casing string, tension is maximum? Why?

97
Collapse, Tension, and Burst

Example:
Calculate burst and collapse pressure at surface and casing setting depth
(CSD) for the following problem.

CSD=8000 ft
dPp/dD=0.55 psi/ft
MW=11 ppg

TD=12000 ft
Pp=8500 psi
Gas Gradient=0.1
psi/ft

98
Collapse, Tension, and Burst (Cont.)

Collapse:

@ Surface:
𝑃𝑐 = 𝑃𝑒 − 𝑃𝑖 = 0 − 0 = 0
@ CSD:
𝑃𝑐 = 𝑃𝑒 − 𝑃𝑖 = 0.052 ∗ 𝑀𝑊 ∗ 𝐶𝑆𝐷 = 0.052 ∗ 11 ∗ 8,000 = 4,576 psi

99
Collapse, Tension, and Burst (Cont.)

Burst:
@ Surface:
𝑃𝑏 = 𝑃𝑖 − 𝑃𝑒 = (𝑃𝑝 −0.052 ∗ ρ𝑓2 ∗ 𝑇𝑉𝐷) − 0 = 8500 − 0.1 ∗ 12000 = 7300 𝑝𝑠𝑖
@ CSD:
𝑃𝑏 = 𝑃𝑖 − 𝑃𝑒 = (𝑃𝑝 −0.052 ∗ ρ𝑓2 ∗ (𝑇𝑉𝐷 − 𝐶𝑆𝐷)) − 0.052 ∗ ρ𝑓1 ∗ 𝐶𝑆𝐷
= 8500 − 0.1 ∗ (12000 − 8000) − 0.55 ∗ 8000 = 3700 𝑝𝑠𝑖

100
Collapse, Tension, and Burst (Cont.)(See Learning Aid API p. 15)

Tension:
Axial force has a detrimental effect on casing collapse resistance. So, while
doing casing design, that effect MUST be taken into account.
Example: What would be the 7” casing, 23 lb/ft, K55, if 2000 ft of 7” casing,
23 lb/ft, N80 is hung from?
Weight of 7” casing, N80= 2000 ∗ 23 = 46000 𝑙𝑏𝑠

101
Collapse, Tension, and Burst (Cont.) (See Learning Aid API p. 31 and
32)
Example cont’d:
46000
Axial Load Factor (ALF)= 366000 = 0.126
From the table, we have:
Collapse Strength Reduction Factor (CSRF)=0.960
So, new collapse resistance= 0.96 ∗ 3270 = 3139 𝑝𝑠𝑖
Collapse resistance reduced from 3270 to 3139 psi.

102
Lost-Circulation Situation

During a lost-circulation situation, the maximum external pressure would

result from a column of drilling mud in the annulus (the beneficial effects of
mud solid settling will be ignored) and the internal pressure would result from
empty casing.
The collapse pressure is expressed by:

Pcollapse = 0.052 TVDcsg seat ρmud

103
Field Practice

Field practice during the running of casing is to fill each joint of casing with
mud as it is made up and run in the hole.
External pressure is slightly greater than internal pressure.
When small drilling rigs run heavy casing strings a practice of "floating in" the
casing is often employed.
Maximum mud level depth allowed in the casing should be calculated so a
collapse failure cannot occur.

104
Lost-Circulation while running casing is the Worst Case

Lost-circulation situation is the worst case:

The reduction of collapse resistance that results when a tube is
placed in axial tension causes a trial and error solution technique.
Establishing the tension load at the exact time maximum collapse
load is applied is not possible.
The axial tension while running casing is calculated from the casing
weight per foot and the buoyancy factor.
Overpull, that may result from pipe sticking while running or
reciprocating the casing string during cementing, is handled by
calculating and then setting an operational maximum overpull
allowed during the running and cementing operation.
Determining the axial stress after the cement has set and the pipe
landed in the casing head is difficult.
The accepted conservative method used is to assume the tension
load during maximum collapse load is due to the dry air weight of the
casing.

105
Tension Design Criteria

Tension design criteria are based on an assumption of

stuck casing near the bottom while the casing is run into
the hole.
A certain amount of overpull in excess of the hanging
weight is necessary to free the pipe.
A maximum pull is then calculated and specified in the
running and cementing procedure.
In directional drilled wells, the deviation plan can be used
to determine the area of the casing string that will be
under additional tension due to bending.

106
Result of Combination String Design
At the bottom of the lowest section,
collapse rules the design.
The top of the lowest section depends on
two things:
The greatest depth at which the next
most economical casing can be used
based on its corrected (reduced by
tension due to the dry hanging weight of
the lower section) collapse pressure
rating,
Simultaneously a check of tension at
the top of this lowest section (so this
section is not pulled apart by some
operation).
The corrected collapse pressure rating
can't be calculated without first computing
the axial tension.

107
Intermediate Casing

The collapse and tension criteria for the intermediate

casing are similar to the surface casing.

The burst design loading condition of the surface casing

would be expensive to meet, in addition to the fact that
the resulting pressure is higher than the working pressure
of the surface BOP stacks and choke manifolds for most
rigs.

Remembering that an underground blowout is preferred

to a surface blowout, the acceptable mud loss from the
casing is limited to the maximum amount less a safety
margin that will cause the working pressure of the surface
equipment to be reached.

108
Intermediate Casing with Liner

The burst design must consider the intermediate casing

and liner as a single string.
The burst load is limited based on the fracture gradient
below the liner.

109
Production Casing

Burst design assumes a BHP (Bottom Hole Pressure)

due to formation pore pressure and a gaseous produced
fluid in the well.
The production casing must not fail if the tubing fails.
The beneficial effect of cement is ignored.
Collapse is based on an empty casing and mud density
on the outside.
A tubing leak near the bottom would remove most of the
completion fluid and essentially leave the casing empty.
Tension load criteria would be the same as on surface
and intermediate strings.

110
Special Design Considerations ASK

Changing Internal Pressure

Changing External Pressure
Thermal Effects
Subsidence Effects
Casing Landing―The four common methods for landing casing are:
1. 1. Land casing with the same tension that was present when
cement displacement was completed
2. 2. Land casing in tension at the freeze point = neutral point (top of
cement)
3. 3. Land casing with the neutral point of axial stress at the freeze
point ????
4. 4. Land casing in compression at the freeze point
5. 5. In all landing the type of casing hanger design should match
landing conditions.

111
Probabilistic Reliability-Based Design of Casings

Distribution of the thin-walled pressure

vessel burst strength of a 9⅝-in., 47-
lbm/ft, L80 casing.

112
Lesson 3 Wrap Up

What is still unclear?

What questions do you have about the topics we have discussed before we
move on?

Homework
Review Advanced Drilling Glossary Terms
Review Learning Aid 2.1: Fundamental Unit Conversions
Review Learning Aid 2.1: API
Assignment 2.3 Read Aadnoy pages 26—52

113
Daily Drilling Report Review: Handout

Each day in class students will briefly (5 minutes) review the Daily Drilling
Report to check on well.
Students will continue to plot the time vs depth chart started earlier.
Students will briefly discuss any changes or concerns.

114
Lesson 4: Casing Problems
(to be added after editing)

115
Credits

Developer
Lloyd R. Heinze, Ph.D., Petroleum Engineering/Texas Tech University

Contributors:
Rui V. Sitoe, Ph.D., Department of Mechanical Engineering, UEM
Anadarko: Darrell Hebert, Michael Arispe, David Bump, Scott
Chesebro, Reba Stevens, Steve Bosworth
Victoria Johnson, Instructional Designer

Sponsor:

116