Casing Designxxxxx

Well Design Spring 2011
Prepared by: Tan Nguyen

Well Design

PE 413

Casing Design
The casing design process involves
three distinct operations:
1. The selection of the casing
sizes and setting depths;
2. The definition of the operational
scenarios which will result in
burst, collapse and axial loads
3. The calculation of the magnitude
of these loads and selection of
an appropriate weight and grade
of casing.
Casing Design
Introduction
Casing Design
Calculate Loads on the Casing Axial Load
The axial load on the casing can be either tensile or compressive, depending on
the operating conditions.
The force F
ten
tending to pull apart the pipe is resisted by
the stregth of the pipe walls, which exert a counterforce F
2
.

Where o
yield
is the minimum yield strength and A
s
is the
cross-sectional area of steel. Thus, the pipe-body strength:

Equation 2 is used to calculate the minimum force that
would be expected to cause permanent deformation of the
pipe.
s yield
A F o =
2
1
( )
2 2
4
d d F
n yield ten
= o
t
2
Casing Design
Calculate Loads on the Casing Axial Load
Example 1
Compute the body-yield strength for 20, K-55 casing with a nominal wall thickness
of 0.635 and a nominal weight per foot of 133 lbf/ft.

Example 1
Solution:
d = 20.00 2(0.635) = 18.73

( )
2 2
4
d d F
n yield ten
= o
t
( ) lbf F
ten
000 , 125 , 2 73 . 18 20 000 , 55
4
2 2
= =
t
Casing Design
Calculate Loads on the Casing Burst Pressure
The casing will experience a net burst loading if the internal radial load exceeds
the external radial load.
u u u
2
sin
d
r r ds = = =
Let u be small enough
u d
d
L P F
br
2
1
=
tL F s

=o 2
2
2
u
o
d
tL F
s
=
Casing Design
2 1
2F F =
d
t
P
s
br
o 2
=
3
where o
s
is the nominal steel strength. Equation 3 is used only for thin-wall
casing. In drilling application, it is suggested that one should use Barlows
equation to calculate P
br
for thick-wall casing.
n
yield
br
d
t
P
o 2
875 . 0 =
4
API recommends use of this equation with wall thickness rounded to the nearest
0.001 and the results rounded to the nearest 10 psi.
Casing Design
If casing is subjected to internal pressure higher than external, it is said that casing
is exposed to burst pressure. Burst pressure conditions occur during well control
operation or squeeze cementing.
Equation (4) is used to calculate the internal pressure at which the tangential stress
at the inner wall of the pipe reaches the yield strength of the material. The factor
0.875 represents the allowable manufactruing tolerance of -12.5% on wall thickness.
Because a burst pressure failure will not occur until after the stress exceeds the
ultimate tensile strength, using a yield strength criterion as a measure of burst
strength is an inherently conservative assumption.
Casing Design
Example 2
Compute the burst-pressure rating for 20, K-55 casing with a nominal wall thickness
of 0.635 and a nominal weight per foot of 133 lbf/ft
Solution:
n
yield
br
d
t
P
o 2
875 . 0 =
psi P
br
056 , 3
) 20 (
) 635 . 0 )( 000 , 55 ( 2
875 . 0 = =
Rounded to the nearest 10 psi:
psi P
br
060 , 3 =
The casing will experience a net collapse loading if the external radial load exceeds
the internal radial load. The greatest collapse load on the casing will occur if the
casing is evacuated (empty) for any reason.
Casing Design
Calculate Loads on the Casing Collapse Pressure
If external pressure exceeds internal pressure, the casing is subjected to collapse.
Such conditions may exist during cementing operations or well evacuation. Collapse
strength is primarily function of the materials yield strength and its slenderness
ratio, d
n
/t.
Casing Design
p
e
, p
i
external and internal pressure
o
r
, o
t
radial and tangential stresses
Note: equations (5) and (6) are used under no axial tension or axial
compression. Data in Table 7.6 apply only for zero axial tension and no pipe
bending.
5
6
Casing Design
Example 3
Consider a drillpipe of E-75 4 outer diameter with a unit weight of 20 lb/ft inside
a wellbore filled with 9.5 ppg mud. At a location of 3800 ft from the surface,
pressure inside the pipe is 2000 psi, and pressure outside the pipe is 1700 psi.
Determine the tangential and radial stresses at r = r
o
.
Example 3
= - 1700 psi
= - 564.4 psi
E-75 4 and 20 lb/ft drillpipe has an inner diameter of 3.64 in. Considering r is
equal to r
o
= 2.25
The collapse strength criteria consist of four collapse regimes determined by yield strength
and d
n
/t. Each criterion is discussed next in order of increasing d
n
/t.
Yield strength collapse:
Yield strength collapse is based on yield at the inner wall. This criterion does not represent
a collapse pressure at all. For thick wall pipes (d
n
/t < 15), the tangential stress exceeds the
yield strength of the material before a collapse instability failure occurs.
Assumed that the pipe is subjected only to an external pressure p
e
. From eq. (6), the
absolute value of tangential stress o
t
is always greatest at the inner wall of the pipe and that
for burst and collapse loads. Hence, the yield strength collapse occurs at the inner wall: r =
r
i
then equation (6) becomes:
Casing Design
Collapse Pressure Regimes
( )
2 2
2
2
i o
o e
t
r r
r p
= o
( )
i o
o e
t
r r t
r p
+
=
2
2
o
7
8
9
Rearrange equation (8) gives equation (9) to calculate the critical pressure for
yield strength collapse, P
cr
( )
(
(

=
2
/
1 /
2
t d
t d
P
n
n
Y YP
o
Casing Design
Plastic collapse:
Plastic collapse is based on empirical data from 2,488 tests of K-55, N-80 and P-110
seamless casing. No analytic expression has been derived that accurately models
collapse behavior in this regime. The minimum collapse pressure for the plastic
range of collapse is calculated by equation (10).
3 2
1
/
F F
t d
F
P
n
Y P

(
= o
10
Casing Design
Transition Collapse:
Transition collapse is obtained by a numerical curve fitting between the plastic and
elastic regimes. The minimum collapse pressure for the plastic-to-elastic transition
zone is calculated by equation (11)
11
(
=
5
4
/
F
t d
F
P
n
Y T
o
Casing Design
Elastic Collapse:
Elastic collapse is based on theoretical elastic instability failure; this criterion is
independent of yield strength and applicable to thin-wall pipe (d
n
/t > 25). The
minimum collapse pressure for the elastic range of collapse is calculated by using
equation (12)

Most oilfield tubulars experience collapse in the plastic and transition regimes.

12
( ) ( ) | |
2
6
1 / /
10 95 . 46
=
t d t d
P
n n
E
Casing Design
Casing Design
( ) ( )
3 16 2 10 5
1
10 53132 . 0 10 21301 . 0 10 10679 . 0 8762 . 2 Y Y Y F

+ + =
Y F
6
2
10 50609 . 0 026233 . 0

+ =
( ) ( )
3
13
2
7
3
10 36989 . 0 10 10483 . 0 030867 . 0 93 . 465 Y Y Y F

+ + =
( )
( )
( )
( )
( )
( )
( )
2
1 2
1 2
1 2
1 2
1 2
3
1 2
1 2 6
4
/ 2
/ 3
1 /
/ 2
/ 3
/ 2
/ 3
10 95 . 46
(
+
(
=
F F
F F
F F
F F
F F
Y
F F
F F
F
( )
1 2 4 5
/ F F F F =
Casing Design
Apply only when
axial stress is
zero and no
internal pressure
Casing Design
Example
Compute the collapse pressure rating for 20, K-55 casing with a nominal wall
thickness of 0.635 and a nominal weight per foot of 133 lbf/ft.
Solution:
d
n
/t = 20/0.635 = 31.49
This is the transition collapse

|
|
.
|
\
|
=
5
4
/
F
t d
F
p
n
Y T
o
psi p
T
493 , 1 036 . 0
49 . 31
989 . 1
000 , 55 =
|
.
|
\
|
=
All the pipe strength equations previously given are based on a zero axial stress
state. This idealized situation never occurs in oilfield applications because pipe in
a wellbore is always subjected to combined loading conditions.
The fundamental basis of casing design is that if stresses in the pipe wall exceed
the yield strength of the material, a failure condition exists. Hence the yield
strength is a measure of the maximum allowable stress. To evaluate the pipe
strength under combined loading conditions, the uniaxial yield strength is
compared to the yielding condition.
Casing Design
Combined Stress Effects
The most widely accepted yielding criterion is based on the maximum
distortion energy theory, which is known as the Huber-Von-Mises Theory. This
theory states that if the triaxial stress exceeds the yield strength, a yield failure
is indicated. Note that the triaxial stress is not a true stress. It is a theoretical
value that allows a generalized three-dimensional stress state to be compared
with a uniaxial failure criterion (the yield strength).
Casing Design
( ) ( ) ( )
Y z r r t t z VME
o o o o o o o o > + + =
2 2 2
2
1
13
Where
o
Y
minimum yield stress, psi
o
VME
triaxial stress, psi
VME: Von Mises Equivalent
o
z,
o
t
, o
r
axial tress, tangential
stress, and radial stress, psi
Casing Design
Setting the triaxial stress equal to the yield strength and solving equation (13)
give the results:

Equation (14) is for the ellipse of plasticity. Combining Eq. (14) and eq. (6)
together and let r = r
i
, will give the combinations of internal pressure, external
pressure and axial stress that will result in a yield strength mode of failure.

|
|
.
|
\
| +
|
|
.
|
\
| +
=
+
Y
i z
Y
i z
Y
i t
p p p
o
o
o
o
o
o
2
1
4
3
1
2
14
Casing Design
As axial tension increases,
the critical burst-pressure
increases and the critical
collapse-pressure decreases.
In contrast, as the axial
compression increases, the
critical burst-pressure
decreases and the critical
collapse-pressure increases.
Casing Design
Example
Compute the nominal collapse pressure rating for 5.5, N-80 casing with a nominal
wall thickness of 0.476 and a nominal weight per foot of 26 lbf/ft. In addition,
determine the collapse pressure for in-service conditions in which the pipe is
subjected to a 40,000 psi axial tension stress and a 10,000 psi internal pressure.
Assume a yield strength mode of failure.
Example
For collapse pressure rating, r = r
i
then eq. (6) becomes
( )
2 2
2 2 2
2
i o
o e i o i
t
r r
r p r r p
+
= o
( )
Y
i
i o
o e i o i
Y
i t
p
r r
r p r r p
p
o o
o
+
+
=
+
2 2
2 2 2
2
|
|
.
|
\
|
|
|
.
|
\
|
=
+
Y
e i
i o
o
Y
i t
p p
r r
r p
o o
o
2 2
2
2
( )
|
.
|
\
|
|
|
.
|
\
|
=
+
000 , 80 548 . 4 5 . 5
5 . 5 2
2 2
2
e i
Y
i t
p p p
o
o
649 , 12 649 , 12
e e i
Y
i t
p p p p
=
=
+
o
o
Example
From eq. (14) with we have 0 =
+
Y
i z
p
o
o
1 =
+
Y
i t
p
o
o
1
649 , 12
=
e
p
psi p
e
649 , 12 =
Example
For in-service conditions of o
z
= 40,000 psi and p
i
= 10,000 psi
649 , 12
000 , 10
e
Y
i t
p p
=
+
o
o
625 . 0
000 , 80
000 , 10 000 , 40
=
+
=
+
Y
i z
p
o
o
Solving eq. (14) gives
5284 . 0
649 , 12
000 , 10
=
=
+
e
Y
i t
p p
o
o
psi p
e
684 , 16 =

Casing Designxxxxx

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Well Design Spring 2011

Prepared by: Tan Nguyen

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