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P1M6110 Casing Design Manual PDF
P1M6110 Casing Design Manual PDF
ENI S.p.A.
Agip Division
ORGANISING
DEPARTMENT
TYPE OF
ACTIVITY'
ISSUING
DEPT.
DOC.
TYPE
REFER TO
SECTION N.
PAGE.
OF
STAP
134
6110
TITLE
CASING DESIGN MANUAL
DISTRIBUTION LIST
Eni - Agip Division Italian Districts
Eni - Agip Division Affiliated Companies
Eni - Agip Division Headquarter Drilling & Completion Units
STAP Archive
Eni - Agip Division Headquarter Subsurface Geology Units
Eni - Agip Division Headquarter Reservoir Units
Eni - Agip Division Headquarter Coordination Units for Italian Activities
Eni - Agip Division Headquarter Coordination Units for Foreign Activities
NOTE: The present document is available in Eni Agip Intranet (http://wwwarpo.in.agip.it) and a CDRom version can also be distributed (requests will be addressed to STAP Dept. in Eni Agip Division Headquarter)
Date of issue:
28/06/99
Issued by
REVISIONS
P. Magarini
E. Monaci
28/06/99
C. Lanzetta
A. Galletta
28/06/99
28/06/99
PREP'D
CHK'D
APPR'D
The present document is CONFIDENTIAL and it is property of AGIP It shall not be shown to third parties nor shall it be used for
reasons different from those owing to which it was given
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INDEX
1.
2.
3.
4.
5.
6.
INTRODUCTION
1.1.
PURPOSE OF CASING
2.1.
Casing
2.1.1.
2.1.2.
2.1.3.
2.1.4.
7
7
7
7
7
2.2.
Profiles
Onshore Wells
Offshore Wells - Surface Wellhead
Offshore Wells - Surface Wellhead & Mudline Suspension
Offshore Wells - Subsea Wellhead
8
8
9
10
11
12
3.1.
Conductor Casi ng
15
3.2.
Surface Casing
15
3.3.
Intermediate Casing
15
3.4.
Drilling Liner
16
3.5.
Production Casing
17
3.6.
17
21
22
4.1.
CASING SPECIFICATION
22
4.2.
23
4.3.
NON-API CASING
25
28
5.1.
General
28
5.2.
Stress-Strain Diagram
28
5.3.
30
36
6.1.
Range lengths
36
6.2.
38
38
39
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9.
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41
7.1.
WELLBORE FORCES
42
7.2.
42
44
45
DESIGN CRITERIA
46
8.1.
BURST
8.1.1.
Design Methods
8.1.2.
Company Design Procedure
46
46
47
8.2.
COLLAPSE
8.2.1.
Company Design Procedure
50
50
8.3.
TENSION
8.3.1.
General
8.3.2.
Buoyancy Force
8.3.3.
Company Design Procedure
8.3.4.
Example Hook Load During Cementing
54
54
54
59
59
8.4.
BIAXIAL
8.4.1.
8.4.2.
8.4.3.
8.4.4.
STRESS
General
Effects On Collapse Resistance
Company Design Procedure
Example Collapse Caclulation
62
62
62
64
65
8.5.
BENDING
8.5.1.
General
8.5.2.
Determination Of Bending Effect
8.5.3.
Company Design Procedure
8.5.4.
Example Bending Calculation
67
67
68
70
70
8.6.
CASING WEAR
8.6.1.
General
8.6.2.
Volumetric Wear Rate
8.6.3.
Factors Affecting Casing Wear (Example)
8.6.4.
Wear Factors
8.6.5.
Detection Of Casing Wear
8.6.6.
Casing Wear Reduction
8.6.7.
Wear Allowance In Casing Design
8.6.8.
Company Design Procedure
72
72
73
76
80
86
86
87
88
8.7.
SALT SECTIONS
8.7.1.
General
8.7.2.
External Loading Due To Salt Flow
8.7.3.
Company Design Procedure
89
89
89
94
CORROSION
96
9.1.
General
9.1.1.
Exploration and Appraisal Wells
9.1.2.
Development Wells
9.1.3.
Contributing Factors to Corrosion
96
96
96
97
9.2.
Forms Of Corrosion
9.2.1.
Sulphide Stress Cracking (SSC)
9.2.2.
Corrosion Caused By CO2 And Cl-
98
98
105
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9.2.3.
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0
107
9.3.
108
9.4.
Corrosion Inhibitors
109
9.5.
109
109
110
110
110
111
9.6.
113
9.7.
Ordering Specifications
114
9.8.
114
114
115
118
118
119
120
120
120
120
121
122
122
122
123
126
126
129
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1.
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INTRODUCTION
The selection of casing grades and weights is an engineering task affected by many factors,
including local geology, formation pressures, hole depth, formation temperature, logistics and
various mechanical factors.
The engineer must keep in mind during the design process the major logistics problems in
controlling the handling of the various mixtures of grades and weights by rig personnel without
risk of installing the wrong grade and weight of casing in a particular hole section. World-wide,
experience has shown that the use of two/three different grades or two/three different weights
is the maximum that can be handled by most rigs and rig crews.
After selecting a casing for a particular hole section, the designer should consider upgrading
the casing in cases where:
Extreme wear is expected from drilling equipment used to drill the next hole
section or from wear caused by wireline equipment.
Buckling in deep and hot wells.
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1.1.
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PURPOSE OF CASING
Casing tubulars are placed in a wellbore for the following reasons:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
Providing internal pressure containment when the tubing system leaks or fails.
Preventing wellbore fluids from contaminating production.
Providing protection for completion equipment.
Providing access to producing formations for remedial operations.
Providing cement integrity across producing formations.
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2.
2.1.
CASING PROFILES
The following are the various casing configurations which can be used for onshore and
offshore wells.
2.1.1.
Onshore Wells
2.1.2.
Drive/structural/conductor casing
Surface casing
Intermediate casings
Production casing
Intermediate casing and drilling liners
Intermediate casing and production liner
Drilling liner and tie-back string.
2.1.3.
2.1.4.
Drive/structural/conductor casing
Surface casing and landing string
Intermediate casings and landing strings
Production casing
Intermediate casings and drilling liners
Drilling liner and tie-back string.
Drive/structural/conductor casing
Surface casing
Intermediate casings
Production casing
Intermediate casing and drilling liners
Intermediate casing and production liner
Drilling liner and tie-back string.
Refer to the following sections for descriptions of the casings listed above.
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Guide the drilling string and subsequent casing into the hole. The conductor in
offshore drilling may form a part of the piling system for a wellhead jacket or piled
platform.
Provide centralisation for the inner casing strings which limits column buckling.
They do not carry direct axial loads except during initial installation of the surface
casing.
Reduce wave and current loadings imposed on the inner strings.
Provide sacrificial protection against oxygen corrosion in the splash zone.
Minimise the transfer of stresses to the inner casings resulting from the
settlement and rotational movement of gravity platforms.
The conductor casings are usually driven completely to depth or, alternatively, run into a
predrilled or jetted hole and cemented. If they are driven, they must be designed to withstand
hammering loads.
Conductor casings, in offshore drilling with subsea BOP's, are usually either jetted into place
or cemented in a predrilled hole. They support a Temporary Guide Base which
accommodates and aligns all future wellhead installations for both the drilling and production
phases. They directly carry both the axial and bending loads imposed by the wellhead, but are
rigidly connected to the next casing with centralisers and cement in order to dissipate loading
and minimise resulting stresses.
2.2.1.
Surface Casing
The surface casing is installed to:
Prevent poorly consolidated shallow formations from sloughing into the hole.
Enable full mud circulation.
Protect fresh water sands from contamination from the drilling mud.
Provide protection against hydrocarbons found at shallow depths.
The surface casing string is cemented to surface or seabed and is the first casing on which
BOPs can be mounted. It is important to appreciate that the amount of protection provided
against internal pressure will only be as strong as the formation strength at the casing shoe,
hence it may be necessary to vent any influx taken through the surface string, rather than
attempt containment.
The surface string usually supports the wellhead and subsequent casing strings.
In offshore wells, above the top of the cement, the surface casing must be centralised to limit
column buckling.
The annulus between the conductor and surface string is usually left uncemented above the
mudline to minimise load transfer and bending stresses in the surface string.
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2.2.2.
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Intermediate Casing
These are used to ensure there is adequate blow-out protection for deeper drilling and to
isolate formations or hole profile changes, that can cause drilling problems.
The first intermediate string is the first casing providing full blow-out protection. Its setting
depth is often chosen so that it also isolates troublesome formations, loss zones, shallow
hydrocarbons, water sands, or the build-up section of deviated wells. It is usually cemented
up into the shoe of the conductor string and in some cases all the way to surface.
It is essential to install an intermediate casing string whenever there is a risk of experiencing a
kick which could cause breakdown at the previous casing shoe, and/or severe losses in the
open hole section.
An intermediate casing string is, therefore, nearly always set in the transition zone above or
below significant overpressures, and in any cap rock below a potential severe loss zone.
Similarly, it is good practice when appraising untested or deeper horizons, to case off the
known hydrocarbon bearing intervals as a contingency against the possibility of encountering
a loss circulation zone. Obviously the latter is intended primarily for massive reservoir
sections rather than sand-shale sequences with numerous small reservoirs and subreservoirs. An intermediate string may also be set simply to reduce the overall cost of drilling
and completing the well by isolating intervals which have been found to cause mechanical
problems in the past.
For example it may be desirable to isolate:
The designer should plan to combine many of these objectives when selecting a single
casing point. A liner may be used instead of a full intermediate casing and difficult wells may
actually contain several intermediate casings and/or liners. Caution should be taken when
using liners as it is necessary to ensure the higher casing is designed for the pressures at
lower depths.
The cement should cover all hydrocarbon zones and any salt or other creeping evaporites.
Zones containing highly corrosive formation waters are also often cemented off, especially
where there may be aquifer movement which replenishes the corrosive elements around the
wellbore.
Longer cement columns are sometimes required to prevent buckling of the casing during
deeper drilling. Many operating companies cement up inside the previous casing shoe for this
reason and is legislated on by some regulatory authorities.
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2.2.3.
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Production Casing
This is the string through which the well will be completed, produced and controlled
throughout its life.
On exploration wells this life may amount to only a very short testing period, but on most
development wells it will span a significant number of years during which many repairs and
recompletions may be performed. It is essential therefore that production casing retains its
integrity throughout its life.
In most cases, the production casing will serve to isolate the productive intervals, to facilitate
proper reservoir maintenance and/or prevent the influx of undesired fluids. In other cases,
accumulation conditions are such that the well can be cased with an open hole section below
the casing for an open hole completion (Refer to the completion design manual). The size of
the production casing should be selected to meet with the desired method of completion and
production.
On production wells the drilling engineer must design the casing in conjunction with the
completion engineer to ensure the optimum completion design is obtained. This usually
impacts on the production casing design with regard to:
It is also possible that the casing itself could be used as a conduit for maximising well
deliverability (casing flow), for minimising the pressure losses during frac jobs, for chemical
injection or for lift gas. Consideration must be given to production operations which will affect
the temperature of the production casing and impose additional thermal stresses. Annulus
thermal expansion can cause production casing collapse when it is cemented up into the
intermediate casing. The loads to which a production casing is subjected are, therefore, quite
different from those imposed during drilling.
It is very important that the selection of the steel grade and connections for the production
string are made correctly.
Special considerations are required where the production casing will be drilled through and
may therefore suffer some damage e.g.: open hole (barefoot) completions, open hole gravel
packs, liner completions, deep zone appraisal.
In a liner completion, both the liner and casing form the production string and must be
designed accordingly.
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2.2.4.
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Liner
A liner is a string of pipe which is installed but does not extend all the way to surface. It is
hung a short distance above the previous casing shoe and is usually cemented over its entire
length to ensure it seals within the previous casing string.
Drilling liners may be installed to:
Reduce costs.
Minimise the length of reduced diameter production tubing and the consequent
adverse effect upon well flow potential.
Meet with rig tensional load limitations on occasions on deep wells.
Either type of liner may subsequently be tied-back to surface with a string of pipe stabbed into
a liner hanger Polished Bore Receptacle (PBR).
There are a number of disadvantages to installing liners, including:
The risk of poor pressure integrity, either across the liner lap due to poor
cementation or as a result of wear to the casing from which the liner is hung off.
The risk of the liner running equipment being cemented in the hole.
The difficulty of obtaining a good cementation due to smaller liner to hole and liner
to production casing clearances.
The need to set a retrievable bridge plug above the liner lap if the BOP stack
needs to be removed. (This does not apply to completion operations when a
tubing string has been run and landed.)
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3.
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When planning, all available information should be carefully documented and considered to
obtain knowledge of the various uncertainties.
Information is sourced from:
The key factor to satisfactory picking of casing seats is the assessment of pore pressure and
fracture pressures throughout the well.
As the pore pressures in a formation being drilled approach the fracture pressure at the last
casing seat then installation of a further string of casing is necessary.
figure 3.a and figure 3.b show typical examples of casing seat selections.
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Casing is set at depth 1, where pore pressure is P1 and the fracture pressure is
F1.
b)
Drilling continues to depth 2, where the pore pressure P2 has risen to almost
equal the fracture pressure (F1) at the first casing seat.
c)
Another casing string is therefore set at this depth, with fracture pressure (F2).
d)
Drilling can thus continue to depth 3, where pore pressure P3 is almost equal to
the fracture pressure F2 at the previous casing seat.
This example does not include any safety or trip margins, which would, in practice, be taken
into account.
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3.1.
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CONDUCTOR CASING
Setting depth is usually shallow and selected so that drilling fluid may be circulated to the mud
pits while drilling the surface hole. The casing seat must be in an impermeable formation with
sufficient fracturing resistance to allow fluid circulation to the surface.
Where working with subsea wellheads, no there is no circulation through the conductor string
to the surface. It is set deep enough to assist in stabilising the guide base to which guide lines
are attached.
Large sizes are required (usually 16ins to 30ins diameter) as necessary to accommodate the
size of all subsequently required strings.
3.2.
SURFACE CASING
Setting depths should be in an impermeable section below any fresh water formations.
In some instances, near-surface gravel or shallow gas may need to be cased off shallower.
The depth should be great enough to provide a fracture gradient sufficient enough to allow
drilling to the next casing setting point and to provide reasonable assurance that broaching to
the surface will not occur in the event of BOP closure to contain a kick.
In hard rock areas the string may be relatively shallow, but in soft rock areas deeper strings
are necessary.
3.3.
INTERMEDIATE CASING
The most predominant use of intermediate casing is to protect normally pressured formations
from the effects of increased mud weight needed in deeper drilling.
An intermediate string may be necessary to case off lost circulation zones, salt beds, or
sloughing shales.
In cases of pressure reversals against depth, intermediate casing may be set to allow
reduction of mud weight.
When a transition zone is penetrated and mud weight increased, the normal pressure interval
below surface pipe is subjected to two detrimental effects:
To ensure the integrity of the surface casing seat, leak-off tests are necessary and must be
specified in the Drilling Programme.
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Sometimes it is necessary to alter the setting depth of the intermediate casing during drilling
under certain circumstances such as when:
3.4.
DRILLING LINER
The setting of a drilling liner is often an economically attractive decision in deep wells as
opposed to setting a full string. Such a decision must be carefully considered as the
intermediate string must be designed for burst as if it were set to the depth of the liner.
If drilling is to be continued below the drilling liner then burst requirements for the intermediate
string are further increased which increases the cost of the intermediate string. Also, there is
the possibility of continuing wear of the intermediate string that must also be evaluated.
If a production liner is planned, then either the production liner or the drilling liner should be
tied back to the surface as a production casing.
If the drilling liner is to be tied-back, it is usually better to do so before drilling the hole for the
production liner. By doing this, the intermediate casing can be designed for a lower burst
requirement, resulting in considerable cost savings. Also, any wear to the intermediate string
is spanned prior to drilling the producing interval.
If increasing mud weight will be required, while drilling hole for the drilling liner, then leak-off
tests must be conducted and specified in the casing programme for the intermediate casing
shoe within the Geological Drilling Programme (Refer to the Drilling Procedures Manual).
Insufficient fracture gradient at the shoe may limit the depth of the drilling liner.
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3.5.
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PRODUCTION CASING
Whether production casing or a liner is installed, the depth is determined from the geological
objective. Depths, hence the casing programme, may have to be altered accordingly if depths
come in too high or too low.
The objective and the method of identifying the correct production casing depth should also
be stated in the programme.
To cater for some completion operations, a sufficient amount of sump is required for fill during
production or well intervention operations, run out for logging tools and to accommodate lost
tools or dropped TCP guns, etc. Drilling extra hole, for dropping TCP guns or similar reasons,
may be costly and the effectiveness of such considerations should be seriously evaluated
before commitment.
3.6.
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The chart in figure 3.c can be used to select the casing bit sizes required to fulfil many drilling
programme options.
To use the chart:
1)
2)
3)
Determine the casing or liner size for the last size pipe to be installed.
Enter the chart at that point.
The flow of the chart then indicates hole sizes that may be required to set that size pipe
(i.e., 5 Liner inside 6 or 61/2 hole).
Solid lines indicate commonly used bits for that size pipe and can be considered to
have adequate clearance to run and cement the casing or liner (i.e., 51/2 Casing inside
77/8 hole).
The broken lines indicate less common optional hole sizes used (i.e., 5 inside 61/8
hole, etc.).
The selection of one of these broken paths requires special attention be given to the
connection, mud weight, cementing and doglegs.
Large connection ODs, thick mud cake build-up, problem cementing areas (high water
loss, lost returns, etc.) and doglegs all aggravate the attempt to run casing and liners in
low clearance situations.
Once the hole size has been selected. a casing large enough to allow passage of a bit
to make that hole can be selected. The solid lines are commonly required casing sizes.
encompassing most weights (i.e., 61/2 bit inside 75/8 casing).
The broken lines indicate casing sizes where only the lighter weights can be used
(i.e. 61/8 inside 7 casing).
This selection process is repeated until the anticipated number of casing sizes has
been reached.
Note:
figure 3.d shows the standard casing programme and figure 3.e the possible alternative.
further standard casing and hole sizes information is shown in table 3.a.
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3.6.1.
21 OF 134
Outer Casing
Size
Under-Reaming
Minimum Pilot
Hole Size
Under-reamed
Diameter
Maximum
Tool OD
20
181/2
26
18
20
16
17 /2
22
17
16
13 /8
14 /4
17 /2
14
13 /8 (48-68#)
10 /4
12 /4
15
113/4
113/4
85/8
105/8
121/4
10
9 /8 (29.3#)
7 /8
8 /4
11 /2
81/4
85/8 (24-32#)
65/8
75/8
91/2
71/4
85/8 (36-49#)
73/8
7 /8
5 /2
6 /4
8 /2
7 (17-32#)
53/4
24
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4.
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4.1.
CASING SPECIFICATION
The American Petroleum Institute (API) has an appointed Committee on Standardisation of
tubular goods which publishes, and continually updates, a series of Specifications, Bulletins
and Recommended Practices covering the manufacture, performance and handling of oilfield
tubular goods. They also license manufacturers to use the API Monogram on products which
meet with their published specifications therefore can be identified as complying with the
standards.
The API Forum has been in existence since 1924, and their standardisation of oilfield
equipment and practices are almost universally accepted as the world standard on tubulars.
This does not mean that the published performance data is accepted as the best theoretical
representation of the parameters of tubulars.
It is essential that design engineers are aware of any changes made to the API specifications.
All involved with casing design must have immediate access to the latest copy of API Bulletin
5C2 which lists the performance properties of casing, tubing and drillpipe. Although these are
also published in many contractors' handbooks and tables, which are convenient for field use,
care must be taken to ensure that they are current.
Also a library of the other relevant API publications shall be available and design engineers
should make themselves familiar with these documents and their contents.
It should not be interpreted from the above that only API tubulars and connections may be
used in the field as some particular engineering problems are overcome by specialist
solutions which are not yet addressed by API specifications. In fact, it would be impossible to
drill many extremely deep wells without recourse to the use of pipe manufactured outwith API
specifications (non-API).
Similarly, many of the Premium connections that are used in high pressure high GOR
conditions are also non-API.
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When using non-API pipe, the designer must check the methods by which the strengths have
been calculated. Usually it will be found that the manufacturer will have used the published
API formulae (Bulletin 5C3), backed up by tests to prove the performance of his product
conforms to, or exceeds, these specifications. However, in some cases, the manufacturers
have claimed their performance is considerably better than that calculated by the using API
formulae. When this occurs the manufacturers claims must be critically examined by the
designer or his technical advisors, and the performance corrected if necessary.
It is also important to understand, that to increase competition, the API tolerances have been
set fairly wide. However, the API does provide for the purchaser to specify more rigorous
chemical, physical and testing requirements on orders, and may also request place
independent inspectors to quality control the product in the plant.
4.2.
Outside diameter.
Nominal unit weight.
Grade of the steel.
Type of connection.
Length by range.
Manufacturing process
An example of an API table showing the parameters listed above in given in table 4.a.
Reference should always be made to current API specification 5C2 for casing lists and
performances.
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Col 1
Col 2
Size: OD
Col 3
Col 4
Wall Thickness
Col 5
Nominal Wt
Grade
ins
mm
lbs per ft
Grades Inc
ins
mm
Short
219.1
219.1
219.1
219.1
219.1
219.1
219.1
219.1
219.1
244.5
244.5
244.5
244.5
244.5
244.5
244.5
244.5
244.5
244.5
244.5
244.5
273.1
273.1
273.1
273.1
273.1
273.1
273.1
273.1
273.1
273.1
273.1
273.1
273.1
298.5
298.5
298.5
298.5
339.7
339.7
339.7
339.7
339.7
406.4
406.4
406.4
473.0
473.0
508.0
508.0
508.0
508.0
24.00
28.00
32.00
32.00
36.00
36.00
40.00
44.00
49.00
32.30
36.00
36.00
40.00
40.00
43.50
47.00
53.50
59.40
64.90
70.30
75.60
32.75
40.50
40.50
45.50
51.00
55.50
60.70
65.70
59.40
65.70
73.20
79.20
85.30
42.00
47.00
54.00
60.00
48.00
54.50
61.00
68.00
72.00
65.00
75.00
84.00
87.50
87.50
94.00
94.00
106.50
133.00
J, K
H
H
J, K
J, K
C, L, N
C, L, N, P
C, L, N, P
C, L, N, P, Q
H
H
J, K
J, K
C, L, N
C, L, N, P
C, L, N, P
C, L, N, P, Q
C 90 only
C 90 only
C 90 only
C 90 only
H
H
J, K
J, K
C, K, K, N, P
C, L, N, P
P, Q
P, Q
C 90 only
C 90 only
C 90 only
C 90 only
C 90 only
H
J, K
J, K
J,K,N,C,L,P,Q
H
J, K
J, K
C,L,J,K,N,P,Q
C, L, N, P, Q
H
J, K
J, K
H, J, K
J, K
H, J, K
J, K
J, K
J, K
0.264
0.304
0.352
0.352
0.400
0.400
0.450
0.500
0.557
0.312
0.352
0.352
0.395
0.395
0.435
0.472
0.545
0.609
0.672
0.734
0.797
0.297
0.350
0.350
0.400
0.450
0.495
0.545
0.595
0.545
0.595
0.672
0.734
0.797
0.333
0.375
0.435
0.489
0.330
0.380
0.430
0.480
0.514
0.375
0.438
0.495
0.435
0.435
0.438
0.438
0.500
0.635
6.71
7.72
8.94
8.94
10.16
10.16
11.43
12.70
14.15
7.92
8.94
8.94
10.03
10.03
11.05
11.99
13.84
15.47
17.07
18.64
20.24
7.09
8.89
8.89
10.16
11.43
12.57
13.84
15.11
13.84
15.11
17.07
18.64
20.24
8.46
9.52
11.05
12.42
8.38
9.65
10.92
12.19
13.06
9.52
11.13
12.57
11.05
11.05
11.13
11.13
12.70
16.13
X
X
X
X
X
8 /8
85/8
85/8
85/8
85/8
85/8
85/8
85/8
85/8
95/8
95/8
95/8
95/8
95/8
95/8
95/8
95/8
95/8
95/8
95/8
95/8
103/4
103/4
103/4
103/4
103/4
103/4
103/4
103/4
103/4
103/4
103/4
103/4
103/4
113/4
113/4
113/4
113/4
133/8
133/8
133/8
133/8
133/8
16
16
16
185/8
185/8
20
20
20
20
24 OF 134
Type of Thread
X
X
X
X
Long
Buttress
Extreme Line
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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REVISION
STAP-P-1-M-6110
4.3.
PAGE
IDENTIFICATION CODE
NON-API CASING
Eni-Agip Division and Affiliates policy is to use API casings whenever feasible. Some
manufacturers produce non-API casings for H2S and deep well service where API casings do
not meet requirements. The most common non-API grades are shown in the attached table
figure 4.a shows the API and non-API materials available and the environment in which they
are recommended to be used.
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Domain
Mild Environment
Domain A
Domain B
Domain C
Domain D
Material
Domain E
Domain F
SM 95G
SM 125G
API
SM 80S
SM 90S
SM 95S
SM 85SS
SM 90SS
SM C100
SM C110
SM 9CR 75
SM 9CR 80
SM 9CR 95
SM 13CR 75
SM 13CR 80
SM 13CR 95
SM 22CR 65*
SM 22CR 110**
SM 22CR 125**
SM 25CR 75*
SM 25CR 110**
SM 25CR 125**
SM 25CR 140**
SM 2535 110
SM 2535 125
SM 2242 110
SM 2242 125
SM 2035 110
SM 2035 125
SM 2550 110
SM 2550 125
SM 2550 140
SM 2060 110***
SM 2060 125***
SM 2060 140***
SM 2060 155***
SM C276 110***
SM C276 125***
SM C276 140***
L 80
C 90
T 95
1Cr 0.5Mo Steel
Modified AISI 4130
Domain G
SM
Designation
J 55
N 80
P 110
(Q 125)
Cr or Cr-Mo Steel
API
13Cr Steel
Modified AISI 420
Wet CO2 with a little H 2S
Corrosion
26 OF 134
REVISION
STAP-P-1-M-6110
Application (Refer to
figure 4.a)
PAGE
IDENTIFICATION CODE
Notes
Higher yield
strength for sour
service
Quenched and
tempered
Quenched and
tempered
Duplex phase
Stainless steels
*
Solution Treated
** Cold drawn
As cold drawn
As cold drawn
*** Environment
with free
Sulphur
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PAGE
IDENTIFICATION CODE
27 OF 134
REVISION
STAP-P-1-M-6110
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PAGE
IDENTIFICATION CODE
28 OF 134
REVISION
STAP-P-1-M-6110
5.
5.1.
GENERAL
Failure of a material or of a structural part may occur by fracture (e.g. the shattering of glass),
Yield, wear, corrosion, and other causes. These failures are failures of the material. Buckling
may cause failure of the part without any failure of the material.
As load is applied, deformation takes place before any final fracture occurs. With all solid
materials, some deformation may be sustained without permanent deformation, i.e. the
material behaves elastically.
Beyond the elastic limit, the elastic deformation is accompanied by varying amounts of
plastic, or permanent, deformation, If a material sustains large amounts of plastic deformation
before final fracture. It is classed as ductile material, and if fracture occurs with little or no
plastic deformation. The material is classed as brittle.
5.2.
STRESS-STRAIN DIAGRAM
Tests of material performance may be conducted in many different ways, such as by torsion,
compression and shear, but the tension test is the most common and is qualitatively
characteristics of all the other types of tests.
The action of a material under the gradually increasing extension of the tension test is usually
represented by plotting apparent stress (the total load divided by the original cross-sectional
area of the test piece) as ordinates against the apparent strain (elongation between two
gauge points marked on the test piece divided by the original gauge length) as abscissae.
A typical plot for a carbon steel is shown in figure 5.a.
From this, it is seen that the elastic deformation is approximately a straight line defined by
Hooke's law, and the slope of this line, or the ratio of stress to strain within the elastic range,
is the modulus of elasticity E, sometimes called Young's modulus.
Beyond the elastic limit, permanent, or plastic strain occurs.
If the stress is released in the region between the elastic limit and the yield strength (see
above) the material will contract along a line generally nearly straight and parallel to the
original elastic line, leaving a permanent set.
In steels, a curious phenomenon occurs after the elastic limit, known as yielding. This gives
rise to a dip in the general curve followed by a period of deformation at approximately constant
load. The maximum stress reached in this region is called the upper yield point and the lower
part of the yielding region the lower yield point. In the harder and stronger steels, and under
certain conditions of temperature, the yielding phenomenon is less prominent and is
correspondingly harder to measure. In materials that do not exhibit a marked yield point, it is
customary to define a yield strength. This is arbitrarily defined as the stress at which the
material has a specified permanent set (the value of 0.2 percent is widely accepted in the
industry).
For steels used in the manufacturing of tubular goods the API specifies the yield strength as
the tensile strength required to produce a total elongation of 0.5 and 0.6 percent of the gauge
length.
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PAGE
IDENTIFICATION CODE
29 OF 134
REVISION
STAP-P-1-M-6110
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PAGE
IDENTIFICATION CODE
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30 OF 134
REVISION
STAP-P-1-M-6110
The denominations of the different grades are based on the minimum yield strength, e.g.:
Grade
H 40
40,000psi
J 55
55,000psi
C 75
75,000psi
N 80
80,000psi
etc.
In the design of casing and tubing strings the minimum yield strength of the steel is taken as
the basis of all strength calculations
As far as chemical properties are concerned, in API 5CT only the maximum phosphorus and
sulphur contents are specified, the quality and the quantities of other alloying elements are left
to the manufacturer.
API specification 5CT Restricted yield strength casing and tubing however, specifies the
complete chemical requirements for grades C 75, C 95 and L 80.
5.3.
Normalising
Improves machinability.
This is an identical process to annealing except that the steel is
air cooled. As an example API grades J and K55 are heated to
about 860C (1,580F) before cooling.
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PAGE
IDENTIFICATION CODE
31 OF 134
REVISION
STAP-P-1-M-6110
Tempering
Stress relieving
Quenching
See the following tables for process of manufacturing, heat treatments, chemical composition
and mechanical properties of API tubulars.
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PAGE
IDENTIFICATION CODE
ENI S.p.A.
Agip Division
32 OF 134
REVISION
STAP-P-1-M-6110
Tempering
Temperature Min.
Group
Grade
Type
Process of
Manufacture
H 40
J 55
S or EW
S or EW
K 55
S or EW
N 80 (Casing)
S or EW
N 80 (Tubing)
C 75
C 75
C 75
C 75
C 75
C 90
C 90
C 95
L 80
L 80
L 80
P 105
P 110
Q 125
Q 125
Q 125
Q 125
1
2
3
9 Cr
18 Cr
1
2
1
9 Cr
13 Cr
1
2
3
4
S or EW
S or EW
S or EW
S or EW
S
S
S
S
S or EW
S or EW
S
S
S
S
S or EW***
S or EW***
S or EW***
S or EW***
Heat
Treatment
None
None
Note 1
None
Note 1
None
Note 1
Note 1
N&T
Q&T
N&T
Q&T*
Q&T*
Q&T
Q&T
Q&T
Q&T
Q&T*
Q&T*
Q&T or N&T**
Q&T or N&T**
Q&T
Q&T
Q&T
Q&T
1,150
1,150
1,150
1,100
1,100
1,150
1,150
1,000
1,050
1,100
1,100
-
621
621
621
593
593
621
621
538
566
593
593
-
Note:
Full length normalised, normalised and tempered (N&T) or quenched and tempered (Q&T) at the
manufactures option or if so specified on the order.
Type 9 Cr and 13Cr grades may be air quenched
** Unless otherwise agreed between purchaser and manufacturer/processor
*** Special requirements unique to electric welded Q 125 casing are specified in SR11. When
welded Q 125 casing is furnished, the provisions of SR11 automatically in effect.
S
Seamless pipe
EW
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PAGE
IDENTIFICATION CODE
ENI S.p.A.
Agip Division
REVISION
STAP-P-1-M-6110
Group
Grade
Type
33 OF 134
Carbon
Nickel
Copper
Phosphorous
Sulphur
Silicon
max.
max.
max.
max.
max.
max.
Maganese
Molybdenum
Chromium
min
min
max.
min
max.
min
max.
H - 40
J - 55
K - 55
N - 80
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
0.040
0.040
0.040
0.040
0.060
0.060
0.060
0.060
...
...
...
...
C - 75
C - 75
C - 75
C - 75
C - 75
L - 80
L - 80
L - 80
C90
C90
C95
1
2
3
9Cr
13Cr
1
9Cr
13Cr
1
2
...
...
...
0.38
...
0.15
...
...
0.15
...
...
...
0.50
0.43
0.48
0.15
0.22
0.43*
0.15
0.22
0.35
0.50
0.45*
...
...
0.75
0.30
0.25
...
0.30
0.25
...
...
...
1.90
1.50
1.00
0.60
1.00
1.90
0.60
1.00
1.00
1.90
1.90
0.15
...
0.15
0.90
...
...
0.90
...
...
...
...
0.40
...
0.25
1.10
...
...
1.10
...
0.75
NL
...
***
...
0.80
8.0
12.0
...
8.0
12.0
...
...
...
***
...
1.10
10.0
14.0
...
10.0
14.0
1.20
NL
...
***
...
...
...
0.5
0.25
0.5
0.5
0.99
0.99
...
***
...
...
...
0.25
0.35
0.25
0.25
...
...
...
0.040
0.040
0.040
0.020
0.020
0.040
0.020
0.020
0.030
0.030
0.040
0.060
0.060
0.040
0.010
0.010
0.060
0.010
0.010
0.010
0.010
0.060
0.45
0.45
...
1.0
1.0
0.45
1.0
1.0
...
...
0.45
P -105
P110
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
0.040
0.040
0.060
0.060
...
...
Q -125
Q -125
Q -125
Q -125
1
2
3
4
...
...
...
...
0.35
0.35
0.50
0.50
...
...
...
...
1.00
1.00
1.90
1.90
...
...
...
...
.75
NL
NL
NL
...
...
...
...
1.20
NL
NL
NL
0.99
0.99
0.99
0.99
...
...
...
...
0.020
0.020
0.030
0.030
0.010
0.020
0.010
0.020
...
...
...
...
Note:
***
For Grade C - 75, Type 1, Chromium, Nickel and Copper combined shall not exceed 0.50%.
*
The Carbon contents for L - 80 may be increased to 0.50% max. if the product is oil
quenched.
*
The Carbon contents for C - 95 may be increased to 0.55% max. if the product is oil
quenched.
NL
No Limit. Elements shown must be reported in product analysis.
Table 5.B - Chemical Composition of API Tubulars
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PAGE
IDENTIFICATION CODE
ENI S.p.A.
Agip Division
REVISION
STAP-P-1-M-6110
Yield Strength
Group
Grade
34 OF 134
min.
Tensile
Strength
max.
Hardness
min.
psi
MPa
psi
MPa
psi
MPa
max.*
HRC
BHN
H -40
J - 55
K - 55
N - 80
40,000
55,000
55,000
80,000
276
379
379
552
80,000
80,000
80,000
110,000
552
552
552
758
60,000
75,000
95,000
100,000
414
517
655
689
...
...
...
...
...
...
...
...
C - 75 1,2,3
C - 75 9Cr
C - 75 13Cr
L - 80 1
L - 80 9 Cr
L - 80 13 Cr
C - 90
C - 90
C - 90
C - 90
75,000
75,000
75,000
80,000
80,000
80,000
90,000
90,000
90,000
90,000
517
517
517
552
552
552
620
620
620
620
90,000
90,000
90,000
95,000
95,000
95,000
105,000
105,000
105,000
105,000
620
620
620
655
655
655
724
724
724
724
95,000
95,000
95,000
95,000
95,000
95,000
100,000
100,000
100,000
100,000
655
655
655
655
655
655
690
690
690
690
...
22
22
23
23
23
25.4
25.4
25.4
25.4
...
237
237
241
241
241
255
255
255
255
C - 95
95,000
655
110,000
758
105,000
724
...
...
P - 105
P - 110
105,000
110,000
724
758
135,000
140,000
931
965
120,000
125,000
827
862
...
...
...
...
Q -125
Q -125
Q -125
125,000
125,000
125,000
860
860
860
150,000
150,000
150,000
1035
1035
1035
135,000
135,000
135,000
930
930
930
...
...
...
...
...
...
Specified Wall
Thickness
Allowable
Hardness
Variation
Inches
HRC
0.500 or less
0.501 to 0.749
0.750 to 0.999
1.000 and
above
3.0
4.0
5.0
6.0
0.500 or less
0.501 to 0.749
0.750 and
above
3.0
4.0
5.0
In case of dispute, laboratory Rockwell C hardness tests shall be used as the referee
method.
Table 5.C - API Tensile and Hardness Requirements
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IDENTIFICATION CODE
STAP-P-1-M-6110
PAGE
35 OF 134
REVISION
ARPO
PAGE
IDENTIFICATION CODE
ENI S.p.A.
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36 OF 134
REVISION
STAP-P-1-M-6110
6.
6.1.
RANGE LENGTHS
The following tables provide the API tubular length ranges available.
Range
16-25
25-24
24-48
18
28
36
20-24
28-32
20
28
Tubing
** Total range length include
* Range Length for 100% or more of carload
Pup Joint
*** Lengths 2,3,4,6,8,10 and 12ft
Tolerance 3ins
* Carload tolerance shall not apply to orders of less than a carload. For any carload of pipe, shipped
to the final destination without transfer or removal from the car, the tolerance shall apply to each car.
For any order consisting of more than a carload and shipped from the manufacturers facility by rail.
but not to the final destination, the carload tolerance shall apply to the total order, but not to the
individual carloads.
** By agreement between purchaser and manufacturer or processor the total range length for range
1 tubing may be 20-28ft
*** 2ft pup joints may be furnished up to 3ft long by agreement between purchaser and
manufacturer, and lengths other than those listed may be furnished by agreement between
purchaser and manufacturer.
Table 6.A - API Range Length In Feet
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PAGE
IDENTIFICATION CODE
37 OF 134
REVISION
STAP-P-1-M-6110
Range
4.88-7.62
7.62-10.36
10.36-14.63
1.83
1.52
1.83
5.49
8.53
10.97
6.10-7.32
8.53-9.75
0.61
0.61
6.10
8.53
Tubing
** Total range length include
* Range Length for 100% or more of carload
Pup Joint
*** Lengths 0.61, 0.19, 1.22, 1.83, 2.44, 3.05 and 3.66m
Tolerance 76.2mm
* Carload tolerance shall not apply to orders of less than a carload shipped from the manufacturers
or processors facility. For any carload of pipe shipped from the manufacturers or processors
facility to the final destination without transfers or removal from the car, the tolerance shall apply to
each car. For any order consisting of more than a carload and shipped by rail, but not to the final
destination in the rail cars loaded, the carload tolerance shall apply to the total order, but not to the
individual carloads.
** By agreement between the purchaser and manufacturer or processor the total range length for
range 1 tubing may be 6.10-8.53m
*** 0.61m pup joints may be furnished up to 0.91m long by agreement between purchaser and
manufacturer, and lengths other than those may be furnished be agreement between purchaser and
manufacturer.
Table 6.B - API Range Length in Metres
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PAGE
IDENTIFICATION CODE
38 OF 134
REVISION
STAP-P-1-M-6110
6.2.
6.2.1.
Markings
All API tubulars are marked as per API specification 5CT. The following example shows the
marking code.
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39 OF 134
REVISION
STAP-P-1-M-6110
6.2.2.
PAGE
IDENTIFICATION CODE
Colour Coding
Group 1, Group 3, Group 4
In addition to the required identification markings as specified in 6.2.1 above, each length of
casing and tubing shall be colour coded by one or more of the following methods.
A paint band encircling the pipe at a distance not greater than 2ft (0.61m) from the
coupling or box.
A paint band encircling the centre of the coupling.
Paint entire outside surface of coupling.
For pup joints shorter than 6ft (1.83m) in length, the entire surface except the threads shall be
painted.
The colour and number of bands shall be as follows:
Grade H 40
Grade J 55
Grade K 55
Grade N 80
Grade P 105
White
Grade P 110
White
Grade Q 125
Orange
Group 2
1)
A paint band or bands encircling the pipe at a distance not greater than 2ft (0,61m) from
the coupling or box.
Grade C75
One blue band
Grace C75, 9Cr
Grade L80
Grade C90
Grade C95
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3)
4)
40 OF 134
REVISION
STAP-P-1-M-6110
2)
PAGE
IDENTIFICATION CODE
Grade C95
Grace L80
Grade C90
Purple
Grade C95
Brown
For pup joints shorter than 6ft (1.83m) in length, the entire surface except the threads
shall be painted.
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7.
PAGE
IDENTIFICATION CODE
Considering the axial stress (a) in a string of casing, it is obvious that the stress due to the
buoyant weight of the casing below any point of interest will be a major component of the total
axial stress.
Furthermore any changes in the internal and external pressures acting on casing will induce
changes in the axial stress as well as the radial (r) and tangential (t) stresses.
In addition, since the pipe is held or fixed at both ends, changes in all three stresses will occur
due to temperature changes and from the occurrence, and degree, of any buckling effect.
The inter-relationship between these loads can be analysed manually by applying a
combination of Hooke's Law, Lame's Equations and some form of yield criteria. This is
referred to as Triaxial Stress Analysis.
The forces affecting casing design are outlined in section 7.1.
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REVISION
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7.1.
PAGE
IDENTIFICATION CODE
WELLBORE FORCES
Various wellbore forces affect casing design. Besides the three basic conditions (burst,
collapse and axial loads or tension), these include:
Buckling.
Wellbore confining stress.
Thermal and dynamic stress.
Changing internal pressure caused by production or stimulation operations
Changing external pressure caused by plastic formation creep.
Subsidence effects and the effect of bending in crooked holes.
This list above is by no means comprehensive and research in progress may identify some
other effects.
The steps in the casing design process are:
1)
Consider the loading factors for burst first, since burst will dictate the design for the
major part of the string.
2)
Next, the collapse loading should be evaluated and the string sections upgraded if
necessary.
3)
Once the weights, grades and section lengths have been determined to satisfy the
burst and collapse loading, the tensile load can then in turn be evaluated.
4)
The pipe can be upgraded as necessary as the loading is determined.
5)
From all of the above, the appropriate casing connection can be determined although, if
the well is to be completed and the casing exposed to long term production,
consideration may be given to using a premium connection.
The final step is a check on biaxial reductions in burst strength and collapse resistance
caused by compression and tension loads, respectively. If these reductions show the
strength of any part of the section to be less than the potential load, the section should again
be upgraded.
7.2.
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REVISION
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The DF may vary with the capability of the steel to resist damage inflicted from handling and
running equipment.
The company values selected for DFs are a compromise between safety margin and
economics. The use of excessively high DFs guarantees against failure but provides
excessive strength and, therefore, increased cost. The use of low DFs requires accurate
knowledge about the loads to be imposed on the casing as there is less margin available.
Casing is generally designed to withstand stress which, in practice, it seldom encounters due
to the assumptions used in calculations, whereas, production tubing has to bear pressures
and tensions which are known or can be calculated with considerable accuracy.
Furthermore, casing is cemented in place after installation whereas tubing is often recovered
and used again. As a consequence of this, and due to the fact that tubing has to combat
corrosion effects from formation fluid, a higher DF is used for tubing than casing.
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REVISION
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7.2.1.
PAGE
IDENTIFICATION CODE
Burst
Collapse
Tension
H 40
1.05
1.10
1.7
J 55
1.05
1.10
1.7
K 55
1.05
1.10
1.7
C 75
1.10
1.10
1.7
L 80
1.10
1.10
1.7
N 80
1.10
1.10
1.7
C 90
1.10
1.10
1.7
C 95
1.10
1.10
1.7
P 110
1.10
1.10
1.8
Q 125
1.20
1.10
1.8
The tensile DF on grade C 95 and below is 1.7, and higher than C 95 is 1.8.
Note:
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7.2.2.
PAGE
IDENTIFICATION CODE
For the chosen casing (diameter, grade, weight and thread) take the
lowest value from API casing tables, columns 13 through 19. This
value then divided by the applied DF gives the internal pressure
resistance of casing to be used for design calculation.
Collapse
Use only column 11 of the API casing tables and divide the value by
the DF to obtain the collapse resistance for design calculations.
Tension
Use the lowest value from columns 20 through 27 of the API casing
tables and divide it by the DF to obtain the joint strength for design
calculations.
Note:
The term Safety Factor as used in tubing design, implies that the actual physical properties
and loading conditions are exactly known and that a specific margin is being allowed for
safety. The loading conditions are not always precisely known in casing design, and therefore
in the context of casing design the term Safety Factor should be avoided at all times.
Section 8 describes the exact design process in detail including the determination of all the
loading applied.
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DESIGN CRITERIA
8.1.
BURST
46 OF 134
REVISION
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8.
PAGE
IDENTIFICATION CODE
Burst loading on the casing is induced when internal pressure exceeds external pressure.
8.1.1.
Design Methods
The most conservative design for burst assumes the gradient of dry gas inside the casing,
the pressure of which equals the formation pressure of the lowest pressure zone from which
the gas may have originated or, alternatively the fracture pressure of the open hole below the
shoe.
The basis for this design criteria is that a dry gas blow-out is assumed that, when shut-in at
the surface, would either build to the blow-out zone's static shut-in pressure or cause an
underground blow-out once the shut-in pressure reaches the fracture pressure of the
weakest formation exposed in the open hole section.
Most operating companies modify this basic dry gas design concept according to a number
of other influences including:
Based on the vast amount of well data which is currently available, a set of key design
considerations are made:
a)
b)
c)
d)
e)
f)
Blowouts, especially those which are capable of exerting ultra high surface
pressure (i.e. dry gas blowouts), are very rare.
Ultra high surface pressures can only be experienced if an actual dry gas blowout does occur.
High strength casing, regardless of how overdesigned it may be, has no impact
on the reduction of the blow-out risk.
Once a blow-out has occurred, damage to the rig, environment, etc. will have
already commenced, regardless of how strong the casing may be.
If there is a blow-out, even a dry gas blow-out, it does not always concur that the
casing will is exposed to high burst pressures.
Surface wellheads have an advantage over subsea wellheads during drilling
operations, as there is access to any of the previous casing annuli whereas this is
not available with conventional subsea wellheads.
Access to these annuli could in turn provide a means of applying back-up
pressure to a casing string, thus reducing the net burst pressure being exerted on
that particular string. This feature is not always possible if the annulus may is
either cemented to the surface or not cemented into the previous casing shoe.
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REVISION
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The key to this problem is to recognise the rare and exceptional well circumstances that may
require or result in a hard dry gas shut-in. The decision process should be based on the initial
adoption of a middle ground design.
The Eni-Agip Drilling Engineering Department evaluated these key design considerations and
have decided to use the most conservative method and to reduce the obtained results by
40%.
8.1.2.
Internal Pressure
1)
The wellhead burst pressure limit is arbitrary, and is generally set equal to that of
the working pressure rating of the wellhead and BOP equipment but with a
minimum of 140kg/cm2. See BOP selection criteria in section 12.1.
With a subsea wellhead, the wellhead burst pressure limit is taken as 60% of the
value obtained as the difference between the fracture pressure at the casing shoe
and the pressure of a gas column to surface but in any case not less than
2,000psi (140atm).
Consideration should be given to the pressure rating of the wellhead and BOP
equipment which must always be equal to, or higher than, the pressure rating of
the pipe.
When an oversize BOP having a capacity greater than that necessary is selected,
the wellhead burst pressure limit will be 60% of the calculated surface
pressure obtained as difference between the fracture pressure at the casing shoe
with a gas column to surface. Methane gas (CH4) with density of 0.3kg/dm 3 is
normally used for this calculation. In any case it shall never be considered less
than 2,000psi (140atm).
The use of methane for this calculation is the worst case when the specific
gravity of gas is unknown, as the specific gravities of any gases which may be
encountered will usually be greater than that of methane.
2)
3)
The bottom-hole burst pressure limit can be calculated and is equal to the
predicted fracture gradient of the formation below the casing shoe.
Connect the wellhead and bottom-hole burst pressure limits with a straight line to
obtain the maximum internal burst load verses depth.
When taking a gas kick, the pressure from bottom-hole to surface will assume different
profiles according to the position of influx into the wellbore. The plotted pressure versus
depth will produce a curve.
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b)
PAGE
IDENTIFICATION CODE
External Pressure
In wells with surface wellheads, the external pressure is assumed to be equal to the
hydrostatic pressure of a column of drilling mud.
In wells with subsea wellheads:
c)
Net Pressure
The resultant load, or net pressure, will be obtained by subtracting, at each depth, the
external from internal pressure.
Intermediate Casing
a)
Internal Pressure
1)
The wellhead burst pressure limit is taken as 60% of the calculated value obtained
as the difference between the fracture pressure at the casing shoe and the
pressure of a gas column to the wellhead.
In subsea wellheads, the wellhead burst pressure limit is taken as 60% of the
value obtained as the difference between the fracture pressure at the casing shoe
and the pressure of a gas column to the wellhead minus the seawater pressure.
3)
The bottomhole burst pressure limit is equal to that of the predicted fracture
gradient of the formation below the casing shoe.
Connect the wellhead and bottom-hole burst pressure limits with a straight line to
obtain the maximum internal burst pressure.
4)
b)
External Pressure
The external collapse pressure is taken to be equal to that of the formation pressure.
With a subsea wellhead, at the wellhead, hydrostatic seawater pressure should be
considered.
c)
Production Casing
The worst case burst load condition on production casing occurs when a well is shut-in and
there is a leak in the top of the tubing, or in the tubing hanger, and this pressure is applied to
the top of the packer fluid (i.e. completion fluid) in the tubing-casing annulus.
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Internal Pressure
1)
2)
3)
Note:
4)
Note:
b)
49 OF 134
REVISION
STAP-P-1-M-6110
a)
PAGE
IDENTIFICATION CODE
The wellhead burst limit is obtained as the difference between the pore pressure
of the reservoir fluid and the hydrostatic pressure produced by a colum of fluid
which is usually gas (density = 0.3kg/dm 3).
Actual gas/oil gradients can be used if information on these are known and
available.
The bottom-hole pressure burst limit is obtained by adding the wellhead pressure
burst limit to the annulus hydrostatic pressure exerted by the completion fluid.
Generally the completion fluid density is equal to, or close to, the mud weight in
which casing is installed.
It is usually assumed that the completion fluid and mud on the outside of
the casing remains homogeneous and retains the original density values
however this is not actually the case, particularly with heavy fluids, but it is
also assumed that the two fluids will degrade similarly under the same
conditions of pressure and temperature.
Connect the wellhead and bottomhole burst pressure limits with a straight line to
obtain the maximum internal burst pressures.
If it is foreseen that future stimulation or hydraulic fracturing operations
may be necessary, assume: at the perforation depth the fracture pressure
at that point and at the wellhead the fracture pressure at the perforation
depth minus the hydrostatic head in the casing plus a safety margin of
70kg/cm2 (1,000psi).
External Pressure
The external pressure is taken to be equal to that of the formation pressure.
With a subsea wellhead, at the wellhead, hydrostatic seawater pressure should be
considered.
c)
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REVISION
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2)
Since the fracture pressure and mud weight may be greater or lower below the
liner shoe than casing shoe, these values must be used to design the
intermediate casing string as well as the liner.
When well testing or producing through a liner, the casing above the liner is part of
the production string and must be designed according to this criteria.
Tie-Back String
In a high pressure well, the intermediate casing string above a liner may be unable to
withstand a tubing leak at surface pressures according to the production burst criteria. The
solution to this problem is to run and tie-back a string of casing from the liner top to surface,
isolating the intermediate casing.
8.2.
COLLAPSE
Pipe collapse will occur when the external force on a pipe exceeds the combination of the
internal force plus the collapse resistance.
It occurs as a result of either, or a combination of:
8.2.1.
Note :
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Surface Casing
a)
Internal Pressure
For wells with a surface wellhead, the casing is assumed to be completely empty.
In offshore wells with subsea wellheads, the internal pressure assumes that the mud
level drops due to a thief zone.
b)
External Pressure
In wells with a surface wellhead, the external pressure is assumed to be equal to that of
the hydrostatic pressure of a column of drilling mud.
In offshore wells with a subsea wellhead, it is calculated:
c)
Intermediate Casing
a)
Internal Pressure
The worst case collapse loading occurs when a loss of circulation is encountered while
drilling the next hole section with the maximum allowable mud weight. This results in the
mud level inside the casing dropping to an equilibrium level where the mud hydrostatic
equals the pore pressure of the thief zone. Consequently it will be assumed the casing
is empty to the height (H) calculated as follows:
(Hloss-H) x dm = H
loss x
Gp
dm
Gp
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External Pressure
The pressure acting on the outside of casing is the pressure of mud in which casing is
installed.
The uniform external pressure exerted by salt on the casing or cement sheath through
overburden pressure, should be given a value equal to the true vertical depth of the
relative point.
c)
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53 OF 134
REVISION
STAP-P-1-M-6110
Production Casing
a)
Internal Pressure
Assume the casing worst case is being completely empty. It is a fact of life, that during
the productive life of well, tubing leaks often occur and wells. Also wells may be on
artificial lift, or have plugged perforations or very low internal pressure values and, under
these circumstances, the production casing string could be partially or completely
empty. This must be taken into consideration in the design and the ideal solution is to
design for zero pressure inside the casing which provides full safety, nevertheless in
particular well situations, the Drilling and Completions Manager may consider that the
lowest casing internal pressure is the level of a column of the lightest density producible
formation fluid.
b)
External Pressure
Assume the hydrostatic pressure exerted by the mud in which casing is installed.
The uniform external pressure exerted by salt on the casing or cement sheath through
overburden pressure, should be given a value equal to the true vertical depth of the
relative point.
c)
2)
If a drilling liner is to be used in the drilling of a well, the casing above where the liner is
suspended must withstand the collapse pressure that may occur while drilling below
the liner.
When well testing or producing through a liner, the casing above the liner is part of the
production string and must be designed according to this criteria.
Tie-Back String
If the intermediate string above the liner is unable to withstand the collapse pressure
calculated according to production collapse criteria, it will be necessary run and tie-back a
string of casing from the liner top to surface.
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TENSION
8.3.1.
General
54 OF 134
REVISION
STAP-P-1-M-6110
8.3.
PAGE
IDENTIFICATION CODE
Tensile failure occurs if the longitudinal force exerted on a pipe exceeds, either the tensile
strength of the pipe or its connection. Generally, the connection used in a string of casing is
stronger than the pipe body although this must always be confirmed.
For situations where a connection coupling has to be special clearance, (i.e. of a smaller
diameter than the normal) the connection will be weaker or if flush joint pipe must be used in
special circumstances.
Tensile loads are imposed on the casing by:
Note:
8.3.2.
The weight of pipe itself. The highest tensile stresses will occur at the uppermost
portion of the pipe. The tension is the weight of the pipe in air less buoyancy.
Shock loading:
a)
While lowering casing through unstable formations such as cavings where
the casing string may get temporarily stuck before suddenly slipping through
thereby inducing tensile shock loads.
b)
When landing casing in a subsea wellhead from a floater.
Upward and downward reciprocating movements carried out where there is a
tendency to become differential stuck, etc. in order to become free. To free the
pipe considerable pull may be necessary.
Bumping a cement plug.
High internal pressure will induce tensional stresses caused by radial expansion
and, hence, axial contraction.
Bending.
The varying parameters which can affect tensile loading leads to the
estimates used for the tensile forces are more uncertain than the
estimates for either burst and collapse. The DF imposed is therefore
correspondingly much larger.
Buoyancy Force
The effect of buoyancy is generally assumed to be the reduction in weight of the casing string
when it is suspended in a liquid compared to its weight in air.
The buoyancy or reduction in string weight, as observed on the block is actually the resultant
of pressure forces acting on all the exposed horizontal faces and in calculations is defined as
negative as it act upwards, hence reducing the pipe weight.
The areas referred to are the tube end areas, the shoulders at point of changing casing
weights and, to a smaller degree, the shoulders on collars (Refer to figure 8.b).
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REVISION
STAP-P-1-M-6110
a)
55 OF 134
b)
Shoulders on collars
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REVISION
STAP-P-1-M-6110
Well Depth
(m)
Casing Weight
(kg)
Casing Data
Size
(ins)
95/8
95/8
95/8
0-1000
1000-2000
2000-3000
Unit Weight
lbs/ft (kg/m)
47.0
69.9
43.5
64.7
40.0
59.5
Hydrostatic Head
(atm (*))
150
300
450
56 OF 134
Cross Sectional
Area (Af cm2)
87.6
81.0
73.9
Total Casing Weight
Buoyancy (kg)
150 (87.6-81) =
300 (81-73.9) =
450 (73.9) =
Total Buoyancy
37,267kg
69.900
64.700
59.500
194.100
990
2.130
33.255
36.375
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57 OF 134
REVISION
STAP-P-1-M-6110
Fluid Head
Density
Degrees
API
Specific
Gravity
lbs/gal
lbs/cu ft
g/cc
psi/ft
kg/sp
cm/m
Buoyancy
Factor*
60
55
50
45
40
35
30
25
20
15
10
0.738
0.758
0.779
0.801
0.825
0.849
0.876
0.904
0.933
0.985
1.000
1.007
1.031
1.055
1.079
1.103
1.127
1.151
1.175
1.199
1.223
1.247
1.271
1.295
1.319
1.343
1.367
1.391
1.415
1.439
1.463
1.487
1.511
1.535
1.559
1.583
1.607
6.160
6.325
6.499
6.683
6.878
7.085
7.304
7.537
7.786
8.052
8.337
8.400
8.600
8.800
9.000
9.200
9.400
9.800
9.800
10.00
10.200
10.400
10.600
10.800
11.00
11.200
11.400
11.500
11.800
12.000
12.200
12.400
12.600
12.800
13.000
13.200
13.399
46.08
47.31
48.62
49.99
51.45
53.00
58.64
56.38
58.24
60.23
62.36
62.63
64.33
65.82
67.32
68.82
70.31
71.81
73.30
74.80
75.30
77.79
79.29
80.78
82.28
83.78
85.27
86.77
88.27
89.76
91.26
92.75
94.25
95.75
97.24
98.74
100.23
0.738
0.765
0.779
0.801
0.825
0.848
0.876
0.904
0.933
0.965
1.000
1.007
1.031
1.055
1.079
1.103
1.127
1.151
1.175
1.199
1.223
1.247
1.271
1.295
1.319
1.343
1.367
1.391
1.415
1.439
1.463
1.487
1.511
1.535
1.559
1.583
1.607
0.320
0.328
0.336
0.347
0.357
0.368
0.379
0.391
0.404
0.418
0.433
0.435
0.446
0.457
0.467
0.477
0.488
0.498
0.509
0.519
0.529
0.540
0.550
0.561
0.571
0.581
0.592
0.602
0.612
0.823
0.633
0.644
0.654
0.664
0.675
0.585
0.696
0.0738
0.0758
0.0779
0.0801
0.0825
0.0649
0.0876
0.904
0.0933
0.0965
0.1000
0.1007
0.1031
0.1055
0.1079
0.1103
0.1127
0.1151
0.1175
0.1199
0.1223
0.1247
0.1271
0.1295
0.1319
0.1343
0.1367
0.1391
0.1415
0.1439
0.1463
0.1487
0.1511
0.1535
0.1559
0.1583
0.1607
0.905
0.903
0.900
0.897
0.894
0.891
0.688
0.884
0.680
0.675
0.872
0.871
0.868
0.865
0.662
0.859
0.856
.0852
0.849
0.846
0.843
0.840
0.837
0.834
0.831
0.828
0.825
0.822
0.819
0.816
0.613
0.810
0.806
0.803
0.800
0.797
0.794
BF = 1 m / s
BF = Buoyancy Factor
m = Mud Density
s = Steel Density
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REVISION
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Fluid Head
Density
Degrees
API
PAGE
IDENTIFICATION CODE
Specific
Gravity
lbs/gal
lbs/cu ft
g/cc
psi/ft
kg/sp
cm/m
Buoyancy
Factor*
1.631
1.655
1.679
1.703
1.727
1.751
1.775
1.799
1.823
1.847
1.871
1.895
1.919
1.943
1.967
1.991
2.015
2.039
2.063
2.087
2.111
2.135
2.159
2.183
2.207
2.231
2.255
2.278
2.326
2.350
2.374
2.398
13.600
13.800
14.000
14.200
14.399
14.600
14.800
15.000
15.200
15.399
15.600
15.800
16.000
16.200
16.400
16.600
16,800
17.000
17.200
17.400
17.600
17.800
18.000
18.200
18.400
18.600
18.800
19.000
19.400
19.600
19.800
20.000
101.73
103.23
104.72
106.22
107.71
109.21
110.71
112.20
113.70
115.20
116.89
118.19
119.68
121.18
122.68
124.17
125.67
127.16
128.66
130.18
131.65
133.15
134.54
136.14
137.64
139.13
140.63
142.12
145.12
146.61
148.11
149.61
1.631
1.655
1.679
1.703
1.727
1.751
1.775
1.799
1.823
1.847
1.871
1.895
1.918
1.943
1.967
1.991
2.015
2.039
2.063
2.067
2.111
2.135
2.159
.2183
2.207
2.231
2.255
2.278
2.326
2.350
2.374
2.398
0.706
0.716
0.727
0.737
0.748
0.755
0.768
0.779
0.789
0.799
0.610
0.820
0.831
0.841
0.851
0.862
0.872
0.863
0.893
0.903
0.914
0.924
0.935
0.945
0.955
0.955
0.976
0.987
1.007
1.018
1.028
1.038
0.1831
0.1655
0.1579
0.1703
0.1727
0.1751
0.1775
0.1799
0.1823
0.1547
0.1871
0.1895
0.1919
0.1943
0.1967
0.1991
0.2015
0.2039
0.2063
0.2087
0.2111
0.2135
0.2159
0.2183
0.2207
0.2231
0.2255
0.2278
0.2326
0.2350
0.2374
0.2398
0.791
0.788
0.785
0.782
0.779
0.776
0.773
0.770
0.767
0.764
0.761
0.757
0.754
0.751
0.748
0.745
0.742
0.739
0.736
.0733
0.730
0.727
0.724
0.72
0.718
0.715
0.712
0.708
0.792
0.699
0.696
0.693
Buoyancy factor is used is used compensate for loss of weight when steel tubulars are immersed in fluid.
Applicable only when tubing or casing is completely filled with fluid.
Apparent Weight = Weight in Air - Buoyant Force
Buoyancy Force =
Apparent Weight =
Wieght in Air
Steel Density
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8.3.3.
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IDENTIFICATION CODE
= 250,000kg
Mud weight
= 1.70kg/dm 3
Buoyancy factor
= 0.782
= 250,000 x 0.782
= 195,500kg
Buoyancy force
3)
= 54,500kg
Add the additional load due to bumping the cement plug to the casing string weight in
mud.
Note:
= 180kg/cm2
= 388.39cm2
= 388.39 x 180
= 69,910kg
A calculation of this kind is an approximation only because the assumption has been
made that:
More than one section of the casing string may be loaded in compression.
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Example Data
Estimated top of cement
Cemented length of casing
Casing size
Steel grade
Weight (imperial)
Weight (metric)
Internal diameter
Casing shoe depth
Mud weight during cementing operation
Average cement slurry density
Expected mud weight at end of next phase
Estimated bump plug pressure
Next phase total depth
2,800m
1,250m
7ins
P 110
38lbs/ft
56.55kg/m
5.898ins
4050m
1.93kg/l
2.00kg/l
2.16kg/l
140kg/cm2
4400m
248.28cm2
176.26cm2
72.02cm2
65oC
95oC
95.5oC
120.0oC
229t
162t
196t
0t
195t
158t
-3t
0t
75.4oC
103.3oC
27.9 oC
52t
-28t
207t
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API recommendation is to land the casing with the same tension at the end of the
displacement in all wells where the mud density does not exceed 12.5ppg (1.50kg/l) in the
next section.
The second option is used when excessive mud weights are anticipated, to prevent any
tendency of the casing to buckle above the freeze point.
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BIAXIAL STRESS
8.4.1.
General
62 OF 134
REVISION
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8.4.
PAGE
IDENTIFICATION CODE
When the entire casing string has been designed for burst, collapse and tension, and the
weights, grades, section lengths and coupling types are known, the reduction in burst
resistance needs to be applied due to biaxial loading.
The total tensile load, which is tensile loading versus depth, is used to evaluate the effect of
biaxial loading and can be shown graphically.
By noting the magnitude of tension (positive) or compression (negative) loads at the top and
bottom of each section length of casing, the strength reductions can be calculated using the
Holmquist & Nadai ellipse, see figure 8.c
Note:
8.4.2.
The effects of axial stress on burst resistance are negligible for the
majority of wells.
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8.4.3.
64 OF 134
0
0
0.1
0.2
0.3
0.4
0.5
0.6
Y=
0.7
0.8
0.9
1
1.1
0.1
0.2
0.3
0.4
Tensile load
Pipe body yield strength
0.5
0.6
0.7
0.8
0.9
1.1
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8.4.4.
PAGE
IDENTIFICATION CODE
= 8,610psi (605kg/cm2)
= 745,000lbs (338t)
Buoyancy factor
= 0.859
x=
5,750 x 47.62
= 274 t
1,000
From the curve or stress curve factors in figure 8.g, if X = 0.695 then Y = 0.445 and the
collapse resistance against tensile load can be determined:
Collapse resistance under load = Nominal Collapse Rating x 0.445
Refer to figure 8.e for a graphical representation of this calculation.
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66 OF 134
REVISION
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BENDING
8.5.1.
General
67 OF 134
REVISION
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8.5.
PAGE
IDENTIFICATION CODE
When calculating tensile loading, the effect of bending must also be considered, if applicable.
The bending of the pipe causes additional stress in the walls of the pipe. This bending causes
tension on the outside of the pipe and in compression on the inside of the bend, assuming the
pipe is not already under tension (Refer to figure 8.f).
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8.5.2.
PAGE
IDENTIFICATION CODE
Eq. 8.A
where:
Af
TB
MB D
2J
Eq. 8.B
where:
MB
ExJ
MB L
EJ
Eq. 8.C
where:
MB
Obtaining MB =
E J
from equation 2), equation 1) becomes:
L
E D
2L
Eq. 8.D
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Then, by using the more current units giving the build-up or drop-off angles in degrees/30m,
we obtain the final form of the equation for TB as follows:
TB
Af
E D Af
TB =
2 L
Eq. 8.E
180 30
1
L=
R
E D Af
TB =
180 2 30
Eq. 8.F
R=
Eq. 8.G
x x (2.1 x 10 6 ) (25 x 4) x D x Af
x
2 x 180
30 x 100
TB = 15.52 x
TB =
When:
Af
Square inches
Degrees/100ft
TB
Note:
Since most casing has a relatively narrow range of wall thickness (from
0.25 to 0.60ins), the weight of casing is approximately proportional to its
diameter. This means the value of the bending load increases with the
square of the pipe diameter for any given value of build-up/drop-off rate.
At the same time, joint tension strength rises a little less than the direct
ratio. The result is that bending is a much more severe problem with
large diameter casing than with smaller sizes.
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REVISION
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8.5.3.
PAGE
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8.5.4.
Calculation:
1)
2)
3)
4)
5)
6)
7)
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71 OF 134
REVISION
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CASING WEAR
8.6.1.
General
72 OF 134
REVISION
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8.6.
PAGE
IDENTIFICATION CODE
There is no reliable method of predicting casing wear and defining the reduction in casing
properties due to the reduction in casing performance through decreases in burst and
collapse values which are proportional to the reduction in wall thickness. However, theoretical
predictions may be made as described in this section.
For most purposes, consideration of wear allowances can be restricted to deviated wells with
the most likely wear spot at the kick-off point where burst reduction will be the greatest
consideration. In a vertical well , casing wear is usually in the first few joints below the
wellhead or intervals with a high dogleg severity. In deviated wells, wear will be over the buildup and drop off sections.
Figure 8.H - Casing Wear
Rotary speed.
Tool joint lateral load and diameter.
Drilling rate.
Inclination of the hole.
Severity of dog legs.
Casing wear factor.
The location and magnitude of volumetric wear in the casing string can be estimated by
calculating the energy imparted from the rotating tool joints to the casing at different casing
points and dividing this by the amount of energy required to wear away a unit volume of the
casing. The percentage casing wear at each point along the casing is then calculated from
the volumetric wear.
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REVISION
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Mud properties.
Lubricants.
Drill solids.
Tool joint roughness.
Tool joint hardness.
Note:
8.6.2.
The chemical action of gases such as H2S, CO2 and 02 tends to reduce
the surface hardness of steel and, thus, contributes significantly to the
rate of wear.
Eq. 8.H
where:
V
Specific Energy
The frictional energy imparted to the casing by the rotating tool joint equals:
Energy Input Per Foot = Friction Force Per Foot x Sliding Distance
Eq. 8.I
where:
Friction Force Per Foot = Friction Factor x Tool Joint Lateral Load Per Foot
Sliding Distance = n x TJ Diameter x Rotary Speed x Contact Time
and
Tool Joint Contact Time =
S x TJL
DPJL
where:
S
Drilling distance(ft)
TJL
DPJL
Eq. 8.J
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TJLLPF x TJL
DPJL
Eq. 8.K
where:
L
DPJL
Eq. 8.L
Combining eq. 8.h-eq. 8.l shows that the Wear Volume V equals:
v=
60 x x F x L x D x N x S
P
Eq. 8.M
where:
V
The tool joint and drill pipe lengths do not appear in Equation 6 because they do not
effect the amount of casing wear in the linear model.
Note:
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8.6.3.
PAGE
IDENTIFICATION CODE
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REVISION
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78 OF 134
REVISION
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79 OF 134
REVISION
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REVISION
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8.6.4.
PAGE
IDENTIFICATION CODE
Wear Factors
Tool Joint
Water+Betonite+Barite
Smooth
0.5 to 1
Water+Betonite+Lubricant (2%)
Smooth
0.5 to 5
Water+Betonite+Drill Solids
Smooth
5 to 10
Water
Smooth
10 to 30
Water+Betonite
Smooth
10 to 30
Water+Betonite+Barite
Slightly Rough
20 to 50
Water+Betonite+Barite
Rough
50 to 150
Water+Betonite+Barite
Very Rough
200 to 400
Drilling Fluid
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81 OF 134
REVISION
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Tool Joint
Casing
Wear, %
Wear
Factor
Friction
Factor
Remarks
Smooth Steel
0.043
18.2
5.6
0.21
75
1417
0.29
27.8
10.8
0.20
21.8
7.6
0.15
Tungsten Carbide
(spherical granules)
7.6
1.95
0.21
Tungsten Carbide
(spherical)
Agip Tungsten
Carbide
17.2
5.5
0.19
Low vibration
Agip Austenite
14.6
4.3
0.18
Low vibration
Aluminium
Bronze
9.5
2.3
0.32
High friction
Rough Tungsten
Carbide
Smooth Tungsten
Carbide
0.014
Hughes Smooth X
Drilco Sphere
Armacor-M
0.027
5.9
1.1
0.15
Amorphous material
Arnco-200X
0.018
7.0
1.43
0.14
Chromium Carbide
Colmonoy 5
0.016
5.9
1.06
0.15
Nickle base
Triboloy-800
0.020
4.2
0.65
0.12
Duocor
9.7
2.24
0.24
Titanium Carbide
Stellite 6
9.7
2.19
0.17
Cobal base
6.6
1.27
0.15
Sensitive in salt
mud
BP-1
10.2
2.53
0.19
Steel machine
ground smooth
BP-2
18.6
6.74
0.21
Polished Chrome
Cobalt Molybdenum
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figure 8.r below shows casing wear versus tool joint passes.
Water+Betonite+Barite
Rubber Protector
1 to 2
Water
Rubber Protector
4 to 10
Drilling Fluid
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REVISION
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84 OF 134
REVISION
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REVISION
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Drilling Fluid
Mud Weight
(lbs/gal)
Tool Joint
Weighting
Material
Wear Factor
(10-l0psi-1 )
Oil+Bentonite
10
Smooth
Barite
0.9 to 1.2
Water+Bentonite
10
Smooth
Barite
0.8 to 1.6
Water+Bentonite
10
Smooth
Iron Oxide
3 to 4
Water+Betontite
10
Smooth
Drill Solid
5 to 11
Water+Betontite
10
Smooth
Sand
11 to 13
Water+Betontite
8.8
Smooth
None
22 to 27
Table 8.F - Effect of Weighting Material on Casing Wear Factor (Bol, 1985)
Weighting materials were found to reduce casing wear in all cases. Wear was greatest (F=
22 to 27), when no weighting material was present to act as a buffer between the tool joint
and the casing. The addition of silica sand to the bentonite and water reduced the casing
wear in half, (F = 11 to 13).
Drill solids (F = 5 to 11) produced less wear than silica sand.
Iron oxide (F = 3 to 4), which is often considered very abrasive, produced less wear than all of
the other weighting materials except barite. This is apparently due to the small size of the iron
oxide weighting particles.
These tests indicate that the size of the weighting particles may be more important than the
composition of the particles.
Oil based and water based muds weighted with barite produced minimal wear (F = 0.8 to
1.6). This shows the importance of having good solids control when using heavily weighted
muds.
Shell (Bol, 1985) found that the addition of 2% lubricant to an unweighted mud consisting of
water and bentonite significantly reduced casing wear refer to figure 8.v.
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86 OF 134
REVISION
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8.6.6.
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8.6.7.
PAGE
IDENTIFICATION CODE
3)
4)
If the allowable operating time is less than the anticipated operating time, use heavier casing
(or increases the grade) 100m above and to 60m below the wear point until the allowable
operating time exceeds the anticipated operating time.
If the allowable operating time is greater than the anticipated operating time (say estimated 50
days allowable versus estimated 20 days operating) do not include a wear allowance. If the
allowable operating time and the anticipated operating time are about the same, either:
a)
b)
Monitor casing wear during drilling, and commission an intermediate string if the
worn casing strength approaches the design loads.
In any given situation whether option a) or b) is exercised will be dependent upon a number of
factors, many of which are beyond the scope of routine casing design.
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Option a)
Is the conservative approach, but it may be too high, given the gross uncertainties inherent in
wear estimations. However, in rank wildcats, particularly in remote locations, it may be
justified.
Option b)
Requires a base caliper survey to be run immediately after installing the casing string,
followed by runs at discrete intervals during the drilling phase.
If wear is proven to have occurred, and an intermediate string has to be commissioned early,
the deeper objectives of the well may not be reached. However, conditions as drilling
proceeds may indicate that the design loads assumed are not going to be encountered and
the reduction in casing strength is acceptable.
In any event, valuable data on casing wear in the area will be obtained and field practices may
be improved as result of the attention paid to wear, eventually leading to a reduction in overall
wear rates.
In most cases, option b) is preferred.
8.6.8.
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SALT SECTIONS
8.7.1.
General
89 OF 134
REVISION
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8.7.
PAGE
IDENTIFICATION CODE
Salt formations often exhibit plastic flow properties which can cause exceedingly high loads
on casing. The rate of salt flow is a function of its composition, temperature, depth or
overburden pressure and also probably influenced by how it is bedded or interbedded with
other formations.
The problem of salt formations has to be assessed on an individual well to well and/or area to
area basis.
The objectives for drilling through salt zones should be:
a)
b)
With regards to trouble free drilling, sticking due to salt flow, mud problems from salt
contamination, hole enlargement and the well's overall casing programme, are the prime
factors to be considered.
There are other factors that have to not be under evaluated such as:
Control of gas flows from porous zones interbedded in the salt, differential sticking
in porous zones.
Abnormal pressure due to entrapment of pressure by salt.
Shale sloughing from interbedded or boundary shales.
To prevent casing collapse, the designer should plan for non-uniform salt loading, obtaining
the best possible cement job, using casing with higher than normal collapse ratings and
possibly two strings of casing through the salt section.
Running casing in salt sections is rather a cementing problem than a casing design problem.
In some cases, two strings may be more advantageous as experience has demonstrated that
it is not practical to design a casing string to resist collapse. This technique is probably the
most reliable and safest approach for preventing casing collapse but is probably not
necessary for the majority of salt sections.
8.7.2.
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REVISION
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Another source of non-uniform loading is bending of the casing as a result of curvature of the
wellbore. Consider an initially straight casing length under external pressure and axial loads
that are insufficient to result in collapse. Now assume that the casing is gradually bent by an
additional external force as for example due to salt flowing (Refer to figure 8.y below).
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8.7.3.
PAGE
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For production casing exposed to salt formations, assume the casing will be
always evacuated at some point during the well life.
The uniform external pressure exerted by salt on the casing (or cement sheath)
due to overburden pressure should be given a value equal to the true vertical
depth to the point in question.
Proper cement placement opposite a salt section is often difficult due to washout.
Any beneficial effects of the cement sheath should be ignored during design of the
casing.
If the wellbore is deviated, additional axial forces due to hole curvature should be
considered when determining the collapse resistance of the casing.
Conclusions:
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CORROSION
9.1.
GENERAL
96 OF 134
REVISION
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9.
PAGE
IDENTIFICATION CODE
A production well design should attempt to contain produced corrosive fluids within tubing.
They should not be produced through the casing/tubing annulus.
However, it is accepted that tubing leaks and pressured annuli are a fact of life and as such,
production casing strings are considered to be subject to corrosive environments when
designing casing for a well where hydrogen sulphide (H2S) or carbon dioxide (CO2) laden
reservoir fluids can be expected.
During the drilling phase, if there is any likelihood of a sour corrosive influx occurring,
consideration should be given to setting a sour service casing string before drilling into the
reservoir.
The BOP stack and wellhead components must also be suitable for sour service.
9.1.1.
Use of casing and wellhead equipment with a metallurgy suitable for sour service.
Use of high alkaline mud to neutralise the H2S gas.
Use of inhibitors and/or scavengers.
These measures will provide a degree of short term protection necessary to control corrosion
of the casing in the hole during the drilling phase.
9.1.2.
Development Wells
Casing corrosion considerations for development wells can be confined to the production
casing only.
Internal corrosion
The well should be designed to contain any corrosive fluids (produced or injected) within
the tubing string by using premium connections.
Any part of the production casing that is likely to be exposed to the corrosive
environment, during routine completion/workover operations or in the event of a tubing
or wellhead leak, should be designed to withstand such an environment.
External corrosion
Where the likelihood of external corrosion due to electrochemical activity is high and the
consequences of such corrosion are serious, the production casing should be
cathodically protected (either cathodically or by selecting a casing grade suitable for the
expected corrosion environment).
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9.1.3.
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Oxygen (O2)
Oxygen dissolved in water drastically increases its corrosivity potential. It can cause
severe corrosion at very low concentrations of less than 1.0ppm.
The solubility of oxygen in water is a function of pressure, temperature and chloride
content. Oxygen is less soluble in salt water than in fresh water.
Oxygen usually causes pitting in steels.
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Temperature
Like most chemical reactions, corrosion rates generally increase with increasing
temperature.
Pressure
Pressure affects the rates of chemical reactions and corrosion reactions are no
exception.
In oilfield systems, the primary importance of pressure is its effect on dissolved gases.
More gas goes into solution as the pressure is increased, this may in turn increase the
corrosivity of the solution.
9.2.
FORMS OF CORROSION
The following forms of corrosion are addressed in this manual:
Corrosion caused by H2S (SSC)
Corrosion caused by CO2 and ClCorrosion caused by combinations of H2S, CO2 and ClCorrosion in injection wells and the effects of pH and souring are not included.
The procedure adopted to evaluate the corrosivity of the produced fluid and the methodology
used to calculate the partial pressures of H2S and CO2 will be illustrated in the following subsections.
9.2.1.
In vertical oil wells, generally corrosion occurs only when the water cut becomes
higher than 15% which is the threshold or commonly defined as the critical level
and it is necessary to analyse the water cut profile throughout the producing life of
the well.
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b)
PAGE
IDENTIFICATION CODE
In highly deviated wells (i.e. deviations >80o), the risk of corrosion by H2S is higher
since the water, even if in very small quantities, deposits on the surface of the
tubulars and so the problem can be likened to the gas well case where the critical
threshold for the water cut drops to 1% (WC >1%).
The following formulae are used to calculate the value of pH2S (partial pressure of H2S) in
both the cases of gas (or condensate gas) wells or oil wells.
Firstly, the potential for SSC occurring is evaluated by studying the water cut values
combined with the type of well and deviation profile. If the conditions specified above are
verified then the pH2S can be calculated.
Gas Or Condensate Gas Well
H2S partial pressure is calculated by:
pH2S = SBHP x Y(H2S)/100
where:
SBHP
Y(H2S) =
pH2S
Basic method.
Material balance method.
If the quantity of H2S in gas at the bubble point pressure [mole fraction = Y(H2S)], is not known
or the values obtained are not reliable, the pH2S is calculated using both methods and the
higher of the two results is taken as the a reliable value. Otherwise the basic method is used.
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Basic Method
This method is used, without comparison with the other method, when the H2S value in the
separated gas at bubble point conditions is known and is reliable or if Y(H2S), molar fraction in
the separated gas at bubble point pressure (Pb) is higher than 2%.
The pH2S is calculated by:
pH2S = Pb x Y(H2S)/100
where:
Pb
Y(H2S) =
Mole fraction in the separated gas at bubble point (from PVT data if
extrapolated)
pH2S
Eq. 9.A
where:
Psep
H2Ssep =
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PM =
1000
GOR
1000 +
(d 29) GOR
23. 6
PMres
23. 6
Eq. 9.B
where:
CiMi / 100
i = 1
PM res =
Ci
Mi
Eq. 9.C
where:
H1
PM
The quantity of H2S in the gas in equilibrium is calculated (per litre of oil):
[H2S]gas = (GOR/23.6 x H2Ssep/106)
Eq. 9.D
where:
GOR
23.6
Conversion factor
Eq. 9.E
where:
K
H2
Henry constant for the reservoir temperature and reservoir oil. (See
procedure for calculating Henry constant)
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In general, H2S corrosion can occur at either the wellhead or bottom-hole without distinction.
There is SSC potential if pH2S >0.0035 atm and STHP >18.63 atm.
Procedure For Calculating Henry Constant
The value of the Henry constant is a function of the temperature measured at the separator.
The mapping method can be applied for temperatures at the separator of between 20C and
200C. Given the diagram in figure 9.a which represents the functions H(t) for the three types
of oils:
Heptane PM
100
N-propyl benzene PM
120
Methylnaphthalene PM
142
If 100 < PM < 120, the mean value is calculated using the H(t) curve of propyl
benzene and the H(t) curve of methylnaphthalene.
If 120 < PM < 142 the mean value is calculated using the H(t) curve of heptane
and the H(t) curve of propyl benzene.
Given FTHT, wellhead flowing temperature, the H1 value is interpolated linearly on
the chosen curve(s). For this purpose the temperature values immediately before
and after the temperature studied are taken into consideration.
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REVISION
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Henry
atm/Y[H 2 S]
130
120
110
100
90
methylnaphthalene PM = 142
80
N-propylbenzene PM = 120
heptane PM = 100
70
60
50
40
30
20
20
30
40
50
60
70
80
90
100 110 120 130 140 150 160 170 180 190 200
T C
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2)
Calculation is of the partial pressure at the wellhead, i.e. when FTHP <Pb:
The data result from the production conditions and only the basic method is used.
Basic Method
pH2S = STHP x Y(H2S) / 100
where:
STHP
Y(H2S)
the PVTs are reliable, Y(H2S) >0.2%, the partial pressure is calculated as:
pH2S = Y(H2S)(1) x FBHP
where:
Y(H2S) = molar fraction in gas separated at FBHP and at reservoir temperature
(from PVT)
the PVTs are not reliable, the material balance method can be used as in the
case of undersaturated oil; these are the worst conditions. The error made can be
high when Pb >FBHP.
If the percentage (ppm) of H2S in the gas under static conditions is not known, the
corresponding value in reservoir conditions is assumed as being partial pressure at the
wellhead.
(2)
If the percentage (ppm) of H2S in the separated gas under static conditions is not
known, the corresponding value in reservoir conditions is assumed as being partial
pressure at the wellhead.
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9.2.2.
PAGE
IDENTIFICATION CODE
Corrosion Caused By CO2 And ClIn the presence of water, CO2 gives rise to a corrosion form which is different to those
caused by the presence of H2S. It also occurs only if the partial pressure of CO2 exceeds a
particular threshold. As in the case of SSC, the possibility that corrosions exist in water cut
values combined with the type of well and deviation profile, is evaluated. If the conditions
described in section 9.2.1 exist, then the pCO2 is then calculated.
Gas Or Condensate Gas Wells
The partial pressure is calculated:
pCO2 = SBHP x Y(CO2)/100
where:
SBHP
Y(CO2) =
pCO2
Y(CO2) =
Mole fraction of CO2 in separated gas at bubble point pressure (from the
PVTs)
pCO2
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Oversaturated Oil
The oil is considered oversaturated when the gas separates in the fluid because the pressure
of the system is lower than bubble point pressure. Two situations may arise:
Case A
FTHP <Pb
FBHP >Pb
Case B
FTHP <Pb
FBHP <Pb
Calculation Of Partial Pressure In Case A:
Calculation of pCO2 in reservoir conditions:
FBHP >Pb pCO2 is calculated in the same way as undersaturated oil wells earlier in this
section.
pCO2 = Pb x Y(CO2)/100
where:
Pb
Y(CO2)
= mole fraction in separated gas at bubble point pressure (from the PVTs)
pCO2
Y(CO2)
STHP
If the percentage (ppm) of CO2 in the gas under static conditions is not known, the
corresponding value in reservoir conditions is assumed as being partial pressure at the
wellhead.
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REVISION
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Y(CO2)
pCO2
Y(CO2)
STHP
Corrosion Caused By H2S, CO2 And ClIt is possible to encounter H2S and CO2 besides Cl-. In this case the problem is much more
complex and the choice of suitable material is more delicate. The phenomenon is diagnosed
by calculating the partial pressures of H2S and CO2 and comparing them with the respective
thresholds.
Note:
(4)
If the percentage (ppm) of CO2 in the gas under flowing/static conditions is not known,
the corresponding value in reservoir conditions is assumed as being partial pressure at
the wellhead.
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9.3.
PAGE
IDENTIFICATION CODE
Cathodic protection
Chemical inhibition
Chemical control
Oxygen scavengers
Chemical sulphide scavengers
pH adjustment
Deposit control
Coatings
Non metallic materials or metallurgical
Control
Stress reduction
Elimination of sharp bends
Elimination of shock loads and vibration
Improved handling procedures
Corrosion allowances in design
Improved welding procedures
Organisation of repair operations.
Means
Surface treatment
Plastic coating
Plating
pH
Temperature
Pressure
Chloride concentration
CO2 concentration
H2S concentration
H2O concentration
Flow rate
Inhibitors
Improvement of the corrosion resistivity of the Addition of the alloying elements micro structure
steel
Table 9.A - Counter Measures to Prevent Corrosion
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9.4.
PAGE
IDENTIFICATION CODE
CORROSION INHIBITORS
An inhibitor is a substance which retards or slows down a chemical reaction. Thus, a
corrosion inhibitor is a substance which, when added to an environment, decreases the rate
of attack by the environmental on a metal.
Corrosion inhibitors are commonly added in small amounts to acids, cooling waters, steam or
other environments, either continuously or intermittently to prevent serious corrosion.
There are many techniques used to apply corrosion inhibitors in oil and gas wells:
9.5.
9.5.1.
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9.5.2.
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9.5.3.
9.5.4.
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REVISION
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In general, ferritic-austenitic (duplex) stainless steel consists of between 40-70% ferrite and
has a typical composition of 22% Cr-5.5% Ni-3% Mo-0.14% N.
The resulting steel has properties that are normally found in both phases: the ferrite promotes
increased yield strength and resistance to chloride and hydrogen sulphide corrosion cracking;
while the austenite phase improves workability and weldability.
This material is used extensively for tubulars used in severe CO2 and H2S conditions.
As a general note, there is a large gap between the 13CR and Duplex Stainless Steels used
as tubulars for their good anti-corrosion properties. This gap is attempted to be filled with
Super 13CR tubing being developed.
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REVISION
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9.6.
PAGE
IDENTIFICATION CODE
FBHT >80 C
60oC< FBHT >80oC
FBHT >80oC
FBHT >80oC
FBHT <80oC
FBHT <150oC
o
150 C< FBHT <200oC
Cl- <50,000
25% Cr-SA
FBHT <150oC
Cl- <50,000
13% Cr-80KSI
Max
FBHT <200oC
Cl- >50,000
22% Cr CW
25% Cr CW
22% Cr
25% Cr
Alternately
L80-Mod, C90-1, T95-1
L80-Mod, C90-1, T95-1
Alternately
22% Cr
13% Cr
Alternately
Cl- <50,000
25% Cr
Alternately
22% Cr
25% Cr
Cl- <50,000
25% Cr
Cl- >50,000
25% Cr CW
FBHT <250oC
Cl- <20,000
25% Cr
FBHT <250oC
Cl- <50,000
25% Cr CW
Cl- <50,000
28% Cr
FBHT <200oC
Cl- <50,000
22% Cr SA
FBHT <250oC
Cl- <50,000
25% Cr SA
FBHT <200oC
Cl- >50,000
28% Cr
Incoloy 825
28% Cr
Incoloy 825
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9.7.
PAGE
IDENTIFICATION CODE
ORDERING SPECIFICATIONS
When ordering tubulars for sour service, the following specifications should be included, in
addition to those given in the above table.
1)
2)
3)
4)
5)
6)
7)
Downgraded grade N80, P105 or P110 tubulars are not acceptable for orders for J55 or
K55 casing.
The couplings must have the same heat treatment as the pipe body.
The pipe must be tested to the alternative test pressure (see API Bulletins 5A and 5AC).
Cold die stamping is prohibited, all markings must be paint stencilled or hot die
stamped.
Three copies of the report providing the ladle analysis of each heat used in the
manufacture of the goods shipped, together with all the check analyses performed,
must be submitted.
Three copies of a report showing the physical properties of the goods supplied and the
results of hardness tests (Refer to step 3 above) must be submitted.
Shell modified API thread compound must be used.
Note:
The steel used in the manufacture of the casing should have been quenched and
tempered. (This treatment is superior to tubulars heated/treated by other methods
e.g. normalising and tempering).
All sour service casing should be inspected using non-destructive testing or
impact tests only, as per API Specification 5CT.
9.8.
9.8.1.
CO2 Corrosion
The following guidelines should be used for the appropriate corrosive environment.
In exploration wells, generally the presence of CO2 in the formation causes little
problems, and will have no influence on material selection for the casing.
In producing wells, the presence of CO2 may lead to corrosion on those parts
coming in contact with CO2 which normally means the production tubing and part
of the production casing below the packer.
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9.8.2.
PAGE
IDENTIFICATION CODE
H2S Corrosion
In exploration wells, if there is high probability of encountering H2S, consideration should
be given to limit casing and wellhead yield strength according to API 5CT and NACE
standard MR-01-75.
In producing wells, casing and tubing material will be selected according to the amount
of H2S and other corrosive media present.
Refer to figure 9.c and figure 9.d for partial pressure limits.
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Domain
Mild Environment
Domain A
Domain B
Domain C
Domain D
Material
Domain E
Domain F
SM 95G
SM 125G
API
SM 80S
SM 90S
SM 95S
SM 85SS
SM 90SS
SM C100
SM C110
SM 9CR 75
SM 9CR 80
SM 9CR 95
SM 13CR 75
SM 13CR 80
SM 13CR 95
SM 22CR 65*
SM 22CR 110**
SM 22CR 125**
SM 25CR 75*
SM 25CR 110**
SM 25CR 125**
SM 25CR 140**
SM 2535-110
SM 2535-125
SM 2242-110
SM 2242-125
SM 2035-110
SM 2035-125
SM 2550-110
SM 2550-125
SM 2550-140
SM 2060-110***
SM 2060-125***
SM 2060-140***
SM 2060-155***
SM C276-110***
SM C276-125***
SM C276-140***
L 80
C 90
T 95
1Cr 0.5Mo Steel
Modified AISI 4130
Domain G
SM
Designation
J 55
N 80
P 110
(Q 125)
Cr or Cr Mo Steel
API
13Cr Steel
Modified AISI 420
Wet CO2 with a little H 2S
Corrosion
117 OF 134
REVISION
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Application
(Refer to figure 9.e)
PAGE
IDENTIFICATION CODE
Notes
Higher yield
strength for sour
service
Quenched and
tempered
Quenched and
tempered
Duplex phase
Stainless steels
*
Solution Treated
** Cold drawn
As cold drawn
As cold drawn
*** Environment
with free
Sulphur
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REVISION
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10.
TEMPERATURE EFFECTS
10.1.
For deep wells, reduction in yield strength must be considered due to the effect on steel by
the temperature.
It no information is available on temperature gradients in the area, a gradient of 3C/100m is
to be used.
Use the values in figure .a10.a for reduction in yield strength.
where:
K0.2
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10.2.
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IDENTIFICATION CODE
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11.
PAGE
IDENTIFICATION CODE
LOAD CONDITIONS
When running casing, shock loads are exerted on the pipe due to:
Sudden deceleration forces (e.g.: if the spider accidentally closes or the slips are
kicked-in when the pipe is moving or the pipe hits a bridge).
Sudden acceleration forces (e.g.: picking the pipe out of the slips or if the casing
momentarily hangs up on a ledge then freed).
Either of the above will cause a stress wave to be created which will travel through the casing
at the speed of sound.
This effect is quantified as follows:
SL = 150 x V x Af
where:
SL
V
Af
150
11.1.
=
=
=
=
11.2.
CEMENTING CONSIDERATIONS
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The mud weight in the annulus is the lowest planned for the section.
The inside of the casing is full of cement slurry, with mud above.
The shoe instantaneously plugs off just as the cement reaches it and the
pressure rises to a value of approximately 1,000psi before the pumps are able to
be shut down.
Cw
Mw
Ai
1,000
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11.3.
PAGE
IDENTIFICATION CODE
PRESSURE TESTING
Casing pressure tests will be carried out according to the pressure stated in the drilling
programme. The leading criteria for pressure testing will be the maximum anticipated
wellhead pressure.
In all cases the test pressure will be no higher than 70% of API minimum internal yield
pressure of the weakest casing in the string or to 70% of the BOP WP.
When establishing an internal casing pressure test, the differential pressure due to a
difference in fluid level and/or fluid density, inside and outside the casing, shall be taken into
account.
Consideration should be taken on the maximum allowable tensile strength of the casing
thread considering the relevant tensile design factor.
Each casing shall be pressure tested at the following times:
When cement plug bumps on bottom with a pressure stated in the drilling
programme.
When testing blind/shear rams of the BOP stack against the casing.
After having drilled out a DV collar.
A cemented liner overlap will be positively tested applying a pressure greater than the lea-off
pressure of the previous casing. If there is any doubt, an inflow test could be carried out, with
a sufficient drawdown to test the liner top to the most severe negative differential pressure
that will exist during the life of the well.
The test pressure shall be held and remain stable for at least 10-15 mins
The test pressure and method for each well are determined on an individual basis and shall
be included in the Geological and Drilling Programme.
11.4.
11.4.1. Buckling
Buckling is a failure of stability which can occur at stress levels well below the yield stress of
the material. Buckling cannot occur where the casing is supported by cement.
Factors responsible for buckling and the degree of buckling are:
All these factors are interrelated but the first three are generally considered major contributors
to buckling, while temperature and pressure changes are primarily the mechanisms that
cause the initial buckling.
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A buckling potential may exist in the uncemented portion of a string of casing, if the:
Buckling of long, uncemented portions of the casing string, in vertical wells, can be prevented
by:
Provided that all casing strings can be landed with full hanging weight, the buckling calculation
is only required on the small percentage of deep vertical wells in which the mud density is to
be raised during the drilling of the next open hole section. Thus, for the majority of wells,
buckling is not a major design problem.
11.4.2. Compressive Loads
Compressive loads can occur in casing strings as a result of:
In most well designs, the total compressive load is the buoyant load of the intermediate
casings, the tubing to production packer overpull and the weight of the wellhead. This
compressive load is carried by the outer casing string. This outer casing is usually the
conductor or surface casing.
When discussing compressive loads it is convenient to consider three types of well where:
a)
b)
c)
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REVISION
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Drilling Phase:
It is highly unlikely that any routine operation (other than extensive reverse circulation)
will cause a long term temperature decrease in the uncemented portion of a casing
string, thus, no loading applies.
b)
Production Phase:
Temperature induced stresses are of no consequence in the outer strings of casing
and attention need only be paid to the production string.
Producers are normally subjected to temperature increases under operating conditions
and the compressive load induced should be treated in the context of buckling.
The tensile loads induced by cooling in high volume injection wells, or in producers
during high volume stimulation treatments or emergency squeeze kills, must be taken
into account.
It should be added to the axial load and included in the design load if the occurrence of
such loading is anticipated
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12.
PAGE
IDENTIFICATION CODE
It should be realised that each drilling area may have local regulations
unique to that particular area which exceed the general requirements
stated in this section, or indeed the Eni-Agip Well Control Policy Manual.
In addition, the various operating companies and their contractors may
also vary from these general requirements, if dictated by individual
company policy and philosophy providing they are not less stringent than
described herein.
The anticipated formation pressure is the governing parameter which dictates the casing
depth, casing selection, BOP selection and pressure rating of the BOP equipment as
described previously in section 2.
The weakest element within any pressure control system determines the maximum pressure
that can be safely controlled.
Individual elements of the pressure control system may exceed the assembly WP, and
under no circumstances should components be used which are less than the
assembly WP. For instance, a 10,000psi choke may be rigged up with a 2,000psi BOP stack
in anticipation of its later use when the 10,000psi BOP stack is nippled up for a subsequent
string of casing.
The equipment in the well control system which has the lowest pressure rating will set the
rating for entire system e.g. 2,000psi stack and 10,000psi choke manifold would be rated to
only 2,000psi WP.
Since the well control system must be able to contain any anticipated formation pressures
that may be encountered, the maximum anticipated surface pressures must first be
calculated.
Many different methods are available to determine the maximum casing pressures which may
be encountered during a kick as described in section 2.
12.1.
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REVISION
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The graph illustrated in the attached figure 12.a has been prepared to enable the first
approximation of the BOP rating necessary for use in drilling an exploration well. To use the
graph, the setting depths of the various casings and the relative pore pressure gradients must
be found or determined during the design phase.
The co-ordinates in the graph are depth and pressure and comprises two groups of lines
respectively, one representing the BOPs to be used while drilling and the other the BOPs to
be used during well testing.
Each group outlines the different solutions available to the various pore pressure gradients.
Example:
The casing program assumes that a well test will be carried out at the shoe of 7
casing. From the diagram shown in table 12.a, the maximum test, drilling
pressure values and the size of BOP to be used should be obtained which is
given in table 12.a below.
Casing
(ins)
Shoe
Depth
(m)
Overburden
Gradient
(kg/cm2/10m)
Pore Press.
Gradient
(kg/cm2/10m)
Fracture
Gradient
(kg/cm2/10m)
BOP
Drilling
(psi)
Size
Production
Test (psi)
20
750
2.23
1.03
1.83
2,000
13 /8
2.620
2.36
1.30
2.01
5,000
9 /8
4.200
2.42
1.70
2.18
10,000
4.830
2.43
2.00
2.29
15,000
H
(Gr - Dg ) (Kg/cm2 )
10
where:
H
Gf
Dg
In the case of a well test, this pressure roughly corresponds to the limit value required for
pumping gas into the formation and is thus actually attainable in practice.
This hypothesis however is completely unrealistic in the drilling design, for which 60% of the
pressure Pmax will be used as limit value according to company policy in burst design
criteria, section 8.1. This value is also adopted by many other companies as the realistic
criterion of choice.
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12.2.
PAGE
IDENTIFICATION CODE
KICK TOLERANCE
Kick tolerance is the term used to define the maximum kick volume which can be safely
controlled by any well control method with constant BHP without fracturing the formation
below the last casing shoe.
The most dangerous situation is when the top of the kick reaches the casing shoe. This is
calculated with the following formula:
Ptop =
Gp H (Gi Hi + Gm Hm )
10
PP
Hi =
10
10
[HS (Gf r Gm ) + Gm H 10 PP ]
Gm Gi
Vshoe = Ca x Hi
V1 x P1 = P2 X V2
V1bottom x Pp = Vshoe x Pfr
where:
Ca
H
Hi
HS
Gfr
Gm
PP
Gi
Ptop
Gp
Hm
Pfr
=
=
=
=
=
=
=
=
=
=
=
=
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Appendix A - ABBREVIATIONS
API
BG
BHA
BHP
BHT
BOP
BPD
BPM
BSW
BUR
BWOC
BWOW
CBL
CCD
CCL
CET
CGR
CP
CRA
CW
DC
DHM
DLP
DLS
D&CM
DOB
DOBC
DOR
DP
DST
DV
ECD
ECP
EMS
EMW
EOC
ESD
ESP
FBHP
FBHT
FPI/BO
FTHP
FTHT
GLR
GMS
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GOC
GOR
GPM
GPS
GR
GSS
HAZOP
HHP
HP/HT
HW/HWDP
IADC
ID
IPR
JAM
KMW
KOP
LAT
LCM
LCP
LEL
LOT
LQC
LWD
MAASP
MD
MLS
MMS
MODU
MOP
MPI
MSL
MSS
MW
MWD
NACE
NDT
NMDC
NSG
NTU
OBM
OD
OH
OIM
OMW
ORP
OWC
P&A
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PBR
PCG
PDC
PDM
PGB
PI
PLT
ppb
ppg
ppm
PV
PVT
Q
Q/A Q/C
RFT
RKB
ROE
ROP
ROU
ROV
RPM
RT
S (HDT)
S/N
SBHP
SBHT
SCC
SD
SDE
SF
SG
SICP
SIDPP
SPM
SR
SRG
SSC
STG
TCP
TD
TGB
TOC
TOL
TVD
TW
UAR
UR
PAGE
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VBR
VDL
VSP
W/L
WBM
WC
WL
WOB
WOC
WOW
WP
YP
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Appendix B - BIBLIOGRAPHY
Document:
STAP Number
STAP-P-1-M-6140
STAP-P-1-M-6100
Overpressure Manual
STAP-P-1-M-6130
STAP-P-1-M-6160
STAP-P-1-M-6150
API Specification 5C
Holmquist & Nadai
Shell (Bol, 1985)
NACE Standard MR-01-75
Sumitomo Metals Literature