Faculty of Engineering

Petroleum Engineering Department

Drilling Engineering II
Fourth Stage

Lecture # 16
Casing Design

Pshtiwan Jaf 1
pshtiwan.jaf@koyauniversity.org
 Graphical Method for Casing Design
Additional Tensile Loads

1. Buoyancy: Wb = Wair x BF

2. Shock Load: Fs = 3200 Wn

3. Bending Force: FB = 63 D Wn Ø

2
 Graphical Method for Casing Design
Example:
An exploration well is to be drilled to a total depth of 13900 ft, relevant data are as follows:
Drilling Program: Casing program:
0-350 ft, 26 in hole 20 in casing to be set at 350 ft
350-6200 ft, 17 in hole 13 3/8 in casing to be set a t 6200 ft
6200-10400 ft, 12 in hole 9 5/8 in casing to be set at 10400 ft
10400-13900 ft, 8 in hole 7 in casing to be set at 13900 ft
The casing head housing will be installed on the 20" casing. The 7" casing will be run to the surface

Mud program: Formation Fluid gradient:

Down to 350 ft , Mud weight is 65 pcf 𝒑𝒔𝒊
0 - 6200 ft , 𝑷𝒇 = 𝟎. 𝟒𝟔𝟓 𝒇𝒕
Down to 6200 ft Mud weight is 67 pcf 𝒑𝒔𝒊
Down to 10400 ft Mud weight is 73 pcf 6200 ft – 10400 ft, 𝑷𝒇 = 𝟎. 𝟒𝟖 𝒇𝒕
𝒑𝒔𝒊
Down to 13900ft Mud weight is 87 pcf 10400ft – 13900 ft, 𝑷𝒇 = 𝟎. 𝟓𝟕 𝒇𝒕3
 Graphical Method for Casing Design
Example:
Surface Factor:
Burst = 1.1
Collapse = 0.85
Tension = 1.8
The 12 1/4“ hole experienced a maximum dog-leg severity of 3°/100 ft. The deviation at
other sections to be neglected.

Shock loads are to be included in the design of 9 5/8" and 7“ casing strings.

For collapse, burst and yield strength values refer to API tables.

Design suitable casing strings for the given hole sizes, taking into consideration the
available casing grades and the maximum expected pressures. 4
 Graphical Method for Casing Design
Example:

5
 Graphical Method for Casing Design
Solution:
A. 20" Casing
Since the setting depth is shallow (350 ft), it is assumed that no gas exist at this
shallow depth and kick calculation will be based on a water kick situation in which
formation gradient 0.465 psi/ft.

Collapse:
At surface = 0 psi
65
At shoe = × 350 = 158 𝑝𝑠𝑖 (Assumes 100% casing evacuation as in total loss).
144

6
 Graphical Method for Casing Design
Solution:
A. 20" Casing
Burst:
Burst = Internal Pressure – External Pressure
At shoe
𝑃𝑓 𝑎𝑡 𝑛𝑒𝑥𝑡 𝑇𝐷 = 6200 × 0.465 = 2883 𝑝𝑠𝑖
𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 𝑃𝑓 − 𝑇𝐷 − 𝐶𝑆𝐷 𝐺
= 2883 − 6200 − 350 0.4653 = 163 𝑝𝑠𝑖

𝐸𝑥𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 𝐶𝑆𝐷 × 𝐺𝑚

65
= 350 × = 158 𝑝𝑠𝑖
144

𝐵𝑢𝑟𝑠𝑡 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 163 − 158 = 5 𝑝𝑠𝑖 7

 Graphical Method for Casing Design
Solution:
A. 20" Casing
Burst:
At surface
Burst pressure= 𝑃𝑓 − (𝑇𝐷 × 𝐺)

𝐵𝑢𝑟𝑠𝑡 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 2883 − (6200 × 0.465) = 0 𝑝𝑠𝑖

8
 Graphical Method for Casing Design
Solution:
A. 20" Casing
Collapse (psi) Burst (psi)
Surface 0 0
Shoe 158 5

The selection of this string does not normally require a graph, and it is determined by comparing the
strength properties of available casing with existing pressures.

From table 10.4, it can be seen that all the available grades have collapse and burst values higher
than the calculated above.

Hence, select grade K55, 94# which have collapse pressure of 520 psi, burst pressure of 2110 psi and
yield strength of 1479000 Ib. It should be noted that the grade K55, 94# is the cheapest of the three
available grades.

This string will be checked later whether it is capable of carrying other casing strings. 9
 Graphical Method for Casing Design
Solution:
B. 13 3/8" Casing
Collapse:
At surface = 0 psi
67
At shoe = × 6200 = 2885 𝑝𝑠𝑖 (Assumes 100% casing evacuation as in total
144
loss).

The collapse line is drawn between 0 at surface and 2885 psi at 6200 as shown in
the figure.
From table 10.5, the collapse resistances of the available grades as adjusted for a
safety factor of 0.85 as in below table.
10
 Graphical Method for Casing Design
Solution:
B. 13 3/8" Casing
Collapse:

Collapse Resistance (psi)

Grade Wt (Ib/ft) Coupling
SF = 1 SF = 0.85
K55 54.5 LTC 1130 1329
K55 68 BTS 1950 2295
L80 72 BTS 2670 3141

The collapse resistance values are plotted as vertical lines as shown in the figure

11
 Graphical Method for Casing Design
Solution:
B. 13 3/8" Casing
Collapse:

12
 Graphical Method for Casing Design
Solution:
B. 13 3/8" Casing
Burst:
Burst = Internal Pressure – External Pressure
At shoe
𝑃𝑓 𝑎𝑡 𝑛𝑒𝑥𝑡 𝑇𝐷 = 10400 × 0.48 = 4992 𝑝𝑠𝑖
𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 𝑃𝑓 − 𝑇𝐷 − 𝐶𝑆𝐷 𝐺
= 4992 − 10400 − 6200 0.1 = 4572 𝑝𝑠𝑖

𝐸𝑥𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 𝐶𝑆𝐷 × 𝐺𝑚

= 6200 × 0.465 = 2883 𝑝𝑠𝑖

𝐵𝑢𝑟𝑠𝑡 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 4572 − 2883 = 1689 𝑝𝑠𝑖 13

 Graphical Method for Casing Design
Solution:
B. 13 3/8" Casing
Burst:
At surface
Burst pressure= 𝑃𝑓 − (𝑇𝐷 × 𝐺)

𝐵𝑢𝑟𝑠𝑡 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 4992 − (10400 × 0.1) = 3952 𝑝𝑠𝑖

The burst line can now be drawn between 3952 psi at surface and 1689 psi at 6200
as shown in the figure.

From table 10.5, the burst resistances of the available grades as adjusted for a
safety factor of 1.1 as in below table. 14
 Graphical Method for Casing Design
Solution:
B. 13 3/8" Casing
Burst:

Burst Resistance (psi)

Grade Wt (Ib/ft) Coupling
SF = 1 SF = 1.1
K55 54.5 LTC 2730 2482
K55 68 BTS 3450 3136
L80 72 BTS 5380 4891

The burst resistance values are plotted as vertical lines as shown in the figure

15
 Graphical Method for Casing Design
Solution:
B. 13 3/8" Casing
Collapse & Burst:

16
 Graphical Method for Casing Design
Solution:
B. 13 3/8" Casing
Selection:
The selection should consider the lightest weights first as these grades are the
cheapest.

On the basis of collapse only, the figure indicates the given grades are suitable for
the following depths.
Depths (ft) Grades & Weights
0 – 3050 K55, 54.5#
0 – 4200 K55, 68#
0 – 6200 L80, 72#
17
 Graphical Method for Casing Design
Solution:
B. 13 3/8" Casing
Selection:
On the basis of burst only, the figure indicates the given grades are suitable for the
following depths.
Depths (ft) Grades & Weights
4200 – 6200 L80, 72#
2400 – 6200 K55, 68#
0 – 6200 K55, 54.5#

When selection is based on both collapse and burst, the figure indicates that grade
K55, 54.5 does not satisfy the burst requirement from 0 to 4200 ft. Also grade K55,
68 does not satisfy the burst from 0 to 2400 ft.
Hence, selection from 0 to 2400 ft is limited to grade L80, 72#. 18
 Graphical Method for Casing Design
Solution:
B. 13 3/8" Casing
Selection:
Below 2400 ft, grade K55, 68# is suitable for collapse from 0 to 4200 ft and the
burst from 2400 ft to 4200 ft.

Hence, the middle selection consists of K55, 68# from 2400 ft to 4200 ft.

The last section of the hole can only be satisfied by grade L80, 72# in both collapse
and burst as shown in the figure

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 Graphical Method for Casing Design
Solution:
B. 13 3/8" Casing
Selection:
Hence selection based on both collapse and burst is as below:
Weight in air (1000
Depths (ft) Grades & Weights
Ib)
0 – 2400 L80, 72# 172.8
2400 – 4200 K55, 68# 122.4
4200 – 6200 L80, 72# 144
Total Weight in air (1000 Ib) 439.2

Note that grade K55, 54.5# has been rejected since it does not satisfy both collapse
and burst at once along any section of the hole.
20
 Graphical Method for Casing Design
Solution:
B. 13 3/8" Casing
Tension:
By ignoring the buoyancy, bending and shock forces, the suitability of selected grades in
tension can be checked by comparing the weight in air carried by each section with its
yield strength.
Hence starting from the bottom, the results will be as below: (Note the yield point
strengths are obtained from table 10.5 as the lowest value of either the body or coupling
yield strength).
Wt of section Cumulative Wt in SF=Yield
Grades & Weights
(1000 Ib) (1000 Ib) strength/cumulative Wt
144 L80, 72# 144 1650/144 = 11.5
122.4 K55, 68# 266.4 835/266.4 = 3.13
172.8 L80, 72# 439.2 1650/439.2 = 3.8
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 Graphical Method for Casing Design
Solution:
B. 13 3/8" Casing
Pressure Testing:
After the casing is landed and cemented, it is the practice to test the casing prior to
drilling the casing shoe.

The testing pressure employed by some operating companies is 60% of the burst rating of
the weakest grade of casing in string. Hence:
0.6 × 3450 = 2070 𝑝𝑠𝑖
During pressure testing an extra tensile force is exerted on the casing and the SF
should again be > 1.8 for the top joint (or the joint of the weakest grade), Then
𝑇𝑜𝑡𝑎𝑙 𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑓𝑜𝑟𝑐𝑒 𝑑𝑢𝑟𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟 𝑡𝑒𝑠𝑡𝑖𝑛𝑔 𝑎𝑡 𝑡𝑜𝑝 𝑗𝑜𝑖𝑛𝑡
𝜋 2
= 𝑊𝑎𝑖𝑟 × 𝐵𝐹 + ( 𝐼𝐷 × 𝑡𝑒𝑠𝑡𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒)
4 22
 Graphical Method for Casing Design
Solution:
B. 13 3/8" Casing
Pressure Testing:
67
𝐵𝐹 = 1 − = 0.863
489.5

𝑇𝑜𝑡𝑎𝑙 𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑓𝑜𝑟𝑐𝑒 𝑑𝑢𝑟𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟 𝑡𝑒𝑠𝑡𝑖𝑛𝑔 𝑎𝑡 𝑡𝑜𝑝 𝑗𝑜𝑖𝑛𝑡

𝜋
= 𝑊𝑎𝑖𝑟 × 𝐵𝐹 + ( 𝐼𝐷 2 × 𝑡𝑒𝑠𝑡𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒)
4
𝜋 2
= 439200 × 0.863 + 12.347 × 2070 = 626877 𝐼𝑏
4
1661000
𝑆𝐹 𝑖𝑛 𝑇𝑒𝑛𝑠𝑖𝑜𝑛𝑓𝑜𝑟 𝑡𝑜𝑝 𝑗𝑜𝑖𝑛𝑡 = = 2.65
626877 23
 Graphical Method for Casing Design
Solution:
B. 13 3/8" Casing
Biaxial Effect:
Check the weakest grade of the selected casing for biaxial effects as follows:

𝑊𝑒𝑖𝑔ℎ𝑡 𝑐𝑎𝑟𝑟𝑖𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑤𝑒𝑎𝑘𝑒𝑠𝑡 𝑗𝑜𝑖𝑛𝑡 266400

𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑟𝑎𝑡𝑖𝑜 = = = 0.32
𝑌𝑖𝑒𝑙𝑑 𝑠𝑡𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑏𝑜𝑑𝑦 (𝑜𝑟 𝑐𝑜𝑢𝑝𝑙𝑖𝑛𝑔) 835000

For 0.32 tensile ratio, table 10.8 shows that the collapse resistance of the casing is reduced to 80% of its
original, hence: 0.8 x 1950 = 1560 psi.

67
𝐶𝑜𝑙𝑙𝑎𝑝𝑠𝑒 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑢𝑒 𝑡𝑜 𝑚𝑢𝑑 𝑎𝑡 2400 = × 2400 = 1117 𝑝𝑠𝑖
144
1560
𝑆𝐹 (𝑏𝑖𝑎𝑥𝑖𝑎𝑙) = = 1.4
1117
24
 Graphical Method for Casing Design
Solution:
B. 13 3/8" Casing
Final Selection:
Hence selection based on Collapse, Burst, Tension, Pressure Testing and Biaxial
Loads is as below:

Depths (ft) Grades & Weights

0 – 2400 L80, 72#
2400 – 4200 K55, 68#
4200 – 6200 L80, 72#

25