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CASING DESIGN
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Casing
Setting
Depths
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E X A M P L E : C A S I N G S EA T S E L E C T I O N
Solution
(1) The required hydrostatic pressure of mud
is taken as equal to pore pressure + 200 psi,
where 200 psi is the magnitude of overbalance.
Any reasonable value of overbalance may be
used depending on company policy.
(2) Calculate the pore pressure and mud
pressure gradients by simply dividing pore
pressure and mud pressure by depth to
obtain the gradient in psi/ft.
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Solution
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Casing Sizes
The casing sizes and string configuration are dictated by the size
of the smallest casing string to be run in hole. Once the smallest
casing size is known all subsequent casing sizes (and hole sizes) are
selected.
The smallest casing size is selected on the basis of operational
considerations such as:
the size and configuration of the completion string or well testing
and/or the size of the logging tools to be run through the casing.
The drilling engineer will collate this information from the
geology, reservoir engineering and production engineering
departments.
The objective of the drilling engineer is to use the smallest casing
sizes possible. It can be readily appreciated that if it is acceptable
to use a 4” casing string as the production casing then the next
string will be 7”, the next 9 5/8” and so forth. Hence, if only
three casing strings are required then the surface string can be 9
5/8”. This slimhole design will result in considerable savings in
drilling and equipment costs.
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commonly
less represent
configuration
lines
dotted
used
The
)
These operations will result in radial (burst and collapse) and axial
(tensile and compressive) loads on the casing strings. since the
operations conducted inside any particular string (e.g. the surface
string) will differ from those inside the other strings (e.g. the
production string) the load scenarios and consequent loads
will be specific to a particular string.
The definition of the operational scenarios to be considered
is one of the most important steps in the casing design process and
they will therefore generally be established as a company policy.
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Casing Collapse 1
Casing Collapse 2
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Casing Collapse 3
Casing Collapse 4
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Casing Collapse 5
Collapse Load
The casing will experience a net collapse loading if the
external radial load exceeds the internal radial load.
The greatest collapse load on the casing will occur if
the casing is evacuated (empty) for any reason. The
collapse load, pc at any point along the casing
can be calculated from:
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p Internal p
Pressur
e
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Burst Load
The casing will experience a net burst loading if
the internal radial load exceeds the external
radial load.
The burst load, pb at any point along the
casing can be calculated from:
pb = pi - pe
In designing the casing to resist burst loading the
pressure rating of the wellhead and BOP stack
should be considered since the casing is part of
the well control system.
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External Loads, Pe
The following issues are considered when
deciding upon the external load to which
the casingwill be subjected:
(a.) The pore pressure in the formation (pore
pressure) If the engineer is satisfied
that it will be possibleto displace all
of the mud from the annulus between the
casing and borehole during the cementing
operation, and that a satisfactory cement
sheath can be achieved, the formation pore
pressure is generally used to determine the
load acting on the casing below the top of
cement in the annulus, after the cement has
hardened.
External Loads, Pe
(b.) The weight of the mud in which the casing was
run.
If a poor cement bond between the casing and
cement or cement and borehole is anticipated
then the pressure due to a column of mud in the
annulus is generally used to determine the load
acting on the casing below the top of cement in
the annulus, after the cement has hardened.
If the mud has been in place for more than 1 year
the weighting material will probably have settled
out and therefore the pressure experienced by
the casing will be due to a column of mud
mixwater (water or base-oil).
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External Loads, Pe
(c.) The pressure from a colomn of cement
mixwater
The pressure due to the cement mixwater is
often used to determine the external load
on the casing during the producing life of the
well.
This pressure is equal to the density of fresh
or seawater in the case of water-based mud
and base oil in the case of oil based mud.
The assumption is that the weighting
material in the mud (generally Barite) has
settled from suspension.
External Loads, Pe
(d.) The pressure due to a column of
cement slurry
The pressure exerted by a column of
cement slurry will be experienced by
the casing until the cement sets. It is
assumed that hardened cement does not
exert a hydrostatic pressure on the
casing.
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External Loads, Pe
(e.) Blockage in the annulus
If a blockage of the annulus occurs during a
stinger cement operations (generally
performed on a conductor casing). The
excess pumping pressure on the cement will
be transmitted to the annulus but not to the
inside of the casing.
This will result in an additional external load
during stinger cementing. In the case of
conventional cementing operations a
blockage in the annulus will result in an
equal and opposite pressures inside and
outside the casing.
Internal Loads, Pi
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Internal Loads, Pi
Internal Loads, Pi
(d.) production Tubing leak
Inthe case of production casing specifically a
leakin the production tubing will result
in the tubing pressure being exposed to the casing.
The closed in tubing pressure is used as the basis of
determining the pressure on the casing.
This is calculated on the basis of a column of gas
against the formation pressure.
The pressure below surface is based on the
combined effect of the tubing head pressure
and the hydrostatic pressure due to a
column of packer fluid (if there is
any in the annulus).
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Internal Loads, Pi
(e.) fracture pressure of Open formations
When considering the internal loads on a casing
string the fracture pressure in any formations open
to the internal pressures must be considered.
The pressure in the open hole section cannot
exceed the fracture pressure of the weakest
formation.
Hence, the pressures in the remaining portion of the
borehole and the casing will be controlled by this
fracture pressure.
The formation just below the casing shoe is generally
considered to be the weakest formation in the
open hole section.
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Axial Load
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䃰ˬ
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䓀ˬ
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妀˲
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妀˲
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繐˲
1. 2 1/ 2
SA S A
YPA = YP 1 − 0.75 − 0.5
P
Y YP
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Example
FA 100,000
SA = = = 24,820 psi
Area π 5.52 − 5.012 2
( )
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S
2
YPA = 1 − 0.75 A − 0.5 S A YP
Example cont’d Y
p
Y
p
The axial tension will reduce the collapse pressure rating
to:
2
24,820 24,820
YPA = 1 − 0.75 − 0 .5 55,000
55,000 55,000
= 38,216 psi
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Example 3 - cont’d
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霰˲
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.
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Required Design
Tension 1.8
100,000 lbf 180,000 lbf
Burst 1.1
10,000 psi 11,000 psi
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DESIGN CRITERIA
BURST
Burst loading on the casing is induced when
internal pressure exceeds external pressure.
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.
皀˱
DESIGN CRITERIA
Most operating companies modify this basic
‘dry gas’ design concept according to a
number of other influences including:
• Casing wear considerations
• Amount of open hole section
• Depth of the shoe
• DF applied
• Current BOP rating, etc.
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Conductor:
The maximum burst load is experienced if
the well is closed in after a gas kick has been
experienced.
The pressure inside the casing is due to formation
pore pressure at the bottom of the well and a
colomn of gas which extends from the bottom of
the well to surface. It is assumed that pore
pressure is acting on the outside of the casing.
Note that it would be very unusual to close a
well in due to a "shallow" kick below the
conductor.
It would be more common to allow the influx to
flow to surface and divert it away from the rig.
This is to avoid the possibility of formation
fracture below the shoe.
1ӎ
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Surface Casing:
Once the surface casing has been set a BOP
stack will be placed on the wellhead and in
the event of a kick the well will be closed in
at surface and the kick circulated out of the
well.
The surface casing must therefore be able to
withstand the burst loads which will result
from this operation. some operators will
require that the casing be designed to
withstand the burst pressures which would
result from internal pressures due to full
evacuation of the well to gas.
苰˱
Surface Casing:
The maximum collapse loads may be
experienced during the cement operation or
due to lost circulation whilst drilling ahead.
The design scenario to be used for collapse
of surface is when the casing is fully
evacuated due to lost circulation whilst
drilling.
In this case the casing is empty on the inside
and the pore pressure is acting on the outside.
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Surface Casing:
The maximum burst load is
experienced if the well is closed in
after a gas kick has been experienced.
The pressure inside the casing is due to
formation pore pressure at the bottom of
the well and a column of gas which
extends from the bottom of the well to
surface.
It is assumed that pore pressure is acting
on the outside of the casing.
1˭
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Intermediate Casing:
The intermediate casing is subjected to similar loads
to the surface casing.
The design scenario to be used for collapse of
intermediate casing is when the casing is fully
evacuated due to lost circulation whilst drilling.
In this case the casing is empty on the inside and the
pore pressure is acting on the outside.
The maximum burst load is experienced if the
well is closed in after a gas kick has been
experienced.
The pressure inside the casing is due to formation
pore pressure at the bottom of the well and a column
of gas which extends from the bottom of the well to
surface.
It is assumed that pore pressure is acting on the
outside of the casing.
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1˭
Production Casing:
The design scenarios for burst and collapse or
the production casing are based on production
operations.
The design scenario to be used for burst of
production is when a leak is experienced in
the tubing just below the tubing hanger.
In this event the pressure at the top of the casing
will be the result of the reservoir pressure minus
the pressure due to a column of gas.
This pressure will the act on the fluid in the
annulus of well and exert a very high internal
pressure at the bottom of the casing.
The design scenario to be used for collapse
of production is when the annulus between the
tubing and casing has been evacuated due to say
the use of gaslift.
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