DRLLING ENGINEERING

Chapter 9

CASING DESIGN

PNGE 310 1
 Functions of Casing – 1,2,3,4,5,6

• Prevents caving or washout of formations

• Prevents contamination of fresh water aquifers
• Provides a means of controlling pressure
• Facilitates installation of subsurface equipment
• Provides a flow path for production fluids
• Isolates the wellbore fluids from subsurface
formations and formation fluids

PNGE 310 2
 Casing Types - 1

• Drive pipe
• Conductor casing
• Surface casing
• Intermediate casing
• Production casing
• Liner
• Tie-back liner

PNGE 310 3
 Casing Types - 2

Casing Type Common Sizes, Setting Depths,

in. ft
Drive pipe 26 – 42 >100

Conductor pipe 16 – 48 300 – 1000

Surface casing 7 – 16 1000 - 5000

Intermediate casing 7 - 11¾

Production casing 3½ – 9⅝

Liner 5-7

Tie-back liner

PNGE 310 4
 Manufacture of Casing – 1,2,3

1. The seamless process

2. The electric welding process
a. Electrical resistance welding
b. Electric flash welding

PNGE 310 5
 API Standards for Casing - 1

• API RP 5A3, “Recommended Practice on Thread

Compounds for Casing, Tubing, Line Pipe, and Drill
Stem Elements”
• API RP 5A5 “Field Inspection of New Casing, Tubing
and Plain-End Drill Pipe”
• API Spec 5B “Specification for Threading, Gauging,
and Thread Inspection of Casing, Tubing, and Line
Pipe Threads”
• API RP 5B1, “Gauging and Inspection of Casing,
Tubing and Line Pipe Threads”

PNGE 310 6
 API Standards for Casing - 2

• API SPEC 5CT “Specification for Casing and Tubing”

• API RP 5C1, “Recommended Practice for Care and Use
of Casing and Tubing”
• API BULL 5C2, “Bulletin on Performance Properties of
Casing, Tubing, and Drill Pipe”
• API BULL 5C3, “Bulletin on Formulas and Calculations
for Casing, Tubing, Drill Pipe and Line Pipe Properties”
• API BULL 5C4, “Bulletin on Round Thread Casing Joint
Strength with Combined Internal Pressure and
Bending.”
• API RP 5C5, “Recommended Practice on Procedures
for Testing Casing and Tubing Connections”
PNGE 310 7
 Casing Classifications – 1,2,3,4,5,6

1. Outside diameter, OD 4.5 to 20-in.

2. Wall thickness 0.205 to 0.635-in.
3. Grade H-40, J-55, K-55,
C-75, L-80, N-80,
C-90, C-95, P-110,
Q-125
4. Type of joint Round tread,
Buttress tread,
Extreme Line
5. Range of length 1 16’ – 25’
2 25’ – 34’
3 >34’
6. Weight per unit length 9.50 to 133.00 lbs/ft

PNGE 310 8
 Elements of Thread - 1

1. Thread depth
2. Pitch (Lead)
3. Taper
4. Form

Pitch

Thread depth

PNGE 310 9
Elements of Thread – 2, 3

PNGE 310 10
 Casing Threads and Couplings - 1

A. Round thread (8 threads/inch, V-type, ¾-in. taper)

1. STC [CSG]
2. LTC [LCSG]

PNGE 310 11
 Casing Threads and Couplings – 2,3

B. Buttress thread (5 threads/inch, ¾-in. taper, 1-in

taper for CSG sizes larger than 16-nin.)
1. Regular coupling
2. Regular coupling higher grade
3. Special clearance coupling
4. Special clearance coupling higher grade

PNGE 310 12
 Casing Threads and Couplings - 4

C. Extreme line [XCSG] (6 threads/inch for 5” & 7⅝”, 5

threads/inch for 8⅝” & 10 ¾”)
1. Standard joint
2. Optional Joint

PNGE 310 13
 Casing Threads and Couplings - 5

D. VAM (Vamonec) 5 threads/inch, metal-to-metal seal

E. Buttress double seal [BDS]

World Oil - Casing Reference Tables 2015

PNGE 310 14
 Metal Pipe Properties

Yield Strength .
Ultimate Strength

Load A
.. B
.C
Fracture Strength

Elastic Plastic

Range Range

Elongation

PNGE 310 15
 API Grades of Casing
API Grade Minimum Yield Maximum Yield Minimum
Strength, psi Strength, psi Ultimate
Tensile
Strength, psi
H-40 40,000 80,000 60,000
J-55 55,000 80,000 75,000
K-55 55,000 80,000 95,000
C-75 75,000 90,000 95,000
L-80 80,000 95,000 95,000
N-80 80,000 110,000 100,000
C-90 90,000 105,000 100,000
C-95 95,000 110,000 105,000
P-110 110,000 140,000 125,000
Q-125 125,000 150,000 135,000
PNGE 310 16
Non-Standard Grades of Casing (USS)

API Grade Minimum Yield Maximum Yield Minimum

Strength, psi Strength, psi Ultimate
Tensile
Strength, psi
C-100 100,000 115,000 110,000
C-110 110,000 125,000 120,000
140 140,000 170,000 150,000
V-150 150,000 180,000 160,000

PNGE 310 17
 Casing Setting Depth Selection – 1,2

Fig. 7.20 and Fig. 7.21 1 SPE Textbook Series Vol. 2

PNGE 310 18
Casing Setting Depth Selection Examples – 1,2,3

Fig. 7.1 SPE Textbook Series Vol. 2

PNGE 310 19
 Casing-Bit Size Selection - 1

1. Start at the bottom (target depth) and select the lowermost

casing (production casing).
2. Select the bit size that drills a hole to allow the lowermost
casing to go through it.
A. Make sure there is a proper space between hole diameter and
casing OD to provide passage of casing without getting stuck
and also to allow proper cementing.
3. Select the next upper casing that permits previously selected bit
to go through it.
A. Make sure there is sufficient clearance between bit diameter
and casing ID to prevent stuck drill string and also to provide
proper circulation for mud cleaning. Small clearance will create
high velocity and good cutting removal but causes increased
pressure for pump and circulation system.

PNGE 310 20
 Casing-Bit Size Selection - 2

3. Select the next bit size that drills a hole to allow the previous
casing to go through it.
A. Make sure there is a proper space between hole diameter and
casing OD to provide passage of casing without getting stuck
and also to allow proper cementing.
4. Select the next upper casing that permits previously selected
bit to go through it.
A. Make sure there is sufficient clearance between bit diameter
and casing ID to prevent stuck drill string and also to provide
proper circulation for mud cleaning. Small clearance will create
high velocity and good cutting removal but causes increased
pressure for pump and circulation system.
5. Repeat previous two steps until surface is reached.

PNGE 310 21
Casing-Bit Size Selection (Figure 7.18, Textbook)

PNGE 310 22
PNGE 310 23
Forces Considered for Casing Design –
1,2,3,4,5,6

1. External pressure (Collapse)

2. Internal pressure (Burst)

3. Axial loading (Tension)

1. Pipe strength
2. Joint strength

4. Bending forces

5. Shock loads

6. Field handling

PNGE 310 24
Forces Considered for Casing Design –
7,8,9,10

 Design is based on most severe conditions

 During displacement
 During the life of the well

 Collapse Criteria:
 Maximum force on the outside (Max. at bottom)
 Minimum force inside the casing
 Impact of tension is determined

 Burst Criteria
 Maximum force inside casing
 Minimum force on the outside (Min. at top)

 Tension (Maximum at top)

 Pipe and joints are evaluated for tension load

PNGE 310 25
 Collapse Forces – 1,2

 External loads
 Freshwater
 Saltwater
 Formation pressure
 Drilling fluid
 Unset cement
 Internal loads
 Empty casing
 Gas
 Oil
 Freshwater
 Saltwater
 Drilling fluid
 Stimulation fluid
 Workover fluid
 Any combination of the above fluids

PNGE 310 26
 Burst Forces – 1,2

 Internal loads
 Gas
 Oil
 Water
 Combination of gas and liquids
 Stimulation fluid
 External loads
 Atmospheric pressure at surface (top)
 Seawater pressure at surface (top)
 Freshwater
 Saltwater
 Drilling fluid
 Formation pressure

PNGE 310 27
 Collapse Pressure
COLLAPSE PRESSURES
Casing Type Internal Pressures
Top Bottom
Surface Casing Zero. Zero (No fluid inside.)
Intermediate Casing Zero. Due to mud density used for the Zero.
next casing setting depth with a
column height equal to the
normal formation pressure at
the casing seat.
•0.052 ρm D = Pg L
Liner Zero. Same as intermediate casing.
Production Casing Zero. Zero.
PNGE 310
External Pressure
Top Bottom
Zero. Due to mud column or
formation pressure gradient. The
load increases due to cement
column if it exists beyond a
certain depth.
Due to mud column and the load
increases due to cement column
if it exists beyond a certain
depth and cement can even be
considered to extend to the
surface.
Zero. Similar to the intermediate
casing but with properties of
mud and cement used for the
intermediate casing and liner.
Zero. Similar to the surface and
intermediate casings with fluid
density equal to the density of
mud used in the last interval.
28
 Burst Pressure
BURST PRESSURES
Casing Type Internal Pressures External Pressure
Top Bottom Top Bottom
Surface Casing Equal to the bottom hole Equal to the formation fracturing Zero. Due to (a) formation pressure
pressure minus the pressure pressure plus a safety margin. gradient or (b) water column
due to gas column (usually (Usually 1 ppg) This is also the pressure.
0.1-0.15 psi/ft) in the annulus. injection pressure (from leak-off
test).

Intermediate Casing Maximum allowable surface
pressure based on the (a)
working pressure of surface
equipment (BOP) or (b)the
attainable pressure after a kick
when the annulus is filled
with gas.
Equal to the formation fracturing Zero. Due to (a) formation pressure
pressure plus a safety margin. gradient or (b) water column
(Usually 1 ppg) This is also the pressure.
injection pressure (from leak-off
test). The annulus is assumed to
be filled with mud and gas.

Liner Same as the intermediate
casing.
Production Casing Bottom hole pressure of the
producing formation minus
pressure due to the fluid
gradient in the tubing.
Same as the intermediate casing. Same as the Same as the intermediate casing.
intermediate
casing.
Pressure at the top plus the Zero. Due to (a) formation pressure
pressure due to the column of gradient or (b) water column
completion fluid inside the pressure.
casing.

PNGE 310 29
 Tension Forces
TENSIONAL FORCES
Casing Type Top Bottom
Surface Casing Equal to the total weight of Equal to the hydrostatic
all casing plus the effects of fluid pressure times the
buoyancy due to change in casing metal area at the
the metal thickness. Also, bottom.
an over pull of 100,000 lbs
or a design factor of 1.6 is
used.

Intermediate Casing Same as the surface casing. Same as the surface casing.

Liner Same as the surface casing. Same as the surface casing.

Production Casing Same as the surface casing. Same as the surface casing.

PNGE 310 30
Common Design/Safety Factors

• Collapse:
• 1.0 – 1.125

•Burst:
• 1.0 – 1.25

•Tension:
• 1.6 – 2.0

PNGE 310 31
Graphical Representation of Collapse Forces

Pressure

Mud

Depth

Internal CSG
Collapse
Strength
Formation

PNGE 310 32
Graphical Representation of Burst Forces

Pressure

CSG
Burst
Internal Strength

Depth

External
Injection

Formation
pressure

PNGE 310 33
Graphical Representation of Tension Forces

Axial Tension

Hanging
Tension
CSG
Tension
Depth Strength

Design Line

PNGE 310 34
 Other Design Considerations

• Shock Loading:

• Changing Internal Pressure

• Thermal Effects

• Subsidence Effects

• Effect of Bending

• Effect of Hydrogen Sulfide

• Effects of Field Handling

PNGE 310 35
 Casing Performance - 1

 Important Performance Properties:

 Axial Tension

 Burst Pressure

 Collapse Pressure

PNGE 310 36
 Casing Performance - 2

Axial Tension
Maximum tension for a given pipe is:

Fa = Aσ yield
π
Fa = σ yield (d OD
2 2
− d ID )
4

Where A is the metal cross-sectional area of pipe and σyield is

the minimum yield strength of steel

PNGE 310 37
 Class Example - 1

Determine the body-yield strength of 10.75-in. (ID=9.85-in.) C-95

casing? (Use an integer value for the answer)

𝜋𝜋 2 2
𝐹𝐹𝑎𝑎 = 𝜎𝜎𝑦𝑦𝑦𝑦𝑦𝑦𝑦𝑦𝑦𝑦 𝑑𝑑𝑂𝑂𝑂𝑂 − 𝑑𝑑𝐼𝐼𝐼𝐼
4

𝜋𝜋
𝐹𝐹𝑎𝑎 = 95,000 10.752 − 9.852
4

𝐹𝐹𝑎𝑎 = 1,383,322 ≅ 1,383,322 𝑙𝑙𝑙𝑙𝑙𝑙

PNGE 310 38
 Casing Performance - 3

Burst Resistance of Steel

Consider the pipe given below (Figure 7-11, SPE Textbook, Vol. 2)
under static conditions:

F1 − 2 F2 = 0

2σ steel t
Pbr =
d

PNGE 310 39
 Casing Performance - 4

Burst Resistance of Steel

Equation is valid for thin-walled pipe (d is the ID)
For thick wall pipe dID is replaced by dOD (Barlow’s Equation)
Barlow’s equation accurate but gives a conservative value and
API uses 87.5% of the minimum yield of strength of steel as:
2σ steel t
Pbr = 0.875
d OD
The wall thicknesses are rounded to nearest 0.001-in. and
results are rounded to the nearest 10 psi

PNGE 310 40
 Class Example - 2

Determine the burst strength of 10.75-in. (ID=9.85-in.) CJ-95

casing? (Use an integer value for the answer)

2𝜎𝜎𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑡𝑡
𝑃𝑃𝑏𝑏𝑏𝑏 = 0.875
𝑑𝑑𝑂𝑂𝑂𝑂

10.75 − 9.85
2 ∗ 95,000 ∗
2
𝑃𝑃𝑏𝑏𝑏𝑏 = 0.875
10.75

𝑃𝑃𝑏𝑏𝑏𝑏 = 6959.3 ≅ 6960 𝑝𝑝𝑝𝑝𝑝𝑝

PNGE 310 41
 Casing Performance – 5,6

Collapse Resistance of Steel

Consider the pipe given below (Figure 7-12, SPE Textbook, Vol.
2) under static conditions.
Radial and tangential stresses are given as:

σr =
( ) (
− Pi ri 2 ro2 − r 2 − Pe ro2 r 2 − ri 2 )
(
r 2 ro2 − ri 2 )

σt =
( ) (
Pi ri 2 ro2 + r 2 − Pe ro2 ri 2 + r 2 )
(
r 2 ro2 − ri 2 )
PNGE 310 42
 Casing Performance - 7

Collapse Resistance of Steel

Assuming zero internal pressure and evaluating tangential
stress at the inner wall yields the collapse resistance of steel.
There are four different modes of collapse based on the ratio
of OD and thickness of a casing:
Yield-strength collapse
Plastic collapse
Transition collapse
Elastic collapse

PNGE 310 43
 Casing Performance - 8

Collapse Resistance of Steel

Yield-strength collapse
 d OD 
 − 1 
Pcollapse = 2σ yield  t
d OD 
 
 t 
Valid for (dOD/t) ratios equal (=) or less than (<) the values given by:

  
 F1 − 2) 2 + 8 F2 + F3   + (F1 − 2 )
  σ  
d OD   yield  
=
t  F3 
2  F2 + 
 σ yield 

PNGE 310 44
 Casing Performance - 9

Collapse Resistance of Steel

Plastic collapse
 
 F1 
Pcollapse = σ yield  − F2  − F3
d OD
 
 t 

Valid for (dOD/t) ratios greater than (>) given by yield-strength criteria and less than
(<) the values given by:

d OD σ yield (F1 − F4 )
=
t F3 +σ yield (F2 − F5 )

PNGE 310 45
 Casing Performance - 10

Collapse Resistance of Steel

Transition collapse

 
 F4 
Pcollapse = σ yield  − F5 
d
 OD 
 t 

Valid for (dOD/t) ratios greater than (>) given by plastic criteria and less than (<) the
values given by:

F2
2+
d OD F1
=
t 3F2
F1
PNGE 310 46
 Casing Performance - 11

Collapse Resistance of Steel

Elastic collapse

46.95 x106
Pcollapse = 2
 d OD   d OD 
  − 1
 t  t 
Valid for (dOD/t) ratios greater than (>) the values given by transition value.

PNGE 310 47
 Casing Performance - 12

Collapse Resistance of Steel

Values of F1, F2, F3, F4 and F5 are given as:
F1 = 2.8762 + 0.10679 x10 −5 σ yield + 0.21302 x10 −10 σ yield
2
− 0.53132 x10 −16 σ yield
3

F2 = 0.026233 + 0.50609 x10 −6 σ yield

F3 = −465.93 + 0.030867σ yield − 0.10483 x10 −7 σ yield

2
+ 0.36989 x10 −13 σ yield
3

3
 3RF 
( )
46.45 x10 6 
2 + RF 
F4 = 
2
 3RF  3RF 
σ yield  − RF  1 − 
 2 + RF   2 + RF 
F5 = F4 RF

F2
RF =
F1 PNGE 310 48
 Casing Performance - 13

Collapse Resistance of Steel

Values of F (Table 7-4, SPE Textbook, Vol. 2)

PNGE 310 49
 Casing Performance - 14

Collapse Resistance of Steel

Values of dOD/t (Table 7-5, SPE Textbook, Vol. 2)

PNGE 310 50