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conservative or out-of-date. Casing and 4 41f2 5 2 51/ tion process.
liner size, in. ,
This article presents /’ /’ Typically, the well design
/{ /’ /’ ,/’
methods for determining process begins with the
Bit and hole 4 3/ 5 7/ 6 1/8 6 1/2 7 7/
the acceptable clearance size, in.
4 8 8
selection of the desired size
/ ,
between casing strings for /’
,
/’
/ ’
/’
production tubing and
particular applications. The Casing and 6 5/8 7 ~
8 5, 85/8 9 5/8
moves up hole. With the
,3,4
result of optimizing clear- liner size, in.
/
, . ’
/ /
very high cost of deep, high-
ance between casing strings /’
,’
,’ /f
/’ / ’ -pressure wells, larger-sized
is that casing sizes often Bit and hole 7 7/ 8 81 j2 8314 9112 10 5/8 , .z 7,4 tubing strings capable of
size, in.
can be reduced, or addi- &I , / ’ conducting economical
‘~hO%%’’ Y”$
tional strings can be accom- flowrates are desired. Pro-
Casing
modated in the well design. duction casing greater than
This is important since 9%-in. OD often is required
more wells are being drilled to accommodate tubing sizes
with the combined chal- as large as 7-in. OD or large
lenges of high pressure, dual subsea completions.
8“’’’’$””’’”8M
high mud weight, high tem- Casing The large production tubing
‘~hoe
perature and deep depths. size constrains the design at
Such wells often require the bottom of the well, and
more casing strings to reach available blowout preven-
TD, yet designers are lim- ters (BOPS) will constrain
ited by existing rig equip- Casing the surface casing size. High
24 30
ment sizes and capabilities. size, in. 66 pressure BOPS, larger than
18%- to 20-in. ID are not rou-
BACKGROUND Fig. 1. In this casing selection chart, solid lines indicate commonly used bits for tinely available today. Fol-
Many years ago, indus- that pipe size, and can be considered adequate clearance to run and cement the lowing traditional rules-of-
casing or liner. The broken lines indicate less common hole sizes used. The selec-
try developed general rales- tion of one of these broken paths requires special attention be given to the con- thumb for selecting casing
of-thumb for clearance nection, mud weight, cementing and doglegs, (Reprinted with permission from clearances will likely
requirements between cas- Oi/ & Gas Journal, pg. 84, Oct. 8, 1978.) severely limit the number
mits optimizingboth drilling and cas- Table 3. API standard drift Typically, weld-on connectors are
ing running properties, solids-free diameter used. Line pipe has different manu-
formate brines, originally proposed facturing tolerances than casing. For
Casing & liners Design ID
for deep slim-hole drilling may bean less, in. example, API Specification 5L does
optimum drilling fluid for limiting Smaller than 9%-in. % not include a specification for drift
surge pressures, frictional losses and 9%-in. to 13%-in. incl. % ID of line pipe.11
equivalent circulating density (ECD) Larger than 13%-in. %6
In addition to normal API manu-
encountered when using reduced- facturing tolerances, the purchaser
clearance casing strings.g can specify special tolerances. When
casing wellbore. API Specification a very-close-tolerance casing pro-
String length. An optimally engi- 5CT sets forth manufacturing gram is used, the outer casing should
neered wellbore design can incor- dimensional requirements for cas- be ordered with special, oversized
porate smaller casing clearances ing and tubing. 10 Non-API casing, drift (diameter and length) and oval-
for liners than are used for full tubing and proprietary connections ity requirements. Many reasonable
strings. When necessary, a casing generally have manufacturing tol- special manufacturing tolerances
string can be run as a liner with a erances equal to or superior to API will have minimum increased cost.
subsequent liner tieback to man- specifications.
age surge pressures. The API manufacturing tolerance HIGH-CLEARANCE
for casing includes OD, weight and CASING CONNECTIONS
Other factors that are less con- wall thickness. These tolerances are: Many early, high-clearance or
trollable, but can significantly con- . OD of casing (non-upset ends) flush joint connections experienced
tribute to casing running surge pres- is +1% and – 0.5% of specified OD costly failures. One company
sures, are: . Casing weight tolerance is reported nine failures in high-clear-
. Length of fluid column below +6.5%, –3.5% per single length ance casing connections in a 7-year
the moving pipe . Casing wall thickness is – 12.5!% period from 1979 to 1985.12 As a
. Compressibility of casing, of specified wall thickness. result of recurrent costly failures in
cement, formation and open hole sec- Casing ID is governed by its OD high-clearance connections, a joint
tions and weight tolerances. With this tol- industry program was developed in
. Axial elasticity of the moving erance, it is possible for the manu- 1986 to perform physical testing and
string factured casing ID to be less than verify high-clearance comection per-
. Compressibility of drilling fluid design ID, but larger than drift ID. formance. The Drilling Engineering
. Eccentricity of casing annulus. For example, 10%-in., 55.5 ppf cas- Association was used as the forum
Fortunately, several advanced ing with the minimum OD and max- for this program (DEA-27), which
computer programs are available imum weight would have an actual involved three operators and five
that can analyze surge pressures ID of 9.633 in., while the design ID is manufacturers.
with accuracy and speed. Mathe- 9.760 in. and special drift is 9.625 The program comprised unique
matical models also can be found in in. Since there is no maximum wall procedures for testing connections,
the literature.g These tools make it thickness nor specified ID, the drift including connections sealing during
possible to optimize the clearance ID is used for that purpose. significant bending, which would
between casing strings. Drift ID is the minimum mandrel occur in a directional well. The pro-
Another engineering concern when diameter (with specified length) that gram also identified design deficien-
designing a reduced-clearance casing must pass unobstructed through the cies in certain connections, verified
wellbore is ECD prior to and during pipe, and which serves to define ID robust performance in some comec-
cementing. These important steps can tolerance, ovality and, to some tions and qualified a new generation
be modeled accurately and calculated extent, casing straightness. Stan- of improved high-clearance connec-
to ensure that pressures resulting dard drift ID is obtained by sub- tions. As a result of the program, high-
from circulation do not exceed for- tracting a standard tolerance from clearance connection failures were
mation fracture pressures and lead the design ID. Table 3 identifies API greatly reduced, however, special test-
to lost returns. Many times “tack and standard drift ID reductions from ing and screening of high-clearance
squeeze” cementing of liners or mul- design ID. Special, larger drift IDs connections not included in the early
tiple stage cementing has been used to accommodate standard bit sizes study are still recommended.
to effectively manage ECD when are included in the API specifica-
reduced-clearance casing designs are tions for special clearance OD cou- WELLHEAD CONSIDERATIONS
used. New cements with novel low plings and for casing straightness. Many unitized, multi-bowl sur-
viscosity weighting agents, such as For casing sizes, the maximum face wellheads were designed to
manganese oxide, also offer promise tolerance on standard API casing accommodate standard casing pro-
to improve cement displacement in coupling OD is + l%, but not greater grams, and have a restricted ID load
reduced-clearance casing annuli. than +% in. Typically, casing cou- shoulder. For example, a typical 13%-
plings have a machined OD for eas- in., top-flange casinghead will have
TUBULAR MANUFACTURING ier inspection, however, complete an ID of 12% to 1%6 in. & a result,
TOLERANCES outside surface machining is not a an additional constraint for casing
It is necessary to know the man- requirement. size selection is the wellhead ID.
ufacturing tolerances of tubulars API line pipe has been increas- While these wellhead restrictions
when designing a reduced-clearance ingly used for shallow casing strings. provide a constraint, the reduced ID
m7
in length. Availability of w ( B ) (c) (D) available bit sizes. Use of
183/~.in= 135&in. 183/+in. la5~.in,
non-standard size casing BOPS BOPS BOPS BOPS conventional casing clear-
rams often is a design con- ances generally are ade-
straint for surface BOPS as quate for routine wells, but
well. 1 33/3-ifl.
22-in. 14-in. are often conservative.
All marine subsea well- Reducing the clearance
heads have a reduced ID between casing strings from
load shoulder. Typically, the traditional values will per-
load shoulder ID is about 95~.ifl. 1 S-in. 11 3/q.if3. mit use of smaller BOPS
17.562 in. for an 18%-in., and rigs. Very detailed engi-
high pressure wellhead.
7-in. 16-in. J 95~.if3.
I
designed a special marine 7-in. Iind 41/.. in. lifl~~
16 95~.in. cation is required before
subsea wellhead with a ..
41/~.in. Ii, :,
reduced-clearance casing
18 7-in. liner -~+
removable load shoulder strings should be used.
giving an almost full bore 4Vz-in. liner .{ For large development
through the wellhead. The drilling programs or criti-
removable load shoulder Fig. 2. Typical designs are shown for wells using conventional clearances (A &
cal applications, special
B) and reduced clearances (C & D) between casing strings. The reduced-clear-
can be installed after a low manufactured tubulars,
ance wellbore (D) saves about 110 tons of casina-. comr)ared to a wellbore with
pressure liner, with high- traditional clearances (A). combined with reduced-
clearance casing connec- clearance casing strings,
tions, has been run and should be used. Reduced-
cemented. wellbore with traditional clearances clearance casing programs in many
(Fig. 2-A). Similar to slim-hole oper- cases will require special tubular
REDUCED-CLEARANCE ations, additional overall well sav- manufacturing specifications and
WELLBORE DESIGNS ings will result fkom reducing drilling field procedures to assure dimen-
Good engineering judgment must mud and cementing volumes. Sub- sions, ovality and straightness.
be used when designing wellbores stantial savings also could result if
with reduced-clearance casing a smaller rig were used. This advan-
strings. Optimum candidates are tage can be significant when a remote ACKNOWLEDGMENTS
hole sections that are relatively free location or available rig equipment Appreciation is expressed to Amoco Pro-
duction Co. for permission to author and pub-
of problems such as tectonically limits BOP equipment size. lish this article. Particular appreciation is
stressed intervals, drawn-down ECD was modeled while circulat- extended to John Pantaleo of Amoco who
sands and high mud weights. The rig ing a 14-ppg, 35-PV, 1O-YP mud for encouraged this undertaking. The author also
must be capable of proper hole clean- the liner set at 12,000 ft, and for each acknowledges Tim Dunn, Dowell Schlum-
berger John Greenip and Jon Barton, Hydril
ing, be able to maintain optimum of the four casing programs shown Co.; and John Simpson, Baker Hughes INTEQ;
mud properties, and be equipped to in Fig. 2. Each liner situation had who contributed to and reviewed this article.
rapidly handle lost mud returns, well an ECD of only about 0.5 ppg equiv- This article was adapted from SPE/IADC
control situations, etc. Drag may also alent. About 0.7 ppg of ECD was cal- paper 37615 presented at the 1997 SPIMAIX
Drilling Conference.
limit the use of close-clearance cas- culated while cementing the 12,000-
ing applications in some wells, and ft liners in Fig. 2 with typical cement
additional planning is also required slurries at normal circulating rates. LITERATURE CITED
to ensure that required casing run- 1 Caste, Robert G., “Use of Bicenter PDC Bit Reduces
ning tools, handling tools and acces- CONCLUSIONS Drilling Cost,” Oil and Gas Journal, Nov. 13, 1995,
2
Leblanc, Leonard, %eaming-While. Drilling Keys Efforts
sories are available. Conventional clearances between to Reduce Tripping on Long Drillstrings,” Ofishore, April
1-----
Ww
Typical wellbore designs using casing sizes used by industry are 3
Dewey, C. H., and G. C. Miller, “Drilling and Under-
conventional clearances between cas- based on standard sizes that, in reamine Simultaneously A Cost-Effective Ontion “ SPE
Paper ~6462, presente; at SPE Annual ~ci%c;l Con-
ing strings and reduced clearances ference and Exhibition, Denver, Oct. 6-9, 1996.
4 Greenip, J. F., “’lhbulars Isolate Down-Hole Pressures,”
between strings are illustrated in Oil and Gas Journal, Oct. 9, 1978.
Fig. 2. For these well designs, clear- L John W. Barker, PE, 5 Dupuis, D,, and A. Sagot, “One Year Experience in Slim-
ance between casing strings can be [ Deepwater Drilling Hole Drilling,” IADC/SPE paper 35124, presented at
IADC/SPE Drilling Conference, New Orleans, March
Teamleader for Vastar
found in Table 1. With a given BOP Resources Inc., Hous-
12-15,1996.
6 “1997 Casing Tables,” World Oil, July 1997.
size, reduced-clearance casing ton, received a 6S 7 Beck, F. E., J. W, Power, and Mario Zanmra, “The Effect
strings can permit adding one or two degree from Texas A&M
-
of Rheology on Rate of Penetration,” SPE paper 29368,
presented at SPE/L40C Drilling conference, Amsterdam,
additional casing strings, which ‘ University in 1974. From Feb. 26-Mar, 2, 1995.
\ ~ 1974 to l%, he wo~ad 8 Howard, Siv. K, “Formate Brines of DriUmg and Com-
could result in deeper drilling or pletion: State of tbe Art,” SPE paper 3049S, presented
.,,,, . . . . . . . j’,I forExxon,PrimtilYwith
larger production tubing. floating type rigs in the at SPE Annual Tkchnical Conference & Exhibition, Dal-
las, Oct. 22-25, 1995.
For some well designs, use of deapwater Gulf of Mexico. He worked for 9 Mitchell, R. F., “Dynamic Surge/Swab Pressure Predic-
reduced clearance between casing Amoco Production Co. in 199611997, in tions,” SPE Drilling Engineering, Sept. 1988.
10 API Specijicdon SCT “Specification for Casing and ‘lhb-
deepwater GOM operations, and recently
strings will permit use of a smaller moved to Vasta~ He is the author or co- ing, fitl.h edition,” API, Washington, 1995.
11 API S~ci/imtion SCT “Specification for Line Pipe, thirty-
BOP. For example, a reduced-clear- author of seven technical papers focused eighth edition,” API, Washington, 1995,
ance wellbore (Fig. 2-D) saves about primarily on deepwater drilling operations. 12 Payne, M. L., et al,, “Joint Industry Qualification Test
Program for High-Clearance Casing Connections,” SPE
110 tons of casing compared to a ML Barker is a member of AADE and SPE. Drilling Engineering, Dec. 1992.