HERIOT-WATT UNIVERSITY
INSTITUTE OF PETROLEUM ENGINEERING
DRILLING ENGINEERING
MUHAMMAD AYUB KASYFI BIN KHAIRUL MIZAM
H00464058
MSc Petroleum Engineering
29th NOVEMBER 2024
Casing Design:
Well-A Data
Well Name A
Production tubing 5 in
Reservoir fluid Gas (gradient 0.1 psi/ft)
Depth of Production 10200-10700 ft
Interval (TVD)
First calculate the mudweight pressure or overweight pressure where I choose to add 120 psi to
pore pressure value to get overweight pressure.
Depth (ft) Pore Pressure (PSI) overweight pressure Fracture Pressure
(PSI) @ = Pore pressure (PSI)
+ 120
500 225 345 408
1000 450 570 817
2000 900 1020 1633
4000 1800 1920 3267
5000 2250 2370 4083
6000 2700 2820 4900
8000 3600 3720 6533
8256 3715 3835 6743
8462 3808 3928 6910
8769 3946 4066 7162
9026 5062 5182 7704
10000 5208 5328 8403
10975 5305 5425 9085
TABLE 1:PRESSURE TABLE
According to graph bellow:
Conductor casing shoe 2200ft
Surface casing shoe 3800 ft
Intermediate casing shoe 6600ft
Production casing 10000ft
GRAPH 1: SHOE CASING GRAPH
SURFACER CASING (20” at 3800 ft)
Design Factors :
(Burst) 1.1
(Collapse) 1.0
Burst design
Internal load: assuming that an influx of gas has occurred and the well is full of
gas to surface.
Pore pressure at bottom hole at 6600 ft = 3060 PSI (interpolation)
8000−6000 3600−2700
INTERPOLATION = =
6600−6000 X −2700
Pressure at surface = bottomhole pressure – gas pressure throughout casing
=3060-(0.1×6600)= 2400 PSI
2400 PSI is lower that the fracture pressure at 3800ft which is 3104 PSI. so the mudweight
pressure will not fracture the formation.
Pressure at 20” casing shoe = 3060 – (0.1×2800) = 2780 PSI
External Load: Assuming that the pore pressure is acting at the casing shoe and zero
pressure at surface.
Pore pressure at casing shoe = 1711 PSI
External pressure at surface = 0 PSI
Summary of Burst Load
Depth External load Internal Load Net Load Design load
(PSI) (PSI) (PSI) (PSI)
Surface 0 2400 2400 2640
Casing shoe 1711 2780 1069 1176
(3800 ft)
Collapse design
Internal load: assuming that the casing is totally evacuated due to losses of drilling fluid.
Internal Pressure at surface = 0 psi
Internal Pressure at shoe = 0 psi
External Load: Assuming that the pore pressure is acting at the casing shoe and zero
pressure at surface.
Pore pressure at the casing shoe = 1711 PSI
External pressure at surface = 0 psi
Summary of Collapse load
Depth External load Internal Load Net Load Design load
(PSI) (PSI) (PSI) (PSI)
Surface 0 0 0 0
Casing shoe 1711 0 1711 1711
(3800 ft)
Intermediate Casing (13 3/8” @ 6600 FT) (calculation at appendix)
Burst design
Internal load: assuming that an influx of gas has occurred and the well is full of
gas to surface
External Load: Assuming that the minimum pore pressure is acting at the casing shoe
and zero pressure at surface.
Summary of Burst load
Depth External load Internal Load Net Load Design load
(PSI) (PSI) (PSI) (PSI)
Surface 0 4208 4208 4629
Casing shoe 3060 4988 1928 2121
(3800 ft)
Collapse design
Internal load: assuming that the casing is totally evacuated due to losses of drilling fluid.
External Load: Assuming that the pore pressure is acting at the casing shoe and zero
pressure at surface.
Summary of Collapse load
Depth External load Internal Load Net Load Design load
(PSI) (PSI) (PSI) (PSI)
Surface 0 0 0 0
Casing shoe 3060 0 3060 3060
(6600 ft)
PRODUCTION CASING (9 5/8” @ 10000 FT) (calculation at appendix)
Burst design
Internal Load: assuming that a leak occurs in the tubing at surface and that the
closed in tubing head pressure (CITHP) is acting on the inside of the top of the casing.
This pressure will then act on the column of packer fluid. The 9 5/8” casing is only
exposed to these pressure down to the Top of Liner (TOL).
External Load: assuming that pore pressure is acting at the liner depth and zero pressure at
surface
Summary of Burst load
Depth External load Internal Load Net Load Design load
(PSI) (PSI) (PSI) (PSI)
Surface 0 4205 4205 4626
TOL (9500 ft) 5133 9458 4325 4758
Collapse design
Internal Load: Assuming that the casing is totally evacuated due to gas lifting operations
External Load: assuming that the maximum pore pressure is acting on the outside of the casing
at the TOL.
Summary of Collapse load
Depth External load Internal Load Net Load Design load
(PSI) (PSI) (PSI) (PSI)
Surface 0 0 0 0
Casing TOL 5133 0 5133 5133
Bit Programme:
Drill bit size: ( based on figure 1)
Surface casing 20”= 26” Bit
Intermediate casing 13 3/8”= 17 ½” Bit
Production casing 9 5/8”= 12 ¼” Bit
FIGURE 1: DRILL BIT SIZE
Cementing Programme:
TABLE 2: TYPE OF CEMENT SLURRY
Cementing programmed:
Surface casing
Surface Casing (20” at 3800 ft)
OD: 20”
Hole Diameter (for surface casing): 26”
Depth: 3800 ft
Shoetrack: assume 60 ft
Rat Hole: assume 20 ft
Single stage cementing is appropriate because the volume is manageable, and there's no need
for additional stages given the design and depth.
Slurry Volume Between The Casing and Hole:
Annular capacity: 1.5053 ft3/ft (from figure 2)
Annular volume= 3800×1.5053 =5720 ft3
Add 10% excessive= 5720 ×1.1 = 6292 ft3
Slurry Volume Below The Float Collar:
Shoetrack capacity 19" 106 lb/ft= 1.9689 ft3/ft (from figure 5)
Shoetrack volume= 1.9689×60=32.86 ft3 =118 ft3
Slurry volume in the Rathole:
Capacities 26" Hole = 3.687 ft3/ft (from figure 2)
Rathole volume = 3.687×20 =73.74 ft3
Add 10% excessive = 73.74×1.1 =81 ft3
Total slurry volume=6292+118+81= 6491ft3
Cement calculation
Slurry Type: Type 1
Reason for Selection:
The density of 13.2 ppg is suitable for shallow depths, where excessive hydrostatic pressure
could cause formation breakdown.
Type 1 slurry has a high yield (1.89 ft³/sk), which helps reduce the number of sacks required for
the large annular volume of the surface casing.
The 8% bentonite additive enhances the slurry's ability to fill irregularities in the borehole.
Total slurry volume
Cement sacks=
yield
6491
= = 3434.4 sacks
1.89
Total mix water= mixwater requirement × cement sacks
1.37×3434.4 =4705.5 =838 bbls
Total Displacement Volume:
𝑉displacement = 𝑉 casing +𝑉 shoe track
= 5720+118=5838 ft3= 1040 bbls
add 2 bbl for surface line = 1042 bbls
Bottom Hole Pressure
The bottom hole pressure (BHP) is the pressure at the casing shoe during the displacement
phase. It is determined by the hydrostatic pressure of the fluid column.
Slurry Density (Type 1):
Density = 13.2 ppg
= 13.2 × 0.052 psi/ft = 0.6864 psi/ft
Hydrostatic Pressure at Casing Shoe (3800 ft):
BHP = Density (psi/ft) × Depth (ft)
BHP = 0.6864 psi/ft × 3800 ft = 2608.32 psi
Summary of cement program surface casing
Stage Single stage cementing
Slurry type Type 1
Slurry Volume 6491 ft3
Cement sacks 3434.4 sacks
Total mixwater 838 bbl
Displacement volume 1042 bbls
BHP 2608.32 PSI
Intermediate Casing (13 3/8” at 6600 ft) (calculation at appendix)
Stage Single stage cementing
Slurry type Type 2
Slurry Volume 5129 ft3
Cement sacks 4460 sacks
Total mixwater 532 bbl
Displacement volume 827 bbls
BHP 5422.56 PSI
Production Casing (9 5/8” at 10000 ft) (calculation at appendix)
Stage Multi stage cementing
Slurry type Type 1 (1st stage)
Type 2 (2nd stage)
Slurry Volume 4627 ft3 (1st stage)
573 ft3 (2nd stage)
Cement sacks 2449 sacks (1st stage)
498 sacks (2nd stage)
Total mixwater 598 bbls (1st stage)
59 bbls (2nd stage)
Displacement volume 749 bbls (1st stage)
9.15 bbls (2nd stage)
BHP 6864 PSI
Appendices
FIGURE 2: VOLUMETIC CAPACITIES 1
FIGURE 3: VOLUMETRIC CAPACITIES 2
FIGURE 4: VOLUMETRIC CAPACITIES 3
FIGURE 5: VOLUMETRIC CAPACITIES 4
FIGURE 6: VOLUMETRIC CAPACITIES 5
Casing Design:
INTERMEDIATE CASING (13 3/8” @ 6600 FT)
Burst design
Internal load: assuming that an influx of gas has occurred and the well is full of
gas to surface.
Pore pressure at bottom hole at 10000 ft = 5208 PSI
Pressure at surface = bottomhole pressure – gas pressure throughout casing
=5208-(0.1×10000)= 4208 PSI
4208 PSI is lower than the fracture pressure at 6600ft which is 5390 PSI. so the mudweight
pressure will not fracture the formation.
Pressure at 20” casing shoe = 5328 – (0.1×3400) = 4988 PSI
External Load: Assuming that the minimum pore pressure is acting at the casing shoe
and zero pressure at surface.
Pore pressure at casing shoe @6600 ft = 3060 PSI
External pressure at surface = 0 PSI
Collapse design
Internal load: assuming that the casing is totally evacuated due to losses of drilling fluid.
Internal Pressure at surface = 0 psi
Internal Pressure at shoe = 0 psi
External Load: Assuming that the pore pressure is acting at the casing shoe and zero
pressure at surface.
Pore pressure at the casing shoe = 3060 PSI
External pressure at surface = 0 psi
PRODUCTION CASING (9 5/8” @ 10000 FT)
Burst design
Internal Load: assuming that a leak occurs in the tubing at surface and that the
closed in tubing head pressure (CITHP) is acting on the inside of the top of the casing.
This pressure will then act on the column of packer fluid. The 9 5/8” casing is only
exposed to these pressure down to the Top of Liner (TOL). The 7” liner protects the
remainder of the casing.
Max. Pore Pressure at the top of the production zone which at 10200ft = 5225 PSI
CITHP (at surface) = Pressure at Top of Perfs - pressure due to column of gas (0.1 psi/ft)
=5225 – (0.1×10200)
=4205 PSI
Assume top linear depth at 9500 ft
Pressure at Top of Liner = CITHP + hydrostatic column of packer fluid
=4205+ 5253 =9458 PSI
External Load: assuming that pore pressure is acting at the liner depth and zero pressure at
surface
Pore pressure at top linear @9500ft = 5133 PSI
External pressure at surface = 0
Collapse design
Internal Load: Assuming that the casing is totally evacuated due to gas lifting operations
Internal Pressure at surface = 0 psi
Internal Pressure at TOL = 0 psi
External Load: assuming that the maximum pore pressure is acting on the outside of the casing
at the TOL.
Pore pressure at the TOL = 5133 PSI
External pressure at surface = 0 psi
Cementing programmed:
Intermediate Casing (13 3/8” at 6600 ft)
OD: 13 3/8”, Hole Diameter: 17 ½”, Depth: 6600 ft, Shoetrack: Assume 60 ft, Rat Hole: Assume
20 ft
Slurry Volume Between The Casing and Hole:
Annular capacity: 0.6946 ft3/ft (from figure 2)
Annular volume= 6600×0.6946 =4584 ft3
Add 10% excessive= 4584 ×1.1 = 5042 ft3
Slurry Volume Below The Float Collar:
Shoetrack capacity12.34” 72 lb/ft = 0.8315 ft3/ft (from figure 5)
Shoetrack volume= 0.8315×60 =49.89 ft3 = 50 ft3
Slurry volume in the Rathole:
Capacities 17 1/2” Hole = 1.6703 ft3/ft (from figure 2)
Rathole volume = 1.6703×20 =33.40 ft3
Add 10% excessive = 33.40×1.1 =37 ft3 Total slurry volume=5042+50+37= 5129 ft3
Slurry Type: Type 2
Reason for Selection:
The density of 15.8 ppg is appropriate for the intermediate casing depth, ensuring sufficient
hydrostatic pressure to prevent gas migration and wellbore stability.
The retarder additive (0.2% D13R) helps maintain pumpability at deeper depths and higher
temperatures.
The lower yield (1.15 ft³/sk) is acceptable because the annular space is smaller, requiring fewer
sacks overall.
Total slurry volume
Cement sacks=
yield
5129
= = 4460 sacks
1.15
Total mix water= mixwater requirement × cement sacks
0.67×4460 =2988.2 =532 bbls
Total Displacement Volume:
𝑉displacement = 𝑉 casing +𝑉 shoe track
= 4584+50=4634 ft3= 825 bbls add 2 bbl for surface line = 827 bbls
Hydrostatic Pressure (psi)=Density (psi/ft)×Depth (ft)
Convert Slurry Density to psi/ft:
Density (psi/ft) = 15.8 ppg × 0.052 = 0.8216 psi/ft
Calculate BHP at Casing Shoe:
BHP = Density (psi/ft) × Depth (ft)
= 0.8216 psi/ft × 6600 ft = 5422.56 psi
Production Casing (9 5/8” at 10000 ft)
OD: 9 5/8”, Hole Diameter: 12 ¼”, Depth: 10000 ft, Shoe track: assume 60 ft, Rat Hole: assume
20 ft.
Multi-Stage Cementing because at 10,000 ft depth, a multi-stage cementing approach is
appropriate to handle the large slurry volume and mitigate risks associated with high-pressure
zones.
Stage 1
Slurry Volume Between The Casing and Hole:
Annular capacity: 0.4166 ft3/ft (from figure 3)
Annular volume= 10000×0.4166 =4166 ft3
Add 10% excessive= 4166 ×1.1 = 4583 ft3
Slurry Volume Below The Float Collar:
Shoetrack capacity 8.835” 40 lb/ft = 0.4257 ft3/ft (from figure 6)
Shoetrack volume= 0.4257×60 =26 ft3
Slurry volume in the Rathole:
Capacities 12 ¼” Hole = 0.81846 ft3/ft (from figure 4)
Rathole volume = 0.81846×20 =16.37 ft3
Add 10% excessive = 16.37×1.1 =18 ft3
Total slurry volume=4583+26+18= 4627 ft3
Slurry type (stage 1): Slurry 1
Reason: The lighter slurry is used in the first stage to reduce hydrostatic pressure and prevent
losses in weaker formations near the top of the production casing.
Total slurry volume
Cement sacks=
yield
4627
= = 2449 sacks
1.89
Total mix water= mixwater requirement × cement sacks
1.37×2449 =3355.13 =598 bbls
Total Displacement Volume:
𝑉displacement = 𝑉 casing +𝑉 shoe track
= 4166+26=4192 ft3= 747 bbls
add 2 bbl for surface line = 749 bbls
Hydrostatic Pressure (psi)=Density (psi/ft)×Depth (ft)
Convert Slurry Density to psi/ft:
Density (psi/ft) =13.2 × 0.052 psi/ft = 0.6864 psi/ft
Calculate BHP at Casing Shoe:
BHP = Density (psi/ft) × Depth (ft)
= 0.6864 psi/ft × 10000 ft = 6864 psi
Stage 2 calculation (perforation zone)
Open hole capacities12 ¼” Hole =0.81864 ft3/ft
Depth= 10700-10000=700 ft
V= 700×0.81864=573ft3
Slurry type: slurry type 2
Reason: A denser slurry is used in the lower section to withstand higher pressures and provide
zonal isolation for the production zone.
Total slurry volume
Cement sacks=
yield
573
= = 498 sacks
1.15
Total mix water= mixwater requirement × cement sacks
0.67×498 =333.7 ft3 =59 bbls
Casing capacities: 0.0734 ft3/ft
Vdisplacement = 0.0734×700 =51.38 ft3= 9.15 bbls
add 2 bbl for surface line = 11.15 bbls