CASING DESIGN

Casings are set into the well mainly for:

• Avoiding interaction between Formation and Wellbore Pressures

• Preventing Wellbore Caving & Collapse

• Facilitating Installation of Wellbore and Wellhead Equipment for Production

• Establishing Confine Production

• Providing means for Pressure Control

• Preventing underground fresh water contamination

• Reducing Water-Cut and Sand in HC Production

CASING DESIGN DETERMINES STARTING SIZE OF THE WELL

Casing Designer (Drilling Engineer) mainly determines:

• Number of and lengths of Casing Strings (on the basis of Pressure Profiles of concerned well)

• Casing Sizing (on the basis of final casing string size)

• Casing Weights and Grades

• Safety Factors (on the basis of Tension, Collapse and Burst which are interacted)

CASING STRING

The total length of casings with uniform outside diameter and run into the well in a single operation
is called Casing String. Each Casing Strings has its upper end at the surface except liners.

SECTION OF A CASING STRING

A continuous length of a Casing String with uniform grade, wall thickness and the same type of joint
throughout is called Section of a Casing String. A Casing String consisting of more than one Section is
called a Combination String.

Types of Casing Strings:

1. Conductor Casing String

2. Surface Casing String (depending on Casing Design, well conditions several Surface Casing
Strings)

3. Intermediate (Protection) Casing String

4. Drilling Liner String (depending on Casing Design)

5. Production Casing String

 6. Production Liner String (depending on Casing Design)

7. Tie-Back String (depending on Casing Design)

Conductor Casing String

In practice, Conductor Casing diameters are from 95/8 to 30 inches, and lengths are from 20 to 1000
ft depending on consolidation of surface formations (collapse risk!).

Purposes:

1. To avoid collapsing unconsolidated surface formations.

2. To facilitate mud flow line to the pits.

3. To provide diverting surface water or gas flows through a rotating head fitted above the flow
line outlet.

Surface Casing String

It usually has diameter between 85/8 and 133/8 inches and length between 300 to 5000 ft.

Purposes (mainly):

• To hold back unconsolidated shallow formations against collapsing and cavitation.

• To protect contamination of shallow water sand zones.

• To facilitate Blow Out Preventer installation at the Wellhead.

• To hold high pressures in between Surface Casing Seat and Next Casing Seat.

• To provide back-up or relief outlet in case of inner casing string ruptures.

Intermediate (Protective) Casing String

Intermediate (Protective) Casing String(s) takes place in between Surface Casing String and
Production Casing String.

Purposes (mainly):

• To case the well bore section for safe drilling to final depth.

• To shut of Subnormal Formation zones against mud lost.

• To shut off Abnormal Formation Pressure zones against formation fluids influx to the
wellbore.

• To isolate troublesome zones such as shales and loose sections against swelling, caving,
collapsing, etc.

• To provide a back-up for Production Casing String.

Drilling Liner String

When Second Intermediate Casing String is required, usually Drilling Liner String is set.

Purposes:

• To reduce the amount of uncased hole.

• To provide back-up for Production Casing String.

Production Casing String

It is the last Casing String which ends either at the top level (Uncased Hole Completion) or at the
bottom level (Cased Hole Completion) of production zone depending on physical properties of
reservoir rock.

Through Production Casing String the well is completed, produced and controlled.

It is usually designed to hold Maximum Shut In Pressure of reservoir, but recommended to be

designed to hold even stimulation pressures just in case.

Production Liner String

When a Drilling Liner String has been run and hung below the Intermediate Casing String, the
Production Liner String may be hung from the end of Drilling Liner String.

Tie Back String

It is extension of Drilling Liner String to the surface, it becomes part of completion casing.

Common Casing String Designs

CASING PIPE CLASSIFICATION

Casing has two parts: Pipe and Coupling.

Casing Pipe itself is classified according to five properties:

1. Outside Diameter (Table 2.3)

2. Wall Thickness (Table 2.3)

3. Grade of the Material (Table 2.3)

4. Joint Type (Table 2.3)

5. Length Range

Outside Diameter and Wall Thickness define Casing Unit Weight. Casings are frequently classified by
Nominal Weight which is adjusted from the True Unit Weight to compensate for Threaded Ends and
Couplings.

CASING GRADES

CASING MINIMUM YIELD

REMARKS
GRADE STRENGT
F-25 25,000 psi 0.5% of the length
H-40 40,000 psi elongates under
J-55 55,000 psi these tensile
N-80 80,000 psi stresses.
0.5% of the length
elongates under
P-110 110,000 psi
these tensile
stresses.

CASING PIPE CLASSIFICATION

FORCES ON CASING STRINGS

The forces are not uniform through the well but change with depth. Therefore, Combination String
comes to the agenda in Casing Design. Here, the highest quality (thus the most expensive) Casing
Grades and Weights are reserved for the Casing String Sections exposed to the most severe forces.

Combination String results savings in cost and material.

CASING LENGTH RANGES

CASING LENGTH RANGE

MINIMUM MAXIMUM
RANGE LENGTH, ft
LENGTH, ft TOLERANCE, ft
1 16-25 18 6
2 25-34 28 5
3 >34 36 6
CASING THREADS AND COUPLINGS

• Casings are joined by Threaded Couplings.

• Couplings are graded as Casings.

• Physical Properties of a Coupling, such as Outside Diameter and the Wall Thickness must be
at least equal to those of the Casing Sections it joints (Table 2.3).

• Couplings are also classified in accordance with the Lengths of the Threads of the Casing they
are to be used as:

- Long Thread Coupling

- Short Thread Coupling

MAKE UP LOSS

Couplings are coupled to the one end of a casing pipe by power tight at a certain torque given by
standards.

The length of coupled casing pipe (from uncoupled end of the casing pipe to the end of coupling at
the other side) is less than the length of casing pipe plus the length of the coupling. This is called
Make Up Loss. Make Up Loss per joint is calculated by

Lj = 0.5Lc – J

where (Lj) is make up loss per joint, (Lc) is length of coupling and J is distance from the end of casing
to the center of coupling.

EXAMPLE PROBLEM

Calculate make up loss per joint for 7 inch OD and 26 lb/ft weight casing with short threads and
coupling. Also calculate the loss per 1000 ft of casing for 2nd grade casing, and the casing required
(LT) per 1000 ft of made up string in terms of L (average length of casing in ft).

SOLUTION

0.5Lc = 7.25 in and J = 0.5 in (From Table 2.6)

# of joints per 1000 ft of tallied casing = 1000 / L

Make Up Loss per 1000 ft = (3.125 in/joint)*(1000/L joint)

=3125/L ft = 3125/12L = 260.42/L ft

Let LT ft of casing required per 1000 ft up string:

Make Up Loss = (LT/1000)*(260.42/L) = (260.42 LT/1000 L = 0.26 LT/L

Thus, to get 1000 ft made up string, required length of tallied casing:

LT – (0.26 LT)/L = 1000

LT(1 – 0.26/L) = 1000

LT[(L – 0.26)/L] = 1000

LT = 1000L / (L-0.26)

JOINT STRENGTH

Joint Strength is the Axial Load supported at a Casing Joint.

Joint Strength is the function of Grade, Size and Weight of the Casing, and effective length of the
thread.

During running casing string, couplings at the upper sections are under higher tension due to the load
suspended below them.

Couplings must also be leak resistant under tension, here Yield Strength is determining factor.

Joint Strength short thread:

(Fjs) = Cs(33.71-de)(de-t-0.071)(24.45t - 0.742)

Joint Strength long thread:

 (Fjl) = 1.647C(25.58-de)(de-t-0.071)(24.45t - 0.742)

de: External (Outside) diameter of casing, in

t: Casing pipe thickness, in

0.07125 in: API Standard (height of thread)

For constant C: go to Table of ‘’Joint Strength Constants’’.

Joint Strength Constants

Joint Grade Cs Cl C
F-25 53.5 134
H-40 72.5 182
J-55 96.5 159 243

N-80 112.3 185 282

P-110 146.9 242 369
Cl/Cs = 1.65

EXAMPLE PROBLEM

Calculate Joint Strength of 7-in, 26-lb/ft, grade J55 casing with long threads and couplings, and
maximum length of casing satisfying required joint strength.
SOLUTION:

t= 0.362 in (Table 2.3)

C=243 (Table: Joint Strength Constants)

(Fjl) = 1.647C(25.58-de)(de-t-0.071)(24.45t-0.742)

(Fjl) = 1.647 X 243(25.58-7)(7-0.362-0.71)(24.45 X 0.362 – 0.742)

(Fjl) = 357,450 lb

Thus:

(357,450 lb) / 26 lb/ft) = 13748 ft of casing with 26 lb/ft weight.

CASING WEIGHTS

Casing Weights are considered in 3 ways:

1. Plain-End Weights: Weight of casing without threads and couplings.

2. Average Weight: Weight of casing with threads and couplings.

3. Nominal Weight: Weight of casing compensated with threads and coupling.

4. Plain-End Weights of Casings

5. Let de is outside diameter, di is inside diameter and t is wall thickness of casing. Then:

6. Mean Diameter = (de + di) / 2

7. Since di = de – 2t

8. Mean Diameter = de – t
 9. Mean Circumference = π(de – t)

10. Cross Sectional Area: A = π*t*(de -t)

11. Volume of 1 ft long casing: V = 12π*t*(de -t) [Link].

12. Density of steel: r = 0.2833 lb/[Link].

13. Plain-end weight of 1 ft Casing = Wp = 0.2833*12*π*t*(de -t) = 10.68t(de -t), lb

Average Weights of Casings

Let Wtc is average weight of 1 ft casing with threads at both ends and a coupling attached power tight
at one end, Lp is plain length of casing, Wp is plain weight of 1 ft casing, Wt is weight of removed
casing, Wc is weight of coupling and L is length of threaded and coupled casing. Then:

Wtc = (LpWp –2 Wt + Wc) / L

Due to Make-Up Loss, Lp = L – (0.5 Lc + J) / 12

Wt = 0.222Ltde2 – 0.074L(de2+ded1+d12)-0.074(Lt-L1)(d12+d1d4+d42)

Since d4 = d1- 0.0625(Lt - L1)

Here, Lt, L1, de and d1 are obtained from Table 2.4 and Table 2.5.
Wc = 0.222Lcdc2 – 0.0445Mdr2 – 0.074(Lc – 2M)(d22 + d2d3 + d32)

Here

d3 = d2 – 0.0625(0.5 Lc – M)

d4 = d1 – 0.0625(Lt – L1)

EXAMPLE PROBLEM

Calculate average weight (lb/ft) for 20 ft length of 7-in, 26-lb, J-55 LT and coupling casing.

SOLUTION

Wtc = (LpWp –2 Wt + Wc) / L

Lp = L – (0.5 Lc + J) / 12 here Lc = 9 in and J = 0.5 (from Table 2.5).

Lp = 20 – (0.5*9+0.5) / 12 = 19.58 ft

Wp = 10.68t(de -t) here de = 7-in (given), and t = 0.362 (from Table 2.3).

Wp = 10.68*0.362(7 – 0.362) = 25.66 lb/ft

Wt = 0.222Ltde2 – 0.074L(de2+ded1+d12)-0.074(Lt-L1)(d12+d1d4+d42)

here de = 7-in (given), Lt = 4 in, L1 = 0,625, d1 = 6,93175 (from Table 2.5).

d4 = d1 – 0.0625(Lt – L1) = 6.93175 – 0.0625(4 – 0.625) = 6.721 in

Wt = 1.862 lb/ft (weight of removed casing).

Wt = 0.222Ltde2 – 0.074L(de2+ded1+d12)-0.074(Lt-L1)(d12+d1d4+d42)

Wt = 0.222*4*72-0.074*0.625*(72+7*6.93175+6.93175 2)-

0.074(4-0.625)*(6.93175 2+6.93175*6.721+6.7212)

Wt = 1.862 lb/ft (weight of removed casing)

Wc = 0.222Lcdc2 – 0.0445Mdr2 – 0.074(Lc – 2M)(d22 + d2d3 + d32)

Here, Lc = 9 in, dc = 7.656 in, M = 0.704, dr = 73/32 in, d2 = 6.90337 in.

d3 = d2 – 0.0625(0.5 Lc – M) = 6.90337 – 0.0625(0.5*9 – 0.704) = 6.666 in

Wc = 0.222*9*7.6562 – 0.0445*0.704*7.093752 – 0.074(9 – 2*0.704)(6.903372 + 6.90337*6.666 +

6.66632)

Wc = 23.7555 lb/ft (weight of coupling)

Wtc = (LpWp –2 Wt + Wc) / L = (19.58*25.66 – 2*1.862 + 23.7555) / 20

Wtc = 26.123 lb/ft (average unit wt of threaded and coupled casing)

CASING WEIGHTS
EXTERNAL PRESSURE (COLLAPSE) EFFECT ON CASING

One of the three forces on casing is External Pressure which tends to collapse it either elastically
(temporal deformation) or plastically permanent deformation) when it is higher than casing internal
pressure.

The ability of casing to withstand against external pressure is called Collapse Resistance.

Collapse resistance is the function of:

1. The ratio of casing diameter to its wall thickness

2. Casing material properties (grade)

3. Axial loading effect on casing either tension or compression

Average Collapse Pressures (Through considering drilling engineering practices, following equations
are used for calculating):

If de/t <14

Average Collapse Pressure (Pc) by Lame Equation:

Pc = 2 Ya {[(de/t)-1]/(de/t) 2}

If de/t >14

Average Collapse Pressure (Pc) by API Equation:

Pc = Ya [2.503/(de/t)-0.046]

Here, Ya is average yield strength (psi), de is outside diameter of casing (in), and t is wall thickness (in).

Minimum Collapse Pressures (Through considering drilling engineering practices, following

equations are used for calculating):

For Elastic Failure:

Pc = (46.95*10 6)/{(de/t)[(de/t)-1]}

For Plastic Failure:

If de/t <14 Pc = 1.5*Ya{[(de/t)-1]/[(de/t) 2]}

If de/t >14 Pc = Ya{[1.877/(de/t)]-0.0345}

Above equations are used for H-40, J-55, N-80 and P-110 grade casings.

If de/t <43.5 Pc = [65000/(de/t)] – 1040

If de/t >43.5 Pc = [(37.66*10 6)/(de/t)3]

Above Stewart’s Equations are used for F-25 grade casing.

COLLAPSE RESISTANCE PROPERTIES OF CASINGS
CASING MAX (de/t) for Average Yield
GRADE Plastic Collapse Strength (Ya), psi
H-40 40,02 50.000
J-55 30,73 65.000
N-80 23,91 85.000
P-110 18,57 123.000
INTERNAL PRESSURE (BURST) EFFECT ON CASING

Collapse risk in deeper portions of casing string is higher than shallower portions of the casing string,
whereas burst risk is vice versa. On the other hand, internal pressure (mud weight) is constant
through the casing string, thus burst risk comes to the agenda in upper portions of the casing string.

Barlow's formula is conventionally used to calculate Burst Pressure (Pb):

Pb = 2S(t/de)

here S is Tensile Strength, psi.

Instead of Tensile Strength, if Minimum Yield Strength (Ymin) is used:

Pi = (1.75 Ymin) / (de/t)

where Pi is Internal Pressure (psi), and Ymin is Minimum Yield Strength (psi).

Reminder: For J-55 S=55000 psi, for N-80 S=80000 psi, etc.
AXIAL LOAD EFFECT ON CASING

Dead weight of casing string causes axial load which tends to fail casing longitudinal besides it lowers
collapse resistance of casing string.

Failure starts from the root of the last perfect thread just because the wall thickness of casing is the
least there.

Axial Stress has no effect on Elastic Collapse, but on Plastic Failure.

The Axial Load (Fa):

Fa = Ymin Aj

where Aj is Root Thread Area and can be calculated by:

Aj = π(t-h)(de – t - h) here h=0.071 (by API standard)

or Aj value can be obtained from Table 2.15 for all sizes and weights of casing.

Collapse Pressure (Pc) must be corrected (Pcc) due to Axial Loading (W):

Pcc = (Pc / K) [(SQRT(K 2 – 3W 2) – W] where K = A*Yave

Plain-end area (A) is obtained from Table 15, K from Table 16

EXAMPLE PROBLEM SOLUTIONS (COLLAPSE)

QUESTION: Calculate the collapse resistance of 16-in 55-lb F-25 casing & 5.5-in 17-lb J-55 casing.

SOLUTION:

a) 16-in 55-lb F-25 casing (Stewart’s Equations are used for F-25)

If de/t <43.5 Pc = [65000/(de/t)] – 1040

If de/t >43.5 Pc = [(37.66*10 6)/(de/t3)]

de = 16 in (given) & t = 0.312 (from Table 2.3)

de/t = 16/0.312 = 51.3 Since 51.3 > 43.5:

Pc = [(37.66*10 6)/(de/t3)] = [(37.66*10 6)/(51.33)] = 280 psi

b) 5.5-in, 17-lb, J-55, de = 5.5 in (given), t = 0.304 (from Table 2.3)

Ya = 65000 (from Table COLLAPSE RESISTANCE PROPERTIES OF CASINGS)

Pc = Ya{[1.877/(de/t)]-0.0345} = 65000{[1,877/(5,5/0,304)]-0.0345}

Pc = 4500 psi

EXAMPLE PROBLEM SOLUTIONS (YIELD)

QUESTION: Calculate the minimum internal yield pressures of 16-in 55-lb F-25 casing & 5.5-in 17-lb J-
55 casing.

SOLUTION: Pi = (1.75 Ymin) / (de/t)

For 16-in 55-lb F-25 casing:

Ymin = 25000 psi (from Table of Casing Grades)

(de/t) = 51.23 (from previous question)

Pi = 5320 psi

For 5.5-in 17-lb J-55 casing:

Ymin = 55000 psi (from Table of Casing Grades)

(de/t) = 18.09 (from previous question)

Pi = 850 psi

EXAMPLE PROBLEM SOLUTIONS (AXIAL LOAD)

QUESTION: Calculate the load could be carried out by the casings of 16-in 55-lb F-25 casing & 5.5-in
17-lb J-55 casing without failure. Compare these calculated loads with joint strengths (Fjs and/or Fjs)
by Table 2.9.

SOLUTION: The Axial Load = Fa = (Ymin) (Aj)

Aj(Root Thread Area)=π(t-h)(de–t-h) here h=0.071 (by API standard)

and checked from Table 2.15

Fjs=Cs(33.71-de)(de-t-0.071)(24.45t-0.742)

Fjl=1.647C(25.58-de)(de-t-0.071)(24.45t-0.742)

For 16-in 55-lb F-25 casing:

Ymin=25000 psi, Aj=11.812 [Link]., Fa=295000 lb, Fjs=258000 lb

For 5.5-in 17-lb J-55 casing:

Ymin=55000 psi, Aj=3.747 [Link]., Fa=205000 lb, Fjs=234000 lb,

Fjl=275000 lb
CORRECTION OF COLLAPSE PRESSURE DUE TO AXIAL STRESS

Collapse Resistance values of casings from Table 2.13 and also calculations of Minimum Collapse
Pressure Equations for Plastic Failure are subject to no axial stress effect.

Axial Stress has no effect on Elastic Collapse, but reduces resistance of casing against Plastic Failure.
Therefore, regarding F-25, H-40, J-55, N-80 and P-110 grade casings below Elastic Failure Equation:

Pc = (46.95*10 6)/{(de/t)[(de/t)-1]}

does not require any correction.

However, regarding H-40, J-55, N-80 and P-110 grade casings Plastic Failure Equations:

If de/t <14 Pc = 1.5*Ya{[(de/t)-1]/[(de/t) 2]}

If de/t >14 Pc = Ya{[1.877/(de/t)]-0.0345}

and below Stewart Equation for F-25 grade casing

If de/t <43.5 Pc = [65000/(de/t)] – 1040

If de/t >43.5 Pc = [(37.66*10 6)/(de/t)3]

requires correction.

Collapse Pressure Correction

Pcc = Pc *(St / So)

here Pc is Plastic Collapse Pressure under no Axial Load, and Pcc is Corrected Plastic Collapse Pressure
under Axial Load of W, So is Yield Stress in pure tension (average yield strength Ya, and St is Apparent
Yield Stress in the tangential direction under Axial Stress Sz).

Let cross-sectional wall area be A, then:

Sz = -(W/A)

Plastic Yield occurs if:

St2 – St Sz + Sz2 = So2

Considering that Sz = (-W/A) and dividing both sides by (So2):

(St2/So2) + (W*Sz/A*So2) + W2/(A2*So2) = 1

Substituting above equation to Corrected Plastic Collapse Pressure (Pcc):

(Pcc /Pc)2 + (2W/K)(Pcc /Pc) + (4W2/K2) – 1 = 0

where K = 2(A*So) and A = πt(de – t).

Solving for (Pcc /Pc)

(Pcc /Pc) = (1/2){(2W/K) +/- SQRT[(4W2/K2) -4(4W2/K2-1]}

(Pcc /Pc) = -(W/K) +/- SQRT[(-3W2 /K2) + (K2 /K2)]

Since (Pcc /Pc) is to be positive, negative root is eliminated.

Solving for Pcc:

Pcc = (Pc/K)*[SQRT(K2 - 3W2) - W]

EXAMPLE PROBLEM SOLUTION FOR CORRECTION OF COLLAPSE PRESSURE DUE TO AXIAL STRESS

QUESTION: Calculate the collapse resistance of 7-in 26-lb N-80 casing if a 2000 ft section of 7-in 29-lb
N-80 casing is suspended below it.

SOLUTION:

For 26-lb N-80 casing:

de/t = 19.337 (Table 2.15 indicates that failure will be plastic)

t = 7/19.337 = 0.362

A = πt(de – t) = 3.14*0.362*(7-0.362) = 7.549 [Link]. (Table 2.15 as well)

Ya = 85000 psi (Table 2.12)

K=2AYa=2*7.549 [Link].*85000 lb/[Link].=1.283*106 lb (Table 2.16 as well)

Pc = 5320 psi (Table 2.13)

W = 2000 ft * 29 lb/ft = 58000 lb

Pcc = (Pc/K)*[SQRT(K2 - 2W2) - W]

Pcc = [5320/(1.283*106)]*[SQRT(1.283*1012-2580002)-58000]=5060 psi

DESIGN FACTOR

Properties of casing indicating maximum allowable stresses based on minimum physical properties in
Design Factor calculation for casing not to fail:

1. Joint Strength (Fj): Resistance of casing at joints to failure under tension.

2. Tensile Yield Load (Fa): Resistance of casing to failure under tension based on minimum yield
strength and cross-sectional area of material.

3. Corrected Collapse Pressure (Pcc): Resistance of casing to failure by collapse under external
pressure.

4. Internal Yield Pressure (Pi): Resistance of casing to failure by burst under internal pressure.
Safety Factor = (Maximum Allowable Stress) / (Actual Working Stress)

Thus:

Joint Load = (Fj) / (Nj)

Axial Load = (Fc) / (Nc)

External Pressure = (Pcc) / (Ne)

Internal Pressure = (Pi) / (Ni)

Since Actual Physical Properties are not exactly known, Design Factor is called instead of Safety
Factor, and avoided to use adjectives of "Maximum" and "Actual":

Design Factor = (Allowable Stress) / (Working Stress)

Design Factor Selection

For any engineering design issue, following fundamental considerations are governed:

1. When reliability and accuracy of strength data increase, design factor decreases.

2. In determining strength data, when similarity between operation conditions and test conditions
increases, design factor decreases.

3. When reliability and accuracy of loading increase, design factor decreases.

4. When possibilities of hazards increase, design factor increases.

By considering failures due to external pressure, internal pressure and axial loading, following
conclusions are obtained:

1. Reliability and accuracy of strength data are almost the same for all three failures.

2. Similarity between operation conditions and test conditions are almost the same for all three
failures.

3. In determining loading data, the worst possible conditions are considered.

4. Possibilities of hazards to personnel is zero for collapse failure, moderate in tension failure, and
high in bursting failure, while economic loss is considerable in any case.

EXAMPLE PROBLEM SOLUTION FOR DESIGN FACTOR CALCULATION

QUESTION

Following combination string is designed:

- From surface to 3740 ft: 7-in 20-lb J-55 casing with short threads and coupling.
 - From 3740 to 7390 ft: 7-in 23-lb N-80 casing with long threads and coupling.

- Mud weight: 10.2 ppg

- Bottom hole pressure: 3000 psi

Calculate the design factors for collapse, burst, joint strength and yield strength for both sections by
assuming the worst axial loading conditions.

SOLUTION

Weight of lower section = (23 lb/ft)*(7390 ft - 3740 ft) = 84000 lb

Corrected Collapse Pressure (Pcc) is to be corrected for axial loading of 20-lb J-55 casing:

K=747000 lb (Table 2.16)

Pcc = (Pc/K)*[SQRT(K2 - 2W2) - W]

Pcc = (2500/747000)*[SQRT(53.7 *1010) – 84000] = 2170 psi

Design Factor for Collapse (Nc)

From Table 2.13:

Collapse Pressure (Pc) = 4300 psi for 23-lb N-80 casing

Collapse Pressure (Pc) = 2500 psi for 20-lb J-55 casing

External pressure at the bottom of the lower section (Ne):

Ne = 0.433*(10.2/8.33) psi/ft * 7390 ft = 3920 psi

External pressure at the bottom of the upper section (Ne):

Ne = 0.433*(10.2/8.33) psi/ft * 3740 ft = 1980 psi

Design Factor for Collapse (Nc)

Nc = 4300/3920 = 1.10 for the lower section

Nc = 2170/1980 = 1.10 for the upper section

Design Factor for Burst (Internal Yield, Ni)

From Table 2.14:

Burst Pressure (Pi) = 6340 psi for 23-lb N-80 casing

Collapse Pressure (Pi) = 3740 psi for 20-lb J-55 casing

Design Factor for Burst (Ni)

Nc = 6340/3000 = 2.12 for the lower section

Nc = 3740/3000 = 1.25 for the upper section

Design Factor for Joint Strength (Nj)

Load on top of the lower section = (23 lb/ft)*(7390 ft-3740 ft)=84000 lb

Load of upper section = (20 lb/ft)*(3740 ft-0 ft)=74800 lb

Load on top of the upper section = 84000 lb + 74800 lb = 158800 lb

From Table 2.9:

Joint Strength (Fjl) = 400000 psi for 23-lb N-80 casing

Joint Strength (Fjs) = 254000 psi for 20-lb J-55 casing

Design Factor for Joint Strength (Ni):

Nj = 400000/84000 = 4.76 for the lower section

Nj = 254000/158800 = 1.60 for the upper section

Design Factor for Axial Load (Na)

From Table 2.15:

Root Thread Area (Aj) = 5.105 sq in for 23-lb N-80 casing

Root Thread Area (Aj) = 4.198 sq in for 20-lb J-55 casing

Unit Stresses at roots of the last perfect thread:

(84000 lb / 5.105 sq in) = 16500 psi for lower section (23-lb N-80 casing)

(158000 lb / 4.198 sq in) = 37800 psi for upper section (20-lb J-55 casing)

Design Factor for Joint Strength (Ni):

Minimum Yield Strength for N-80 = 80000 psi

Minimum Yield Strength for J-55 = 55000 psi

Na = 80000/16500 = 4.85 for the lower section

Na = 55000/37800 = 1.46 for the upper section

CASING & DRILL BIT SIZE SELECTION

Outside Diameter of Production Casing String is the key parameter of Casing Size Selection. To
determine the outside diameter of production casing string, following factors are considered:

- Drilling Cost: Drilling cost increases as hole size increases.

- Method of Production: Required bottom hole production equipment is to be accommodated

into the hole.

- Optimum Production Rate: It is important only where the rate is high enough to cause
reasonable pressure drop.

- Possibility of multi zone completion.

- Number of intermediate casing strings.

 - Fluids produced: It affects bottom hole equipment.

- Type of well (exploration or development)

EXAMPLE PROBLEM FOR CASING SIZE SELECTION

QUESTION: Determine intermediate and surface strings for 5.5-in production casing string.

SOLUTION:

- Production casing OD=5.5-in (given).

- 5.5-in production casing string requires 73/8-in drill bit (Table 2.18).

- Drift diameters for 85/8-in casing vary from 7.386-in to 7.972-in and all casings smaller than
85/8-in have drift diameters less than 7.375-in (Table 2.18). So, intermediate string will be
85/8-in.

- 85/8-in intermediate string 133/4-in drill bit is requires (Table 2.18).

- Drift diameters for 16-in casing vary from 14.822-in to 15.188-in and all casings smaller than
16-in have drift diameters less than 13.750-in (Table 2.18). So, surface string will be 16-in
casing.

- For 16-in surface casing requires 203/4-in drill bit (Table 2.18) but smallest commonly used
bit is 22-in (Table 2.19).

COMBINATION CASING STRING DESIGN

DEFINITION

Casing String combined by more than one Casing Section is called Combination Casing String.

PURPOSE

The purpose of Combination Casing String is to reduce the cost while satisfying calculated three
numbers of Design Factors: joint strength, collapse pressure and internal yield. (Engineering practice
shows that longitudinal yield is satisfied if joint strength is satisfied).

PROCEDURE

1. Determining the casings available in the inventory with lengths, grade, weight and diameter
satisfying the Design Factors to be employed.

2. Considering the worst possible conditions in determining loading data.

3. Assuming internal pressure as reservoir pressure (pws) and external pressure as zero.
Minimum allowable internal yield strength (pi):

pi = pws*Ni

where Ni is internal yield design factor.

The controlling factor in the lower portion is collapse pressure (pc), and in the upper section is joint
strength (longitudinal yield).

4. Calculating the Setting Length (Ls)of the concerned section by

Ls = pc / (0.052*Ni*ρ)

where ρ is fluid density in ppg.

Here, assume that external pressure is due to external fluid column, and internal pressure is zero,
and the cheapest weight and grade of casing satisfying above equation is to be chosen.

To calculate casing section length other than the lowest, the longitudinal tension effect on collapse
pressure is to be considered. This way requires either trial and error (iteration) solution or graphizal
solution. Here, reduced collapse resistance is controlling factor, and joint strength together with
longitudinal yield are to be considered. Casing section is to be designed to satisfy following
equations:

Fj = W*Nj and Ym*Aj = W*Na where W is the weight of suspended casing section below the
concerned depth.

QUESTION

OD: 7-in

MW: 12 ppg

Total Length of combination string: 8000-ft

Formation Pressure Gradient: 0.5 psi/ft

Collapse Design Factor (Nc): 1.125

Joint Strength Design Factor (Nj): 2.00

Yield Strength Design Factor (Na): 1.25

Internal Yield Design Factor (Ni): 1.00

QUESTION

OD: 7-in

MW: 12 ppg

Total Length of combination string: 8000-ft

Formation Pressure Gradient: 0.5 psi/ft

Collapse Design Factor (Nc): 1.125

Joint Strength Design Factor (Nj): 2.00

Yield Strength Design Factor (Na): 1.25

Internal Yield Design Factor (Ni): 1.00

List of available casing with physical properties is given in following table:

Design the combination casing string sections.

SOLUTION

Reservoir Pressure is not given, therefore it is calculated by given Formation Pressure Gradient:

Reservoir Pressure = pws = (pf /D)*D = 0.5 psi/ft * 8000 ft = 4000 psi

Minimum Internal Yield (pi):

pi = pws*Ni = 4000 psi * 1 = 4000 psi

Thus, J-55 20-lb casing is eliminated since its:

Minimum Internal Yield (pi) = 3740 psi < 4000 psi.

Section-1 (The lowest section): Collapse pressure is controlling factor.

Minimum Collapse Pressure:

pc = 0.052*Nc*ρ*Ls = 0.052*1.125*12*8000 = 5620 psi

The cheapest available casing in the list satisfying Minimum Collapse Pressure is 29-lb N-80 with long
threads and coupling (Table 2.3)

which has pc = 6370 psi (Table 2.13) > 5620 psi.

Joint Strength:

Wmax = Fj / Nj = 520000 lb / 2.00 =260000 lb (by Average Yield Strength)

Wmax = Ym*Aj / Na =80000*6.899/1.25 = 442000 lb (by Minimum Yield Strength)

The Maximum Allowable Length for Section-1:

260000 lb/29 lb/ft = 8970 ft<8000 ft (satisfies the total well depth)

Third assumed setting depth of Section-2:

Under this assumption the weight of Section-1 becomes:

W = (8000 ft - 7510 ft)*29 lb/ft = 14210 lb

Corrected collapse pressure becomes:

Pcc = (Pc/K)*[SQRT(K2-3W2)-W]

Pcc = (5320/1283000)*[SQRT(1.646*1012-0.606*109)-14210]=5260 psi

Thus the third assumed length:

Ls = Pc /(0.052*ρ*Nc) = 5260/(0.052*12*1.125) = 7490 ft

Under this assumption the weight of Section-1 becomes:

W = (8000 ft - 7490ft)*29 lb/ft = 14790 lb

And collapse pressure (Pcc) of Section-2 = 5260 psi

If iteration is repeated, next (Pcc) will be 5258 psi and Ls will be 7490 ft.

So, the allowable setting depth of Section-2 is 7490 ft.

Maximum Joint Load for Section-2 (N-80 26-lb long thread casing) where Fjl = 460000 lb (Table 2.9):

Maximum Joint Load = Yjl / Nj = 460000 lb/2.00 = 230000 lb

Maximum Yield for Section-2 which has N-80 26-lb long thread casing where Ym = 80000 lb (Table
Casing Grade Types)

and Aj = 5.998 (Table 2.15):

Maximum Yield = Ym*Aj / Na = (80000*5.998)/1.25 = 384000 lb

Maximum length of Section-2 where the weight of casing suspended below it is 14790 lb:

(23000 lb – 14790 lb) / (26 lb/ft) = 8280 ft > 7490 ft

Section-3: Collapse pressure is controlling factor.

Section-3 will consist of next lighter casing available in the list which is N-80, 23-lb with long thread
and coupling (Table 2.3).

Collapse Pressure = Pc = 4300 psi (Table 2.13).

First assumed setting depth (maximum length):

Ls = Pc /(0.052*ρ*Nc) = 4300/(0.052*12*1.125) = 6130 ft

The weight of Section-2 becomes:

W = (7490 ft – 6130 ft)*(26 lb/ft) = 35400 lb

Total axial load = 14790 lb + 35400 lb = 50200 lb

K = 1132000 lb (Table 2.16)

Corrected pressure (Pcc) becomes:

Pcc = (Pc/K)*[SQRT(K2-3W2)-W]

Pcc = (4300/1132000)*[SQRT(1.281*1012-0.08*1012)-50200]=4090 psi

The second assumed setting depth of Section-3:

Ls = Pc /(0.052*ρ*Nc) = 4090/(0.052*12*1.125) = 5830 ft

By repeating trial and error calculation as in calculating Section-2:

The allowable setting depth of Section-3 Ls = 5780 ft.

Total Weight of Section-1 and Section-2 is calculated as 59200 lb.

Maximum allowable joint load of Section-3 = 400000 lb/2 = 200000 lb.

Maximum yield of Section-3 = 80000*5.105/1.25 = 327000 lb

Maximum length of Section-3 = (200000 lb–59200 lb)/(23 lb/ft)=6120 ft

6120 ft > 5780 ft

Section-4:

Collapse pressure is controlling factor.

The least expensive casing grade of the remaining casings is J-55, 26-lb with short threads and
couplings (Table 2.3).

The allowable setting depth of Section-4 = Ls = 5310 ft.

Total Weight of Section-1, Section-2 and Section-3 is calculated as 71400 lb.

Maximum allowable joint load of Section-4 is 172500 lb.

Maximum yield of Section-4 is 264000 lb

Maximum length of Section-4 is 3890 ft < 5310 ft

Since Maximum Length of Section-4 is less than Maximum Allowable Setting Depth, controlling factor
for Section-5 will be joint strength (not collapse pressure).

Section-5:
Joint Strength is controlling factor.

The least expensive casing grade of the remaining casings is J-55, 26-lb with long threads and
couplings (Table 2.3).

The allowable setting depth of Section-5 Ls = 5310 ft – 3890 ft = 1420 ft

Total Weight of Section-1, Section-2, Section-3 and Section-4 is calculated as 172500 lb.

Maximum allowable joint load of Section-5 = 395000 lb/2 = 197500 lb.

Maximum yield of Section-5 is 264000 lb

Maximum length of Section-5 = (197500lb–172500 lb)/26 lb/ft = 960 ft

Maximum setting depth of Section-5 = 1420 – 960 = 460 ft < 1420 ft

Since Maximum Length of Section-5 is less than Maximum Allowable Setting Depth, controlling factor
for Section-6 will be joint strength (not collapse pressure).

Section-6:

Joint Strength is controlling factor. Here the joint strength is to be greater than Section 5 (>395000
lb). No weight of J-55 in the available casing list satisfies it. The least expensive casing grade of the
remaining casings is N-80, 23-lb with long threads and couplings (Table 2.3).

The allowable setting depth of Section-6 = Ls = 5310 ft – 3890 ft = 1420 ft

Total Weight of all casings below Section-6 is calculated as 172500+(26*960) = 197500 lb.

Maximum allowable joint load of Section-6 = 400000 lb/2 = 200000 lb.

Maximum yield of Section-6 = 80000*5.105/1.25 = 327000 lb

Maximum length of Section-6 = (200000lb–197500 lb)/23 lb/ft = 110 ft

Maximum setting depth of Section-6 = 460 – 110 = 350 ft < 1420 ft

Controlling factor for Section-7 will be joint strength (not collapse pressure).

Section-7:

Joint Strength is controlling factor. Here the joint strength is to be greater than Section 6 (>400000
lb). In the available casing list, the least expensive casing grade of the remaining casings is N-80, 26-lb
with long threads and couplings (Table 2.3).

The allowable setting depth of Section-6 = Ls = 5310 ft – 3890 ft = 1420 ft

Total Weight of all casings below Section-6 is calculated as 172500+(26*960) = 197500 lb.

Maximum allowable joint load of Section-7 = 230000 lb.

Maximum yield of Section-7 = 384000 lb

Maximum length of Section-7 = (230000lb–200000 lb)/26 lb/ft = 1150 ft

Since 1150 ft >350 ft, Section-7 continues to the surface.

GRAPHICAL SOLUTIONS

When joint strength becomes controlling factor, no need to check collapse resistance.

When collapse resistance becomes controlling factor, trial and error calculation can be simplified by
use of charts (Fig. 2.6., Fig. 2.6. and Fig. 2.6.).

In these charts, curved lines are plots of:

Pcc = (Pc/K)*[SQRT(K2-3W2)-W]

and straight lines are plots of:

Pcc = 0.052*ρ*Nc*Ls
QUESTION

Considering previous casing design question, determine the setting depth of Section-2 of the
combination string by using collapse design chart for 7-in casing.

SOLUTION

Section-1 consists of N-80 29-lb casing. Section-2 consists of N-80 26-lb casing.

From Fig.2.7, ρLs is 91000.

Axial load for Section-2:

29 lb/ft * (8000-7580) ft = 12180 lb

From Fig.2.7, ρLs is 90000 and the second assumed setting depth = 90000 / 12 = 7500 ft.

The axial load = (29 lb/ft)*(8000 ft - 7500 ft) = 14500 lb

From Fig.2.7, ρLs is again 90000.

Thus, maximum setting depth of section-2 = 7500 ft (very close to 7490 ft).