Exercise - Production Casing Selection for Collapse, Burst...

Casing Design Workshop: Production Casing Selection for Collapse, Burst and Axial Design

Factor Loads Exercise

(Last Updated 16 December 2015) COPYRIGHT

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Casing Design Workshop

Exercise: Production Casing Selection for Collapse, Burst

and Axial Design Factor Loads

Production Casing Design Example:Applying Design to the Loads

Production Casing

Design factors

We will use a higher burst design factor for the production casing since it may be critical later in the life of the well

True axial load

15.3 ppg mud

Load Type Design Factor for Example

Collapse 1.125

Burst 1.2

Tension 1.6 or 100,000 lb

═════════════════════════════════════════════════════════════════════════Casing Design Workshop

© PetroSkills, LLC., 2016. All rights reserved._____________________________________________________________________________________________

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Available 7 in. Casing

Wt

(lb/ft)

Grade Conn. ID

(in.)

Collapse

(psi)

Burst

(psi)

Joint Strength

(1000 lb)

29 N-80 LT&C 6.184 7030 8160 597

32 N-80 LT&C 6.094 8600 9060 672

29 P-110 LT&C 6.184 8530 11220 797

32 P-110 LT&C 6.094 10780 12460 897

35 P-110 LT&C 6.004 13030 12700 996

Production Casing Load Lines

0

2000

4000

6000

8000

10000

12000

14000

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Dep

th (

ft)

Pressure (1000 psi)

Production Casing Load

Collapse LoadLine

Production

Installation

Production Collapse

0

2000

4000

6000

8000

10000

12000

14000

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Dep

th (

ft)

Pressure (1000 psi)


Collapse DesignLoad

Collapse Load Line

Production 29# N-80

35 # P-110

32 # P-110

32 # N-80

Production Casing Selection for Collapse, Burst and Axial Design Factor Loads Exercise ═════════════════════════════════════════════════════════════════════════

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© PetroSkills, LLC., 2016. All rights reserved.

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Production Burst Loads

0

2000

4000

6000

8000

10000

12000

14000

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Dep

th (

ft)

Pressure (1000 psi)


Burst LoadLines

Shallow Tubing Leak

Tubing Backup

Plug Bump

Burst Design Problem

Our available casing will not satisfy a design for a shallow tubing leak load

Choices:• Design for near surface tubing leak

– Purchase premium casing string– Spend much more money

• Design an alternate string w/ available casing– Accept risk underground casing rupture and cross flow– Design tubing string to resist high collapse pressure (or risk tubing

collapse and loss of packer fluid)

Which do we choose?

Burst Design Choice

Most production casing burst designs:• Use the tubing backup load• Ignore the shallow tubing leak load

Why?• No awareness of the tubing leak consequences• Tubing leak most likely to occur later in well life with lower tubing

pressures (?)• Risk deemed too low to justify extreme casing design and cost

We will do both for comparison



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Production Casing Burst

0

2000

4000

6000

8000

10000

12000

14000

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Dep

th (

ft)

Pressure (1000 psi)


Burst LoadLines

Shallow Tubing Leak

Tubing Backup

Plug Bump

Conventional Choice

Production Collapse Selection

0

2000

4000

6000

8000

10000

12000

14000

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Dep

th (

ft)

Pressure (1000 psi)


Collapse DesignLoad

Collapse Load Line

Production 29# N-80

35 # P-110

32 # P-110

32 # N-80

Production Burst Selection

0

2000

4000

6000

8000

10000

12000

14000

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Dep

th (

ft)

Pressure (1000 psi)

Production Casing Burst Design (alternate)

Burst DesignLoad

Tubing Backup

35 # P-110

32 # P-110

29 # P-110

29 # N-80

32 # N-80

32 # N-80

Too many sections


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Production Burst Selection

0

2000

4000

6000

8000

10000

12000

14000

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Dep

th (

ft)

Pressure (1000 psi)

Production Casing Burst Design (Alternate)

Burst DesignLoad

Tubing Backup

35 # P-110

32 # P-110

29 # P-110

32 # N-80

Axial Load

Installation – running• Inside: mud, 15.3 ppg• Outside: mud, 15.3

Installation – plug bump• Inside: 15.3 ppg mud + 1200 psi above differential displacement

pressure• Outside: tail slurry 16.6 ppg, lead slurry 15.9 ppg, spacer and mud

15.3 ppg

Installation – Post plug bump• Inside: 15.3 ppg mud• Outside: same as plug bump

Production Casing Axial Loads

Plug Bump Post Plug Bump



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Axial Load – Manual Calculations

Four sections• Middle two have same ID and weight

0

1

2

3

1p

0p

1A

2A

0p0A

1 0 1 0 0ˆˆF p A p A

1 1 1W w L

2 2 2W w L

1 1 1F F W

2 1 1 2 1F F p A A

2 2 2F F W

3 3 3W w L

3 2 2 3 2F F p A A

3 3 3F F W

3A

Axial Load Calculations

Cross sectional areas

2 20

2 21

2 22

2 23

ˆ 4 7.000 38.485 in

4 6.004 28.312 in

4 6.094 29.167 in

4 6.184 30.035 in

A

A

A

A


Section weights

1 1 1

2 2 2

3 3 3

35 1959 68,565 lbf

32 8116 259,712 lbf

29 3925 113,825 lbf

W w L

W w L

W w L


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Running Case, pressures

0 0

1

2

ˆ 0.052 15.3 14000 11,138 psi

0.052 15.3 12041 9,580 psi

0.052 15.3 3925 3,123 psi

p p

p

p


Running Case, axial forces

1 0 1 0 0

1 1 1

2 1 1 2 1

2 2 2

ˆˆ 11138 28.312 38.485

113,307 lbf

113307 68565 44,742 lbf

44742

9580 29.167 28.312

36,551 lbf

36551 259712 223,161 lbf

F p A p A

F F W

F F p A A

F F W


Running Case, axial forces

3 2 2 3 2

3 3 3

223161

3123 30.035 29.167

225,872 lbf

225872 113825 339,697 lbf

F F p A A

F F W



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Plug Bump, pressures

0

0

1

2

ˆ 0.052 16.6 1250 15.6 3750

15.3 9000

11,281 psi

11,281 1200 12,481 psi

12481 0.052 15.3 14000 12041

10,922 psi

12481 0.052 15.3 14000 3925

4,465 psi

p

p

p

p


Plug Bump, axial forces

1 0 1 0 0

1 1 1

2 1 1 2 1

ˆˆ 12481 28.312 11281 38.485

80,787 lbf

80787 68565 12,222 lbf

12222

10922 29.167 28.312

2,884 lbf

F p A p A

F F W

F F p A A


Plug Bump, axial forces (cont.)

2 2 2

3 2 2 3 2

3 3 3

2884 259712 256,828 lbf

256828

4465 30.035 29.167

260,704 lbf

260704 113825 374,529 lbf

F F W

F F p A A

F F W


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Post Plug Bump, pressures

0

0

1

2

ˆ 0.052 16.6 1250 15.6 3750

15.3 9000

11,281 psi

0.052 15.3 14000 11,138 psi

0.052 15.3 12041 9,580 psi

0.052 15.3 3925 3123 psi

p

p

p

p


Post Plug Bump, axial forces (cont)

1 0 1 0 0

1 1 1

2 1 1 2 1

ˆˆ 11138 28.312

11281 38.485

118,810 lbf

118810 68565 50,245 lbf

50245

9580 29.167 28.312

42,054 lbf

F p A p A

F F W

F F p A A


Post Plug Bump, axial forces (cont)

2 2 2

3 2 2 3 2

3 3 3

42054 259712 217,658 lbf

217658

3123 30.035 29.167

220,369 lbf

220369 113825 333,654 lbf

F F W

F F p A A

F F W

Minor math error, 334,194



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0

2000

4000

6000

8000

10000

12000

14000

16000

-200 -100 0 100 200 300 400 500 600 700 800 900 1000

Dep

th (

ft)

Axial Load (1000 lb)

7" Casing True Axial Load

True Axial Load

Running

True Axial Load Post Plug Bump

True Axial Load Plug

Bump

Production Axial Load

0

2000

4000

6000

8000

10000

12000

14000

16000

-200 -100 0 100 200 300 400 500 600 700 800 900 1000

Dep

th (

ft)

Axial Load (1000 lb)

7" Casing True Axial Load Design

True Axial Load Plug

Bump

Design Factor = 1.6

Over Pull 100,000 lb 35# P-110

32# P-110

32# N-80

29# P-110

Axial Loads Spreadsheet

Vertical Depth of Section Bottom OD ID

Nominal Weight in Air***

Vertical Section Length

Vertical Depth

Un-buoyed Axial Load

Running True Axial

Load*

Plug Bump

True Axial Load**

Post Plug Bump

True Axial Load**

Design Load w/

k D

Design Load w/

Over pull

ft in in. lbf/ft ft ft 1000 lbf 1000 lbf 1000 lbf 1000 lbf 1000 lbf 1000 lbf

0 1 2 3 4 3 37.000 6.184 29 3925 0 442 340 375 334 599 475

3925 3925 328 226 261 220 417 3617.000 6.094 32 5681 3925 328 223 257 218 411 357

9606 9606 146 41 75 36 120 1757.000 6.094 32 2435 9606 146 41 75 36 120 175

12041 12041 69 -37 -3 -42 -5 977.000 6.004 35 1959 12041 69 -45 -12 -50 -20 88

14000 14000 0 -113 -81 -119 -129 190.000 0

00.000 0

00.000 0

014000

Design Data: Lighter cells denote values at top of a section, darker denote values at bottom

15.3

15.3

1200 Select Load Case for Design:1.6100

15.3 9000 11281 Annular BHP15.6 3750 11138 Inside BHP16.6 1250 143 Differential Displ. Press

14000 Total Length -- Must match total length of string above

Load Case Number:

Fluid Column Lengths

Annular Fluids

Densities

Total Length:

Mud density, m (ppg)

Over pull (1000 lbf)Design Factor, k D

Displacement fluid dens, d (ppg)

Plug Bump Pressure (psi)

Plot 1 Plot 2 Plot 3 Plot 4 Plt Des Plt Ovpl

Clear Plot

2 - Running Case

3 - Plug Bump Case

4 - Post Plug Bump Case

1 - Unbuoyed Case

Clear User Input


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Production Casing Design

7" Production Casing

Collapse BurstJoint

Strength4 7 6.184 29 P-110 LT&C 3925 3925 113825 442102 2.42 1.08 1.333 7 6.094 32 N-80 LT&C 9606 5681 181792 328277 1.00 1.00 1.642 7 6.094 32 P-110 LT&C 12041 2435 77920 146485 1.00 1.74 high1 7 6.004 35 P-110 LT&C 14000 1959 68565 68565 1.04 2.00 high

0 0 00 0 00 0 00 0 0

Totals: 14000 442102Collapse & burst do not

Minimum Design Factors, k D Mud Weight: 15.3 include biaxial effectsCollapse: 1.125Burst: 1.2Tension: 1.6/100,000lb buoyed

** Safety Factor: Strength / (k D * Load)

Section Number OD ID Weight Grade Connection Bottom Length

Section Weight

Cum. Weight

Safety Factors **

Alternate Production Casing Design Example:A Design for Shallow Tubing Leak

Production Casing Burst (Alternate)

0

2000

4000

6000

8000

10000

12000

14000

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Dep

th (

ft)

Pressure (1000 psi)


Burst LoadLines

Shallow Tubing Leak

Tubing Backup

Plug Bump

Alternate Choice



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Production Casing Burst (Alternate)

We must use a higher strength casing

LT&C not recommended at high pressures

Select a proprietary connection

Proprietary Casing

Wt

lb

Grade Connection ID

in.

Collapse Pressure

psi

Internal Yield psi

Joint Strength 1000 lb

26 N-80 Tenaris Blue 6.276 5,410 7,240 604

29 N-80 Tenaris Blue 6.184 7,020 8,160 676

32 N-80 Tenaris Blue 6.094 8,610 9,060 745

35 N-80 Tenaris Blue 6.004 10,180 9,960 814

38 N-80 Tenaris Blue 5.920 11,390 10,800 877

26 P-110 Tenaris Blue 6.276 6,230 9,950 830

29 P-110 Tenaris Blue 6.184 8,530 11,220 929

32 P-110 Tenaris Blue 6.094 10,780 12,460 1,025

35 P-110 Tenaris Blue 6.004 13,020 13,700 1,119

38 P-110 Tenaris Blue 5.920 15,140 14,850 1,206

35 Q-125 Tenaris Blue 6.004 14,310 15,560 1,272

38 Q-125 Tenaris Blue 5.920 16,750 16,880 1,370

Burst Design Selection (Alternate)

0

2000

4000

6000

8000

10000

12000

14000

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Dep

th (

ft)

Pressure (1000 psi)

Production Casing Design Load

Burst DesignLoad

Burst LoadNear SurfaceTubing Leak

38 # Q-125

35 # Q-125

38 # P-110

35# P-110

32 # P-110

29 # P-110

38 # N-80

We can simplify this considerably !


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Simpler Burst Design (Alternate)

0

2000

4000

6000

8000

10000

12000

14000

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Dep

th (

ft)

Pressure (1000 psi)


Burst DesignLoad

Burst LoadNear SurfaceTubing Leak

38 # Q-125

38 # P-110

32 # P-110

Collapse Design Check (Alternate)

0

2000

4000

6000

8000

10000

12000

14000

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Dep

th (

ft)

Pressure (1000 psi)


Collapse DesignLoad

Collapse Load Line

Production

38 # P-110

32 # P-110

38 # Q-125

Axial Load (Alternate)

Installation – running• Inside: mud, 15.3 ppg• Outside: mud, 15.3

Installation – plug bump• Inside: 15.3 ppg mud + 1200 psi above differential displacement

pressure• Outside: tail slurry 16.6 ppg, lead slurry 15.9 ppg, spacer and mud

15.3 ppg

Installation – Post plug bump• Inside: 15.3 ppg mud• Outside: same as previous



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Production Casing Axial Loads

Plug Bump Post Plug Bump

Axial Load – Manual Calculations

Three sections, but:• Top two have same ID and weight• Will consider there are two sections

0

1

2

1p

0p

1A

2A

0p0A

1 0 1 0 0ˆˆF p A p A

1 1 1W w L

2 2 2W w L

1 1 1F F W

2 1 1 2 1F F p A A

2 2 2F F W

Axial Load Calculations (Alternate)

Cross sectional areas

Weight of sections (un-buoyed)

1 1 1

2 2 2

38 9236 350,968lbf

32 4764 152,448lbf

W w L

W w L

2 20

2 21

2 22

ˆ 4 7.000 38.485 in

4 5.920 27.525 in

4 6.094 29.167 in

A

A

A


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Running, pressures

0

0 0

1

ˆ 0.052 15.3 14000 11,138 psi

ˆ 11,138 psi

0.052 15.3 4764 3,790 psi

p

p p

p


Running, axial forces

1 0 0 0 1

1 1 1

ˆˆ 11138 27.525 38.485

122,073 lbf

122073 350968

228,895 lbf

F p A p A

F F W


Running, axial forces

2 1 1 2 1

2 2 2

228895 3790 29.167 27.525

235,118 lbf

235118 152448

387,556 lbf

F F p A A

F F W



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Plug Bump, pressures

0

0

1

ˆ 0.052 16.6 1250 15.6 3750

15.3 9000

11,281 psi

11,281 1200 12,481 psi

12481 0.052 15.3 14000 4764

5,133 psi

p

p

p



1 0 0 0 1

1 1 1

ˆˆ

11281 38.485 12481 27.525

90,610 lbf

90610 350968

260,088 lbf

F p A p A

F F W



2 1 1 2 1

2 2 2

260088 5133 29.167 27.525

268,516 lbf

268516 152488 421,004 lbf

F F p A A

F F W


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Post Plug Bump, pressures

0

0

1

ˆ 0.052 16.6 1250 15.6 3750

15.3 9000

11,281 psi

0.052 15.3 14000 11,138 psi

0.052 15.3 4764 3,790 psi

p

p

p

1 0 0 0 1

1 1 1

ˆˆ

11281 38.485 11138 27.525

127,576 lbf

127576 350968

223,392 lbf

F p A p A

F F W


Post Plug Bump, axial forces


Post Plug Bump, axial forces

2 1 1 2 1

2 2 2

223392 3790 29.167 27.525

229,615 lbf

229615 152488 382,103 lbf

F F p A A

F F W



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Axial Loads Spreadsheet (Alternate)

True Axial Loads

Vertical Depth of Section Bottom OD ID

Nominal Weight in Air***

Vertical Section Length

Vertical Depth

Un-buoyed Axial Load

Running True Axial

Load*

Plug Bump

True Axial Load**

Post Plug Bump

True Axial Load**

Design Load w/

k D

Design Load w/

Over pull

ft in in. lbf/ft ft ft 1000 lbf 1000 lbf 1000 lbf 1000 lbf 1000 lbf 1000 lbf

0 1 2 3 4 3 37.000 6.094 32 4764 0 503 388 421 382 674 521

4764 4764 351 235 269 230 430 3697.000 5.920 38 5474 4764 351 229 260 223 417 360

10238 10238 143 21 52 15 84 1527.000 5.920 38 3762 10238 143 21 52 15 84 152

14000 14000 0 -122 -91 -128 -145 90.000 0

00.000 0

00.000 0

00.000 0

014000

Design Data: Lighter cells denote values at top of a section, darker denote values at bottom

15.3

15.3

1200 Select Load Case for Design:1.6100

15.3 9000 11281 Annular BHP15.6 3750 11138 Inside BHP16.6 1250 143 Differential Displ. Press

14000 Total Length -- Must match total length of string above

Load Case Number:

Fluid Column Lengths

Annular Fluids

Densities

Total Length:

Mud density, m (ppg)

Over pull (1000 lbf)Design Factor, k D

Displacement fluid dens, d (ppg)

Plug Bump Pressure (psi)

Plot 1 Plot 2 Plot 3 Plot 4 Plt Des Plt Ovpl

Clear Plot

2 - Running Case

3 - Plug Bump Case

4 - Post Plug Bump Case

1 - Unbuoyed Case

Clear User Input

Production Casing Axial Load (Alternate)

Axial Design Check (Alternate)


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Production Casing (Alternate)

Casing Design Summary

7" Production Casing

Collapse BurstJoint

Strength3 7 6.094 32 P-110 Tenaris Blue 4764 4764 152448 503416 2.53 1.00 1.472 7 5.920 38 P-110 Tenaris Blue 10238 5474 208012 350968 1.65 1.00 2.271 7 5.920 38 Q-125 Tenaris Blue 14000 3762 142956 142956 1.34 1.02 7.49

0 0 00 0 00 0 00 0 00 0 0

Totals: 14000 503416Collapse & burst do not

Minimum Design Factors, k D Mud Weight: 15.3 include biaxial effectsCollapse: 1.125Burst: 1.2

Section Weight

Cum. Weight

Unbuoyed

Safety Factor **

Grade Connection Bottom LengthSection Number OD ID Weight

Stop here for production

casing project



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Exercise - Production Casing Selection for Collapse, Burst...

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