Faculty of Engineering

Petroleum Engineering Department

Drilling Engineering II
Fourth Stage

Lecture # 13
Casing Design

Pshtiwan Jaf 1
[email protected]
 Casing Design
Introduction
• The casing design process involves three
distinct operations: the selection of the
casing sizes and setting depths; the
definition of the operational scenarios which
will result in burst, collapse and axial loads
being applied to the casing; and finally the
calculation of the magnitude of these loads
and selection of an appropriate weight and
grade of casing.

• The steps in the casing design process are

shown in the figure. 2
 Casing Design
Casing Sizes and Setting Depths
• The casing setting depths are selected on the basis of an assessment of the conditions to be
encountered when drilling the subsequent hole section or, in the case of production casing, the
completion design.

• The first step in deciding upon the setting depth for the surface and intermediate casing strings
is to calculate the maximum pressures that could be encountered in the hole section below the
string in question.

• These pressures must not exceed the formation strength at any point in the hole and in
particular at the casing shoe.

• The highest pressure that will be encountered in the open hole section will occur when
circulating out a gas influx.

• The formation strength can be estimated from nearby well data or by calculation. 3
 Casing Design
Casing Sizes and Setting Depths, cont.
• The procedures for establishing the acceptable setting depth are:

1. Start at Total Depth (TD) of the Well

2. Determine the formation fracture pressure at all points in the well
3. Calculate the borehole pressure profile when circulating out a gas influx from
TD
4. Plot the formation fracture pressure and the wellbore pressure when
circulating out an influx, on the same axes
5. The casing must be set at least at the depth where the two plots cross i.e. this
is the shallowest depth at which the casing can be safely set. If the casing is set
any shallower when drilling this hole section then the formation will fracture if
an influx occurs.
6. Repeat steps 2 to 5 moving up the well, with each subsequent string starting at
the casing setting depth for each string. 4
 Casing Design
Casing Sizes and Setting Depths, cont.
• The setting depth of the casing will also be determined by a range of other
considerations such as: the need to isolate weak formations from high mud
weights; isolate lost circulation zones; and to isolate troublesome formations,
such as shales, which can cause hole problems whilst drilling subsequent
formations.

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 Casing Design
Casing Sizes and Setting Depths, cont.
• The casing sizes and string configuration are dictated by the size of the smallest casing string to
be run in hole. Once the smallest casing size is known all subsequent casing sizes (and hole
sizes) are selected from the previous figure.

• The smallest casing size is selected on the basis of operational considerations such as: the size
and configuration of the completion string or well testing and/or the size of the logging tools to
be run through the casing.

• The drilling engineer will collate this information from the geology, reservoir engineering and
production engineering departments.

• The objective of the drilling engineer is to use the smallest casing sizes possible. It can be
readily appreciated that if it is acceptable to use a 4” casing string as the production casing
then the next string will be 7”, the next 9 5/8” and so forth.

• Hence, if only three casing strings are required then the surface string can be 9 5/8”.

• This slimhole design will result in considerable savings in drilling and equipment costs. 6
 Casing Design
Operational Scenarios and Consequent Loads
• The loads to which the casing will be exposed during the life of the well will depend on
the operations to be conducted: whilst running the casing; drilling the subsequent hole
section; and during the producing life of the well.

• These operations will result in radial (burst and collapse) and axial (tensile and
compressive) loads on the casing strings.

• Since the operations conducted inside any particular string (e.g. the surface string) will
differ from those inside the other strings (e.g. the production string) the load scenarios
and consequent loads will be specific to a particular string.

• The definition of the operational scenarios to be considered is one of the most

important steps in the casing design process and they will therefore generally be
established as a company policy. 7
 Casing Design
Casing Load Calculations
• Having defined the size and setting depth for the casing strings, and defined the
operational scenarios to be considered, the loads to which the casing will be
exposed can be computed.

• The particular weight and grade of casing required to withstand these loads can
then be determined.

• The uniaxial (radial) loads to which the casing is exposed are: Collapse & Burst
loads.

• The axial loads to which the casing is exposed are: Tensile & Compressive loads.
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 Casing Design
Collapse Load
• The casing will experience a net collapse loading if the
external radial load exceeds the internal radial load.

• The greatest collapse load on the casing will occur if the

casing is evacuated (empty) for any reason.

• The collapse load, Pc at any point along the casing can

be calculated from:

𝑃𝑐 = 𝑃𝑒 − 𝑃𝑖
9
 Casing Design
Burst Load
• The casing will experience a net burst loading if the
internal radial load exceeds the external radial load.

• The burst load, Pb at any point along the casing can be

calculated from:

𝑃𝑏 = 𝑃𝑖 − 𝑃𝑒

• The internal, Pi and external, Pe loads which are used in

the determination of the burst and collapse loads on
the casing are derived from an analysis of operational
scenarios.
10
 Casing Design
External Loads
A. The pore pressure in the formation (Pore Pressure)
If the engineer is satisfied that it will be possible to displace all of the mud from the
annulus between the casing and borehole during the cementing operation, and that a
satisfactory cement sheath can be achieved, the formation pore pressure is generally
used to determine the load acting on the casing.

B. The weight of the mud in which the casing was run

If a poor cement bond between the casing and cement or cement and borehole is
anticipated then the pressure due to a column of mud in the annulus is generally used to
determine the load acting on the casing. If the mud has been in place for more than 1
year the weighting material will probably have settled out and therefore the pressure
experienced by the casing will be due to a column of mud mixwater. 11
 Casing Design
External Loads, cont.
C. The pressure from a column of cement mixwater
The pressure due to the cement mixwater is often used to determine the external
load on the casing during the producing life of the well. This pressure is equal to
the density of fresh or seawater. The assumption is that the weighting material has
settled from suspension.

D. The pressure due to a column of cement slurry

The pressure exerted by a column of cement slurry will be experienced by the
casing until the cement sets. It is assumed that hardened cement does not exert a
hydrostatic pressure on the casing.
12
 Casing Design
External Loads, cont.
E. Blockage in the annulus
If a blockage of the annulus occurs during a stinger cement operations (generally
performed on a conductor casing). The excess pumping pressure on the cement
will be transmitted to the annulus but not to the inside of the casing. This will
result in an additional external load during stinger cementing. In the case of
conventional cementing operations a blockage in the annulus will result in an equal
and opposite pressures inside and outside the casing.

F. Full evacuation
The worst case scenario which can arise, from the point of view of collapse loading,
is if the casing is completely evacuated.
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 Casing Design
Internal Loads
A. Mud to Surface
This will be the predominant internal pressure during drilling operations. The
casing designer must consider the possibility that the density of the drilling fluid
may change during the drilling operation, due to for instance lost circulation or an
influx.

B. Pressure due to influx

The worst case scenario which can arise, from the point of view of burst loading, is
if an influx of hydrocarbons occurs, that the well is completely evacuated to gas
and simultaneously closed in at the BOP stack.
14
 Casing Design
Internal Loads, cont.
C. Production Tubing leak
In the case of production casing specifically a leak in the production tubing will
result in the tubing pressure being exposed to the casing. The closed in tubing
pressure is used as the basis of determining the pressure on the casing.

D. Fracture pressure of open formations

The pressure in the open hole section cannot exceed the fracture pressure of the
weakest formation. Hence, the pressures in the remaining portion of the borehole
and the casing will be controlled by this fracture pressure. The formation just
below the casing shoe is generally considered to be the weakest formation in the
open hole section. 15
 Casing Design
Net Radial Loading (Burst or Collapse Load)
• When the internal and external loads have been quantified the maximum net
radial loading on the casing is determined by quantifying the difference between
the internal and external load at all points along the casing.

• If the net radial loading is outward then the casing is subjected to a burst load.

• If the net loading is inward then the casing is subjected to a collapse load.

• The internal and external loads used in the determination of the net load must be
operationally compatible i.e. it must be possible for them to co-exist
simultaneously.
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 Casing Design
Axial Loads
• The axial load on the casing can be either tensile or
compressive, depending on the operating conditions.

• The axial load on the casing will vary along the length
of the casing.

• The casing is subjected to a wide range of axial loads

during installation and subsequent drilling and
production.

• The axial loads which will arise during any particular

operation must be computed and added together to
determine the total axial load on the casing. 17
 Casing Design
Axial Loads, cont.
• The sources of axial loads on the casing are a function of a number of variables:

18
 Casing Design
A. Dry weight of casing (Fwt)
The suspension of a string of casing in a vertical or deviated well will result in an
axial load. The total axial load on the casing (the weight of the casing) in air and
can be computed from the following:
𝐹𝑤𝑡 = 𝑊 cos ∅

B. Buoyant force on Casing (Fbuoy)

When submerged in a liquid the casing will be subjected to a compressive axial
load. This is generally termed the buoyant force and can be computed from the
following:
𝐹𝑏𝑢𝑜𝑦 = 𝑃𝑒 𝐴𝑜 − 𝐴𝑖 𝑂𝑝𝑒𝑛 𝐸𝑛𝑑𝑒𝑑 𝐶𝑎𝑠𝑖𝑛𝑔
𝐹𝑏𝑢𝑜𝑦 = 𝑃𝑒 𝐴𝑜 − 𝑃𝑖 𝐴𝑖 𝐶𝑙𝑜𝑠𝑒𝑑 𝐸𝑛𝑑𝑒𝑑 𝐶𝑎𝑠𝑖𝑛𝑔 19
 Casing Design
C. Bended Stress (Fbend)
When designing a casing string in a deviated well the bending stresses must be
considered. In sections of the hole where there are severe dog-legs (sharp bends)
the bending stresses should be checked. The most critical sections are where
dogleg severity exceeds 10° per 100'. The axial load due to bending can be
computed from the following:
𝐹𝑏𝑒𝑛𝑑 = 64 𝐷𝐿𝑆 𝑂𝐷 (𝑊)

D. Plug Bumping Pressure (Fplug)

The casing will experience an axial load when the cement plug bumps during the
cementation operation. This axial load can be computed from the following:
𝐹𝑝𝑙𝑢𝑔 = 𝑃𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝐴𝑖
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 Casing Design
E. Overpull when casing stuck (Fpt)
If the casing becomes stuck when being run in hole it may be necessary to apply an
overpull’ on the casing to get it free. This overpull can be added directly to the axial
loads on the casing when it became stuck:
𝐹𝑝𝑡 = 𝐷𝑖𝑟𝑒𝑐𝑡 𝑇𝑒𝑛𝑠𝑖𝑜𝑛

F. Effects of Changes in Temperature (Ftemp)

When the well has started to produce the casing will be subjected to an increase in
temperature and will therefore expand. since the casing is restrained at surface in
the wellhead and at depth by the hardened cement it will experience a
compressive (buckling) load. The axial load generated by an increase in
temperature can be computed by the following:
𝐹𝑡𝑒𝑚𝑝 = −200 𝐴𝑠 (∆𝑇) 21
 Casing Design
G. Overpull to Overcome Buckling forces (Fop)
When the well has started to produce the casing will be subjected to compressive
(buckling) loads due to the increase in temperature and therefore expansion of the
casing.
Attempts are often made to compensate for these buckling loads by applying an
overpull to the casing when the cement in the annulus has hardened. This tensile
load (the overpull) is ‘locked into’ the string by using the slip type hanger.

The overpull is added directly to the axial load on the casing when the overpull is
applied.
𝐹𝑜𝑝 = 𝐷𝑖𝑟𝑒𝑐𝑡 𝑂𝑣𝑒𝑟𝑝𝑢𝑙𝑙
22
 Casing Design
H. Axial force Due to Ballooning (During pressure Testing) (Fbal)
If the casing is subjected to a pressure test it will tend to ‘balloon’. since the casing is
restrained at surface in the wellhead and at depth by the hardened cement, this
ballooning will result in an axial load on the casing. This axial load can be computed from
the following:
𝐹𝑏𝑎𝑙 = 2 𝜐 (𝐴𝑖 𝜕𝑃𝑖 − 𝐴𝑜 𝜕𝑃𝑒 )
I. Effect of shock loading (Fshock)
Whenever the casing is accelerated or decelerated, being run in hole, it will experience a
shock loading. This acceleration and deceleration occurs when setting or unsetting the
casing. This shock loading can be computed from the following:
𝐹𝑠ℎ𝑜𝑐𝑘 = 1780 𝑣 𝐴𝑠
A velocity of 5 cm/sec. is generally recommended for the computation of the shock
loading. 23
 Casing Design
Total Axial Loads Ft
• During installation the total axial load Ft is some combination of the loads described above and
depend on the operational scenarios. The objective is to determine the maximum axial load on
the casing when all of the operational scenarios are considered.
• Free Running of Casing: 𝐹𝑡 = 𝐹𝑤𝑡 − 𝐹𝑏𝑢𝑜𝑦 + 𝐹𝑏𝑒𝑛𝑑
• Running Casing taking account of Shock Loading: 𝐹𝑡 = 𝐹𝑤𝑡 − 𝐹𝑏𝑢𝑜𝑦 + 𝐹𝑏𝑒𝑛𝑑 + 𝐹𝑠ℎ𝑜𝑐𝑘
• Stuck Casing: 𝐹𝑡 = 𝐹𝑤𝑡 − 𝐹𝑏𝑢𝑜𝑦 + 𝐹𝑏𝑒𝑛𝑑 + 𝐹𝑜𝑝
• Cementing Casing: 𝐹𝑡 = 𝐹𝑤𝑡 − 𝐹𝑏𝑢𝑜𝑦 + 𝐹𝑏𝑒𝑛𝑑 + 𝐹𝑝𝑙𝑢𝑔 + 𝐹𝑠ℎ𝑜𝑐𝑘
• Cemented with additional overpull: 𝐹𝑡𝑏𝑎𝑠𝑒 = 𝐹𝑤𝑡 − 𝐹𝑏𝑢𝑜𝑦 + 𝐹𝑏𝑒𝑛𝑑 + 𝐹𝑝𝑙𝑢𝑔 + 𝐹𝑝𝑡
• During Drilling and production: 𝐹𝑡 = 𝐹𝑡𝑏𝑎𝑠𝑒 + 𝐹𝑏𝑎𝑙 + 𝐹𝑡𝑒𝑚𝑝
24