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INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Introduction to Hydrocarbon Exploitation


Casing Design

Section
By Pratap Thimaiah

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Well Planning
Drilling Technolo gy-Casing De sig n

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INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Drilling T echnology -Casing Design


Well Construction

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Drilling Team
Drilling Technolo gy-Casing De sig n

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INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Operational Pressures

Overbalance

In balance

Underbalance
Drilling T echnology -Casing Design

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Operational Pressures

 Overbalance

– Condition where the wellbore


pressure >pore pressure.
Drilling Technolo gy-Casing De sig n

– Margin of over balance is


often called safety or trip
margin

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©abalt solutions limited - 2005 September – October 2005


INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Operational Pressures

 In Balance
– Pore pressure of formation=wellbore pressure
Drilling T echnology -Casing Design

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Operational Pressures

 Underbalance
– Wellbore
pressure<formation
pressure.
– Controlled flow of
Drilling Technolo gy-Casing De sig n

formation fluids mixing


with drilling fluids.

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©abalt solutions limited - 2005 September – October 2005


INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Operational Pressures

 Pressure
– Force exerted on a cross section area
– Pressure gradient is pressure exerted per unit
length
Drilling T echnology -Casing Design

 Key objectives of evaluation


– Gain an accurate knowledge of formation
pressure to ensure well control.
– Estimate formation fracture pressure in order to
set working pressures.
– Reduce risks

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Operational Pressures

 Key types of Operating Pressures

– Hydrostatic
– BHCP
– Pump pressure
Drilling Technolo gy-Casing De sig n

– Overburden pressure
– Formation pressure
– Fracture pressure

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©abalt solutions limited - 2005 September – October 2005


INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Hydrostatic Pressure

 Pressure due to unit weight and vertical height


of a static column of fluid.
 Expressed in field units as:
Drilling T echnology -Casing Design

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Bottom Hole Circulating Pressure (BHCP)

 On circulation, pressure losses occur in the


annulus due to friction.
 For circulation to be maintained, these losses
must be overcome by pumps.
 This leads to:
Drilling Technolo gy-Casing De sig n

 BHCP can be expressed in terms of equivalent


circulating density in pounds per gallon (ppg)

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©abalt solutions limited - 2005 September – October 2005


INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Pump Pressure
Pump pressure must
overcome all the losses in
the mud path:

 Surface equipment
(rotary hose,kelly,swivel
etc)
 Drill pipe
 BHA
Drilling T echnology -Casing Design

 Bit
 BHA Annulus
 Drill Pipe Annulus

•All other losses are termed parasitic


losses and calculated from standard
pressure equations

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Overburden Pressure
 Pressure exerted by
total weight of solids
and fluids in the
formation
 Caused by weight of
rock above the area
of interest
Drilling Technolo gy-Casing De sig n

 z is unique and
constant for a
particular formation

 ob can be calculated


by

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INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Formation Pressure

 Pressure exerted by fluids contained in pore


spaces of rocks.
 Depends upon fluid column density & vertical
depth.
 For a normal formation, pore pressure is:
Drilling T echnology -Casing Design

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Formation Pressure

 Normal formation Pressure


– Saline water is common in porous rocks.
– Formation pressure is a function of formation
water density.
– Depending on salinity, pressures range from
Drilling Technolo gy-Casing De sig n

0.433 psi/ft (fresh water) to 0.465psi/ft

 Abnormal formation Pressure


– When Pf<0.433psi/ft -Subnormal
– When Pf>0.465psi/ft -Geopressured or Over
pressured

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©abalt solutions limited - 2005 September – October 2005


INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Fracture Pressure

 Critical pressure to break down


formation or induce fractures.

 Fracture gradient is a plot of


Pressure vs. depth necessary for
this to occur.

 Knowledge of fracture gradient


Drilling T echnology -Casing Design

helps to:

 Determine setting depths


for intermediate casing
strings

 Maximum allowable
annular surface pressure to
control a Kick.

 Maximum allowable Mud


density during drilling.

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Leak off Test


 Method for positive determination of maximum mud weight permitted
in an open hole section of well.
 The crew performs test in first few feet of new hole drilled below a
new casing shoe.
 The results when converted to equivalent mud weight, determines
maximum mud weight the section can withstand without loss
circulation.
 Test consists of well closure at surface and pressure application until
mud just begins to inject into formation.
Drilling Technolo gy-Casing De sig n

Procedure
1. After Cementing casing, run with bit and drill string
2. Pressure test casing and drill out casing shoe to about 10 ft of new
formation.
3. Pull bit to casing shoe.
4. Shut off pumps, wait for flow to cease, then close kelly cock and BOP.
5. Using cementing unit pump mud into hole annulus.
6. Monitor pressure build up and volume.
7. Pressure build up is linear until mud begins to bleed into formation.
This is called Leak-off Pressure (PLOT)

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INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Leak off Test

8. as pumping continues, build up curve flattens out until pressure no


longer increases. This is called Injection Pressure.
9. At injectivity point, pump should be shut off and choke closed.
10. Monitor pressure until shut-in pressure falls to equilibrium called Bleed -
off Point.
11. Hold bleed-off pressure for several minutes to confirm no break down.
Drilling T echnology -Casing Design

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Casing Strings

 Conductor
 Surface
 Intermediate
 Production
 Liner
Drilling Technolo gy-Casing De sig n

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INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Drilling T echnology -Casing Design


Casing Strings-Configurations

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Casing Strings

 Reasons for casing off open hole:

– Prevent unstable formations from caving in

– Protect weak formations from mud weights that cause


zones to break.
Drilling Technolo gy-Casing De sig n

– Abnormal pressure isolation in zones.

– Seal off lost circulation

– To complete and produce zone effectively

– Structural support for Bops and Wellheads.

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INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Casing String Types

Conductor Casing

 First casing string to be run from surface to


shallow depth and has the largest
diameter.

 Surface formations usually have low


Drilling T echnology -Casing Design

fracture strength which could exceed


hydrostatic pressure exerted by drilling
fluids.

 Conductor provides a conduit for mud


returns and always cemented to surface.

 Its functions mainly are


– Seal off unconsolidated formations
at shallow depths.
– Prevent wash outs.
– Protection of shallow gas flows.

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Casing String Types

Surface Casing

 The main function is to seal off


the fresh water sands.

 Support the BOP Equipment.


Drilling Technolo gy-Casing De sig n

 The casing setting depth is


important where abnormal
pressures are expected.

 Casing is usually set in


competent formations

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©abalt solutions limited - 2005 September – October 2005


INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Casing String Types

Intermediate Casing

 Isolate troublesome formations


/Transition zones which would
cause drilling problems such as lost
circulation, sloughing shale, high
pressure zones, salt zones etc.
Drilling T echnology -Casing Design

 Number of intermediate strings


may be required depending upon
pore and fracture gradients.

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Casing String Types

Production Casing

 Usually the last string of


casing to be run either
through pay zone or above
pay zone.
Drilling Technolo gy-Casing De sig n

 Isolation of production
interval from other zones.

 Protection of tubing and


other equipment, basis for
well completions.

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INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Casing String Types


Liner
 Short string of casing that does not
extend back to surface.
 Run back inside the previous
casing to provide overlap.
 If required tie-back string can be
extend to wellhead.

Advantages
Drilling T echnology -Casing Design

– Complete wells with light


weight on wellheads and
surface pipe.
– Total cost of production string
is reduced & also
running/cementing times
allowing optimal size of tubing.
– Improved completion flexibility.

Disadvantages
– Possible leak in liner hanger.
– Difficulty in obtaining a good
cementing job due to narrow
annulus.

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Properties of Casing

 Casings are manufactured from different sizes,


lengths, grades and weights.
 API Bulletin 5C2 has specifications for minimum
standards that must be met for each type of
casing.
Drilling Technolo gy-Casing De sig n

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INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Properties of Casing

 Outside Diameter (OD):


– Casings vary from 4.5” to 36” .They can be found in the
manufactures catalogue or field books.

 Casing Grade and Properties:

– Grades refer to physical properties of steel in the manufacturing process.


– API Specification contains various grades designated by a letter and number
referring to minimum yield strength.
– Ex- N80 casing has a minimum yield strength of 80,000 psi.
Drilling T echnology -Casing Design

– Manufactures also produce their own grades but have almost similar
properties to API Casings.

Grade Yield Strength Mini (psi) Max Yield Strength (psi) Tensile Strength (psi)
H-40 4000 - 60000
J-55 55000 80000 75000
K- 55 55000 80000 95000
C-75 75000 90000 95000
L- 80 80000 95000 95000
N-80 80000 110000 100000
C-95 95000 110000 105000

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Properties of Casing

 Length of Joint : Casings are


available in three ranges:
– Range 1: 16 to 25 ft
– Range 2: 25 to 34 ft
– Range 3: 34 + ft
Drilling Technolo gy-Casing De sig n

 Weight of Casing: Wall thickness is


indicated by weight per foot.

Weigh t (lb/ft) OD (inches) ID (inches) Wall Thickness (in)


53.5 9.625 8.535 0.545
47 9.625 8.681 0.472
43.5 9.625 8.755 0.435
40 9.625 8.835 0.395

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INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Properties of Casing

 Connections
Drilling T echnology -Casing Design

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Casing Wear
 Adhesive Wear
– Occurs when contact pressure >250 psi
– Pressure and movement cause part of
casing to weld themselves to tool joint.
– Solid phase welding of chip to tool joint
– Transport
– Chip dislodged

 Abrasive Machining Wear


Drilling Technolo gy-Casing De sig n

– Particles of metal shaved off


– Tong die marks and hard facing
– Rapid wear of metal

 Abrasive Grinding Wear


– Contact pressure <250 psi
– Fine particles of metal seen on surface
and wear is slow.
– Particles in mud causing slow polishing
wear.

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©abalt solutions limited - 2005 September – October 2005


INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Casing Wear
Drilling T echnology -Casing Design

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Casing Wear

 Internal Diameter Changes


– Changes in casing sizes
– Change in casing hanger to top of joint
– Wear bushing ID<top casing ID
Drilling Technolo gy-Casing De sig n

Sharp Shoulder Tapered Shoulder


Severe wear Lighter wear

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INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Minimize Casing Wear

 Minimize rotation hours for High ROP Bits and


DHMM.
 Change tong dies in good time
 Specify correct hard banding on tool joints
 Use drill pipe protectors
Drilling T echnology -Casing Design

 Weighted drilling mud


 Smooth transition of ID at changes of casing
size.

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Basic Casing Design

 Casing Design Process


– Data Collection
– Preliminary Design
– Detailed Design
– Triaxial analysis
Drilling Technolo gy-Casing De sig n

– Documentation

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©abalt solutions limited - 2005 September – October 2005


INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Data Collection

 Pore Pressure and Fracture Pressure


– Calculations for burst and collapse pressures.
– Kick tolerance for casing setting depths.
Drilling T echnology -Casing Design

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Data Collection

 Lithology
– Formation types from offset wells vs depth.
Drilling Technolo gy-Casing De sig n

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INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Data Collection

 Final Hole Size


– Minimum size determined by completions.
– Exploration wells require logging to determine
final hole sizes.
– Contingency hole size maybe required for
Drilling T echnology -Casing Design

exploration wells.

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Data Collection

 Temperature gradient
– Yield strength of casing decreases with
temperature increase.
Drilling Technolo gy-Casing De sig n

 Problematic zones
– Offset well analysis
– Identification of problematic zones like salt
diapers, lost circulation zones etc.
– Casing designed to withstand mobile salt
movement.
– Drilling with salt saturated mud.

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©abalt solutions limited - 2005 September – October 2005


INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Data Collection

 Bit and Casing sizes


– Using sizes available in yard or area of
operations

 Life cycle loads


– Artificial lift methods
Drilling T echnology -Casing Design

– Injection systems
– Abandonment plans

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Preliminary Design
Identify
– Wellbore fluid densities
– Casing diameters
 Lowest hole section
determined by IPR and
completion tubing size
 From lowest hole section bit
size, next casing string up
Drilling Technolo gy-Casing De sig n

must have an ID which


allows this bit size to be
passed.
– Casing Shoe setting depths
 Casing shoes should be
cemented in strong &
competent formations.
 Isolating troublesome zones.

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©abalt solutions limited - 2005 September – October 2005


INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Preliminary Design
Casing Setting Depths
1. Initial setting depths is based on pore and fracture pressure gradients.
2. The total depth of well and setting depth of production casing or liner
is driven by logging, testing and completion requirements.
Drilling T echnology -Casing Design

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Preliminary Design
3. Draw mean pore pressure gradient curve along with lithology.Note any
intervals of problematic zones-such as differential sticking, lost
circulation or high pressure gas zones.
4. Draw mud weight curve. It should include 200-400 psi trip margin.
specific companies may require different levels of over balance.
5. Draw predicted fracture gradient curve. Draw a fracture gradient
design curve parallel to predicted with 0.3 to 0.5 ppg reduction, for
kicks and ECD during cementing.
6. Plot mud weights and Leak off tests to provide check of pore pressure
predictions.
Drilling Technolo gy-Casing De sig n

To estimate Casing setting Depths:


 Enter mud at point A (Total depth)
 Move up to point B which determines initial estimated setting depth for
intermediate casing.
 Move across to point C which determines mud weight requirement for
that depth.
 Move up to point D which determines preferred setting depth for
surface casing.
 Move across to point E to identify mud weight required at that depth.

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©abalt solutions limited - 2005 September – October 2005


INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Preliminary Design

 Other factors for casing setting depth


– Shallow gas
– Lost circulation zones
– Formation stability
– Directional well profile
– Fresh water sands
Drilling T echnology -Casing Design

– Salt sections
– High pressure zones
– Competent formations

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Detailed Design

Burst and Collapse Loads


Installation Loads
Service Loads
Drilling Technolo gy-Casing De sig n

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©abalt solutions limited - 2005 September – October 2005


INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Burst Loads

 Burst Pressure=Internal Pressure- External


Pressure exceeding casing burst strength.
Drilling T echnology -Casing Design

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Burst Loads

 Internal Pressures for Burst

– Burst pressures occur when formation fluids


enter the casing while drilling or produce next
hole section. (fig 5.3 pg110 rabia)
Drilling Technolo gy-Casing De sig n

– Assuming a gas kick of pressure Pf from next TD


and gas filling the entire well then internal
pressure at surface and shoe are:

Internal pressure at surface= Pf – G x TD


Internal Pressure at Shoe = Pf – G x (TD-CSD)
Where G= gas gradient (generally 0.1 psi/ft)

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©abalt solutions limited - 2005 September – October 2005


INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Burst Loads

 External Pressures for Burst

1. Ext pressure =0.465 psi/ft x csd (ft)

2. External pressure is not based on the cement


column.
Drilling T echnology -Casing Design

3. If casing is cemented to surface i.e.- conductor and


surface casing
Ext Pressure = maximum expected pore pressure

4. If casing is uncemented i.e.- Intermediate and


production strings then
– In open hole use column of mud to balance lowest pore
pressure.
– Inside another casing, use mud down to TOC and from
TOC to shoe use column of mud to balance lowest pore
pressure in open hole.

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Collapse Loads

 Collapse Pressure = External pressure –


Internal Pressure.
Drilling Technolo gy-Casing De sig n

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INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Collapse Loads

 Occurs mainly due to –


– Cementing
– Salt loading
– Partial or total casing evacuation
Drilling T echnology -Casing Design

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Tension Load

 Due to weight of casing itself.


 Uppermost part/joint of string is weakest, as it
carries total weight of string.
 Other loads arise due to:
– Bending
Drilling Technolo gy-Casing De sig n

– Drag
– Shock
– Pressure testing

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©abalt solutions limited - 2005 September – October 2005


INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Tension Load

 Tensile forces are calculated by:


– Weight of casing in air using TVD.
– Buoyancy force
– Bending force in deviated wells
– Drag force while POOH.
Drilling T echnology -Casing Design

– Shock load due to arresting casing in slips


– Pressure testing forces.

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Tension Calculations

 Weight of casing in air = casing weight (lb/ft) x


TVD (ft)

 Bending Force =63Wn x OD x 


Where Wn = weight of casing
Drilling Technolo gy-Casing De sig n

=dogleg severity , degrees/100ft


 Buoyancy force for open ended casing= Pe (Ae-
Ai) (Fig 5.7,pg 123,Rabia)

 Buoyancy force for closed casing= Pe Ae – Pi Ai


Where Pe=external hydrostatic pressure ,psi
Pi=internal hydrostatic pressure , psi
Ae and Ai are external and internal areas of
casing.

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©abalt solutions limited - 2005 September – October 2005


INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Tension Calculations

 Drag Forces-
– Usually in order of 100,000 lbf.
– Last for the duration of running a joint of casing.
– Results usually when POOH due to tight hole

 Shock Load results when-


– Sudden decelerations are applied
Drilling T echnology -Casing Design

– Casing picked off slips


– Slips kicked in while pipe is moving
– Casing jumps off edge downhole

Fshock = 1780 V As
where V = pipe velocity (ft/s)
As=C/s area.

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Tension Calculations

 Pressure Testing
– Casing should be tested to maximum pressure
which it sees during drilling and production
operations
Test Pressure force ‘Ft’ (lb) =  (ID)2 x test pressure
Drilling Technolo gy-Casing De sig n

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INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Compression Loads

 Arise in casings that carry inner casing strings.


 Weight of inner strings is transferred to larger
supporting string.
 Integrity of surface casings are checked with
buoyant weight of all subsequent strings.
Drilling T echnology -Casing Design

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Service Loads

Loads anticipated while the well is used in service


during production, injection etc through to
abandonment.
 Pressure
 Temperature
Drilling Technolo gy-Casing De sig n

 Buckling
 Point Loads

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©abalt solutions limited - 2005 September – October 2005


INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Service Loads

 Buckling
– Changes in pressure, temperature
etc increase at bottom end of
casing

 Point Loads
– Acting on single location on casing
strings
– Packer setting force
– Weight on packer
Drilling T echnology -Casing Design

– Pressure test against packer

 Temperature
– Thermal expansion of
uncemented casings & fluids.

 Pressure
– Tubing leaks
 Extra pressure exerted into
production casing
 Gas leak below hanger
– Mobile formations
– Well stimulation

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Safety Factor

Safety Factor = Failure Load


Actual applied load

 Safety factor is always >1


Drilling Technolo gy-Casing De sig n

 Used in relation to catastrophic failure and


lifting equipment

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©abalt solutions limited - 2005 September – October 2005


INTRODUCTION TO HYDROCARBON EXPLOITATION

Development Phase

Design Factors
DF = Rating of Pipe
Maximum anticipated service load

 Uses API minimum Yield.


 May be equal or >1
 Used in downhole tubular.

 Typical design factors:


Drilling T echnology -Casing Design

– Burst Design
 API no recommendations
 Generally 1.1 to API Minimum internal yield pressure.
– Collapse Design
 1.0 generally used.
– Compression design factors
 API no recommendations
 Generally 1.00
– Tension design factors
 1.3 (Neal Adams)
 1.8(Preston Moore)
 API Recommends at least 1.11

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©abalt solutions limited - 2005 September – October 2005

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