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This paper was prepared for presentation at the SPE Nigeria Annual International Conference and Exhibition held in Lagos, Nigeria, 05– 07 August 2014.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
The Casing Design Application developed by well engineers in Havilah Hydrocarbon Resources Man-
agement (HHRM) is designed with simplicity to avoid the complicated casing design software in the
market and provide an in-house tool for quick evaluation of casing scheme options. The development of
this MS Excel Based software is motivated by a need to offer a package that accurately predicts relevant
well loads, without compromising designs and making it too conservative and expensive or under-
conservative and unsafe.
The HHRM Casing Design Application considers all the anticipated loadings on the casing string at
the time when the casing is run and throughout the life of the well. The design criteria is such that meet
the conflicting requirements of collapse and burst, while ensuring the tensile loading strength of the
casing are never exceeded. This application also provides triaxial stress analysis to provide high
confidence as regards the ultimate casing scheme to be adopted. This casing design tool has been
developed using Visual Basic macros in the Microsoft Excel Environment.
The different components of the Casing Design Tool are presented in this paper. The tool helps the
designer make recommendation on combination casing strings from a large casing database or selections
based on the client’s inventory. The tool has been tested and the results have been found to be consistent
with commercial software. The casing design tool is applicable to both vertical and deviated wells.
Introduction
Casing serves several important functions in drilling and completion and is one of the most expensive
parts of the drilling project, ranging anywhere from 10 - 20% of the average cost of a completed well
(Jenkins, 1975). Completion requirements and production schedules typically drive the casing design.
The casing design process involves three distinct operations viz: selection of the casing sizes; the
specification of required inputs e.g. setting depths; the operational scenarios which will result in burst,
collapse and axial loads being applied to the casing string(s); the calculation of the magnitude of these
loads and finally the selection of appropriate weight and grade of casing string(s) suitable for the loads
introduced.
In practice, each casing string is designed to withstand the maximal load that is anticipated during
casing landing, drilling, and production operations (Prentice, 1970). Maximal load concept tends to make
the casing design very expensive. Casing cost can be minimized by using a combination casing string -
2 SPE-172466-MS
a casing string with different nominal weights, grades and couplings. By choosing the string with the
lowest possible weight per foot of steel and the lowest coupling grades that meet the design load
conditions, minimal cost is achieved (Raham, S. S. and Chilingarian, G. V., 1995).
Graphical technique is customarily used to select the steel grade that will satisfy the different design
loads. This method was first introduced by Goins et al. (1965, 1966) and later modified by Prentice (1970)
and Rabia (1987). In this approach, a graph of loads (collapse or burst) versus depth is first constructed,
then the strength values of available steel grades are plotted as vertical lines. Steel grades which satisfy
the maximal existing load requirements of collapse and burst pressures are selected thereafter.
Design load for burst and collapse should be considered first. Once the weight. grade, and sectional
lengths which satisfy burst and collapse loads have been determined, the tension load can be evaluated and
the pipe section can be upgraded if it is necessary. The final step is to check the biaxial effect on collapse
and burst loads, respectively. If the strength in any part of the section is lower than the potential load, the
section should be upgraded and the calculation repeated (Raham, S. S. and Chilingarian, G. V., 1995).
Klementich and Jellison (1986) presented the service-life model as an alternative to conventional
casing design which is often inaccurate i.e. too conservative for shallow strings, too liberal for deep
strings. The service-life model analysis approach considers the effects of cementing temperature changes,
ballooning, changes in cross-sectional area, bending and helical buckling. This approach is applicable to
the design of any casing string but is especially useful for deep, high-pressure high-temperature wells. The
calculations in the service-life model and in the subsequent triaxial stress analyses are complex, thus, a
computer program is needed to help determine a feasible string design.
Our approach of selecting combination strings is based on both the maximum load concept and the
service-life model. The Microsoft Excel based Casing Design Application considers all the anticipated
loadings on the casing string; at the time when the casing is run, during cementing and when the well in
put under production.
Casing Design Calculations
To establish the burst and collapse loading conditions in a given situation, the internal and external
pressure profiles for each load case of interest are determined and the difference (Pi – Pe) between them
is taken. Burst and collapse loading conditions are calculated both at the casing shoe and at the surface.
If the resulting load line comprises mainly positive net pressures, it is called a burst load line; if it
comprises mainly negative pressures, it is called a collapse load line. It should be noted that the loading
conditions differ for each casing section and depths.
SPE-172466-MS 3
Table 2—Available Casing Specifications for 13 3/8ⴖ casing in the Design Tool
Weight Burst Collapse Joint Pipe Body
OD (in.) ID (in.) (lb/ft) Grade Connection (Psi) (Psi) Rating (lb) Str. (lb) S/N
Figure 1—Surface Casing Burst Pressure Diagram (J55, 54.5 lb/ft; 13 3/8ⴖ casing selected)
Figure 2—Surface Casing Collapse Pressure Diagram (J55 54.5 lb/ft 13 3/8ⴖ casing (0-1640ft) and C/T-95 72 lb/ft 13 3/8ⴖ casing (1640-3500ft) selected)
Figure 3—Triaxial Equivalent Loading with the casing running loading case
is available. If the available strings can’t be used, the items can be ordered so that the project would be
cxecuted within schedule.
Summary Sheet
The summary sheet gives the client a summary of the casing string selection over the entire well
encompassing all the casing sections from the surface casing to the production casing/liner obtained from
the casing design process. The client job details are entered on this sheet. A schematic of the casing design
scheme is displayed with the casing properties with the setting depths and the combination strings for each
section.
SPE-172466-MS 7
Figure 4 —Wellbore Schematic showing Surface, Intermediate and Production Casing String selection after the design process.
Case Study
Surface Casing Design
13 3/8⬙ surface casing is to be set at 3,500ft using the following data for design:
● Fracture gradient at 3500 ft: 14.6 ppg;
● Mud weight when casing run: 9.2 ppg;
● Tail cement slurry (1000ft): 16.4 ppg;
● Lead cement slurry (2500ft): 12 ppg;
8 SPE-172466-MS
Conclusions
An Excel VBA-based Casing design tool for quick selection of combination strings has been presented in
this paper. The tool though based on the maximum load concept, allows the designer to make calculations
based on operational loading conditions during the life of the well. Combination casing strings are selected
via an iterative process which involves select casing that meet the burst loading criteria and them both
burst and collapse. The final combination string selection must meet burst, collapse, tension and triaxial
loading conditions. This casing tool saves time because its input requirements are basic, its calculations
fast and its output is very explicit. Most importantly, it leads to the selection of cost effective casing strings
with high integrity.
Acknowledgments
The authors wish to thank the management of Halivah Hydrocarbon Resources Management (Nigeria)
Ltd. for granting the permission to publish this paper.
Nomenclature
CF Conversion Factor
CSD Casing Setting Depth
DFb Design Factor for burst
DFc Design Factor for collapse
DFt Design Factor for tension
DFVME TriaxialDesign Factor
EFG External Fluid Gradient
Fbend Tension load from bending, lbf
Fbuoy Buoyancy force, lbf
Fop Overpull force, lbf
SPE-172466-MS 9
Subscript
b burst
c collapse
e external
i internal
op overpull
t tension
References
1. Jenkins, P.B. and A.L. Crockford, “Drilling costs,” SPE 5266, SPE-European Meeting, London,
England, April 1975.
2. Prentice, C.M., 1970. Maximum load casing design. J. Petrol. Tech. 22(7); 805–810.
3. Raham, S. S. and Chilingarian, G. V., 1995. “Casing Design: Theory and Practice”, Elsevier
Science B.V. Amsterdam, The Netherlands.
4. Klementich, E. F. and Jellison, M. J., 1986. A Service-Life Model for Casing Strings. SPE Drilling
Engineering. Vol. 1, No. 2; 141–152.
5. Goins, W.C., Jr., 1965, 1966. A new approach to tubular string design. World Oil, 161(6,7): 13,
5-140, 83-88; 162(1,2): 79-84, 51-56.
6. Rabia, H., 1987. Fundamentals of Casing Design. Graham & Trotman, London, UK, pp. 1–23.