exercise - production casing selection for collapse, burst...
TRANSCRIPT
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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THIS WORK IS COPYRIGHTED BY PETROSKILLS, LLC. AND DISTRIBUTED UNDER
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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
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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)
Production Casing Load
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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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)
Production Casing Load
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)
Production Casing Load
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)
Production Casing Load
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
Production Casing Selection for Collapse, Burst and Axial Design Factor Loads Exercise ═════════════════════════════════════════════════════════════════════════
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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
Axial Load Calculations
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
Production Casing Selection for Collapse, Burst and Axial Design Factor Loads Exercise ═════════════════════════════════════════════════════════════════════════
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Axial Load Calculations
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
Axial Load Calculations
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
Axial Load Calculations
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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Axial Load Calculations
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
Axial Load Calculations
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
Axial Load Calculations
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
Production Casing Selection for Collapse, Burst and Axial Design Factor Loads Exercise ═════════════════════════════════════════════════════════════════════════
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Axial Load Calculations
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
Axial Load Calculations
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
Axial Load Calculations
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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Axial Load Calculations
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
Production Casing Selection for Collapse, Burst and Axial Design Factor Loads Exercise ═════════════════════════════════════════════════════════════════════════
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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)
Production Casing Load
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 !
Production Casing Selection for Collapse, Burst and Axial Design Factor Loads Exercise ═════════════════════════════════════════════════════════════════════════
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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)
Production Casing Design Load
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)
Production Casing Design Load
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
Production Casing Selection for Collapse, Burst and Axial Design Factor Loads Exercise ═════════════════════════════════════════════════════════════════════════
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Axial Load Calculations (Alternate)
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
Axial Load Calculations (Alternate)
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
Axial Load Calculations (Alternate)
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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Axial Load Calculations (Alternate)
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
Axial Load Calculations (Alternate)
Plug Bump, axial forces
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
Axial Load Calculations (Alternate)
Plug Bump, axial forces
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
Production Casing Selection for Collapse, Burst and Axial Design Factor Loads Exercise ═════════════════════════════════════════════════════════════════════════
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Axial Load Calculations (Alternate)
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
Axial Load Calculations (Alternate)
Post Plug Bump, axial forces
Axial Load Calculations (Alternate)
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)
Production Casing Selection for Collapse, Burst and Axial Design Factor Loads Exercise ═════════════════════════════════════════════════════════════════════════
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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
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