1

UAE University
Faculty of Engineering
Graduation project II
Casing Design in a Vertical Well
Final Presentation

Dr. MD Rahman
Advisor:
Team Members: Omar Ahmed Kamel 200100051
AbdulRahman Hasan 199900460
Ibrahim Hussain Taqi 199900628
Sultan Hussain Ahmed 200106307
2
Presentation Layout
Acknowledgement
Introduction
Light Casing Design For Grade Selection
Heavy Casing Design For Grade Selection
Conductor Casing Design
API Coupling Selections
Economic Considerations
Conclusions
3
Acknowledgment
We would like to express our deepest
thanks and appreciation to:
1) Prof. Reyadh Almehaideb and GP Advisor
MD Rahman
2) Examiners Committee: Prof.Abdulrazq Zekri,
Dr. Shedid Ali and Dr. Bilal El-Ariss
3) ADCO: represented mainly by Mr. Reymond
Khairallah, S.A Turki and Adib Edris
4) Training and Graduation Projects Unit
4

Introduction
Casing is defined as a heavy large steel pipe
which can be lowered into the well for the
following functions:

1) Keeping the hole open by preventing the weak
formations from collapsing.

2) Serving as a high strength flow conduit to
surface for both drilling and production fluids.

3) Protecting the freshwater-bearing formations
from contamination by drilling and production
fluids.


5

Introduction

4) Providing a suitable support for wellhead
equipment and blowout preventers for
controlling subsurface pressure, and for the
installation of tubing and subsurface equipment.

5) Providing safe passage for running wireline
equipment.

6) Allowing isolated communication with selectively
perforated formation(s) of interest.

6
Introduction



The main types of
casing are:

1) Conductor Pipe
2) Surface Casing
3) Intermediate Casing
4) Production Casing
5) Liners

As shown in the Figure

7
Project Objectives
To perform casing design for two vertical
wells by:

1) Data collection from ADCO Company.
2) Selection of casing setting depths.
3) Selection of casing sizes.
4) Determination of number of casings.
5) Selection of casings grades and couplings.
6) Economic Analysis.
8
Light Casing Setting Depth Chart
Setting Depth Chart
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
EMW (ppg)
D
e
p
t
h

(
f
t
)
Formation Pressure
Fracture Pressure
Trip Margin
Depth
Objective
Intermediate Casing Shoe
Surface Casing Shoe
9
Light Casing Program
Depth (ft.) Casing Size (in.) Casing Type
0 - 150 18-5/8 Conductor Pipe
0 - 1620 13-3/8 Surface Casing
0 - 7420 9-5/8 Intermediate Casing
7420 - 8938 7 Production Liner
10
Casing Design For Grade Selection
Casing Design for grade selection is
done based on maximum load and
minimum cost.
Collapse pressure, burst pressure and
tension loads are calculated for all
casings to select there suitable grades.
Pressure testing and biaxial effects are
then checked for all casings.

11
Light Surface Casing Design
12
Light Surface Casing Collapse Pressure
Depth (ft) Collapse Pressure (psi)
0 0
1620 724
Collapse Pressure Vs. Depth
0
500
1000
1500
2000
0 200 400 600 800
Collapse Pressure (psi)
D
e
p
t
h

(
f
t
)
13
Light Surface Casing Burst Pressure
Depth (ft) Burst Pressure (psi)
0 815.18
1620 223.88
Burst Pressure Vs. Depth
0
400
800
1200
1600
2000
0 200 400 600 800 1000
Burst Pressure (psi)
D
e
p
t
h

(
f
t
)
14
Light Surface Casing Grade Selection
Collapse Pressure Vs. Depth
0
400
800
1200
1600
2000
0 200 400 600 800 1000
Collapse Pressure (psi)
D
e
p
t
h

(
f
t
)
K 55
L 80
H 40
J 55
15
Light Surface Casing Grade Selection
Burst Pressure Vs. Depth
0
400
800
1200
1600
2000
0 500 1000 1500 2000 2500 3000
Burst Pressure (psi)
D
e
p
t
h

(
f
t
)
K 55
H 40 L 80
J 55
16
Light Surface Casing Tension Calculations
Grade
Depth
Interval
(ft)
Grade
Weight
(lb/ft)
Buoyant
Weight
(1000 lbf)
Cumulative
Buoyant
weight
(1000 lbf)
Shock
Load
(1000
lbf)
Total
Tension
(1000
lbf)
Yield
Strength
(1000 lbf) SF
J 55 1620 - 1480 50.3 6.03 6.03 160.96 166.99 962
5.7
6
H 40 1480 - 1240 46.2 9.49 15.52 147.84 163.36 541
3.3
1
L 80 1240 - 730 43.4 18.95 34.47 138.88 173.35 1556
8.9
8
K 55 730 - 0 36.5 22.81 57.27 116.8 174.07 962
5.5
3
BF W Interval Depth Weight Bouyant
n
=
n
W Load Shock 3200 =
Load Shock Weight Buoyant Cumulative Tension Total + =
Load Shock Weight Buoyant Cumulative Tension Total + =
Tension Total
Y
SF
p
=
Where BF is Buoyancy factor, W
n
is casing weight in lb/ft and
Y
p
is the grade yield strength in lbf and SF is the safety factor.
17
Light Surface Casing Pressure Testing
Pressure testing calculation :




Safety factor > 1.8, so H-40 can be used.
So, all four grades are safe to be used in the
light surface casing.
67 . 13
10 ) 65587 . 6 85 . 32 (
10 541
3
3
=
+

= =
testing pressure during Tension Total
Y
SF
p
18
Light Intermediate Casing Design
19
Light Intermediate Casing Collapse Pressure
Collapse Pressure (psi) Depth (ft)
0 0
1196.16 2277.53
688.046 7420
Collapse Pressure Vs. Depth
0
2000
4000
6000
8000
0 500 1000 1500
Collapse Pressure (psi)
D
e
p
t
h

(
f
t
)
20
Light Intermediate Casing Burst Pressure
Burst Pressure (psi) Depth(ft)
2500 0
3374 5497.47
115.953 7420
Burst Pressure Vs. Depth
0
2000
4000
6000
8000
0 1000 2000 3000 4000
Burst Pressure (psi)
D
e
p
t
h

(
f
t
)
21
Light Intermediate Casing Grade Selection
Collapse Pressure Vs. Depth
0
2000
4000
6000
8000
0 500 1000 1500 2000
Collapse Pressure (psi)
D
e
p
t
h

(
f
t
)
J 55
H 40
H 40
L 80 P 110
22
Light Intermediate Casing Grade Selection
Burst Pressure Vs. Depth
0
2000
4000
6000
8000
0 2000 4000 6000
Burst Pressure (psi)
D
e
p
t
h

(
f
t
)
P 110
L 80
H 40
23
Light Intermediate Casing Tension Calculations
Grade
Depth Interval
(ft)
Grade
Weight
(lb/ft)
Buoyant
Weight (1000
lbf)
Cumulative
Buoyant weight
(1000 lbf)
Shock Load
(1000 lbf)
Total
Tension
(1000 lbf)
Yield
Strength
(1000 lbf) SF
H 40 7420 - 6250 26 26.04 26.04 83.2 109.24 295 2.70
L 80 6250 - 0 29 155.15 181.19 92.8 273.99 658 2.40
The grades are safe to be used.
The grades are also found suitable if the
total tension load increases due to pressure
testing as the safety factor is much higher
than 1.8.
24
Light Casing Production Liner Collapse Pressure
Collapse Pressure (psi) Depth (ft)
737.483 6920
1421.179 8938
Collapse Pressure Vs. Depth
6000
6500
7000
7500
8000
8500
9000
9500
0 500 1000 1500
Collapse Pressure (psi)
D
e
p
t
h

(
f
t
)
25
Light Casing Production Liner Burst Pressure
Burst Pressure (psi) Depth (ft)
2311.723 6920
2118.306 8938
Burst Pressure Calculations For Liner Design
6000
6500
7000
7500
8000
8500
9000
9500
2000 2200 2400 2600
Burst Pressure (psi)
D
e
p
t
h

(
f
t
)
26
Light Casing Production Liner Tension Calculations
Grade
Depth
Interval (ft)
Grade
Weight
(lb/ft)
Buoyant
Weight
(1000 lbf)
Cumulative
Buoyant
Weight
(1000 lbf)
Shock
Load
(1000 lbf)
Total
Tension
(1000 lbf)
Yield
Strength
(1000 lbf) SF
J 55 8938 7850 16.2 15.09 15.09 51.84 66.93 258 3.85
H 40 7850 6920 14.8 11.78 26.87 47.36 74.23 171 2.30
Both grades are safe for use.
Here, also by calculating the additional
tension due to pressure testing it is found
that the safety factor > 1.8.
27
Heavy Casing Setting Depth Chart
Setting Depth Chart
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
EMW (ppg)
D
e
p
t
h

(
f
t
)
Fracture Pressure
Formation Pressure
Trip Margin
Surface Casing Shoe
1st Inermediate Casing Shoe
2nd Intermediate Casing Shoe
Depth
Objective
28
Heavy Casing Program
Depth Casing Size (in) Casing Type
0 - 150 30 Conductor Pipe
0 - 1610 18-5/8 Surface Casing
0 - 5800 13-3/8 Intermediate Casing
0 - 9420 9-5/8 Intermediate Casing
9420 - 9532 7 Production Liner
29
Heavy Surface Casing Design
30
Heavy Surface Casing Collapse Pressure
Collapse Pressure (psi) Depth (ft)
0 0
703.248 1610
Collapse Pressure Vs. Depth
0
400
800
1200
1600
2000
0 200 400 600 800
Collapse Pressure (psi)
D
e
p
t
h

(
f
t
)
31
Heavy Surface Casing Burst Pressure
Burst Pressure (psi) Depth (ft)
718.06 0
130.41 1610
Burst Pressure Vs. Depth
0
400
800
1200
1600
2000
0 200 400 600 800
Burst Pressure (psi)
D
e
p
t
h

(
f
t
)
32
Heavy Surface Casing Grade Selection
Collapse Pressure Vs. Depth
0
400
800
1200
1600
2000
0 200 400 600 800
Collapse Pressure (psi)
D
e
p
t
h

(
f
t
)
H

4
0
H 40
J

5
5
J 55
K

5
5
Depth
Intervals (ft)
Collapse
Resistance
(psi)
Weight
(lb/ft) Grade
0 780 320 70.6 H 40
780 - 1200 520 82.2 J 55
1200 - 1610 790 93.6 K 55
33
Heavy Surface Casing Grade Selection








All the Grades are suitable for the Burst
Pressure.
Burst Pressure Vs. Depth
0
400
800
1200
1600
2000
0 500 1000 1500 2000 2500
Burst Pressure (psi)
D
e
p
t
h

(
f
t
)
H

4
0
J

5
5
K

5
5
34
Heavy Surface Casing Tension Calculations




Grade
Depth
Interval (ft)
Grade
Weight
(lb/ft)
Buoyant
Weight
(1000 lbf)
Cumulative
Buoyant
weight (lbf/ft)
Shock
Load
(1000 lbf)
Total
Tension
(1000 lbf)
Yield
Strength
(1000 lbf) SF

K 55
1610 - 1200 93.6 32.85 32.85 299.52 332.37 1474 4.43

J 55
1200 - 780 82.2 29.55 62.40 263.04 325.44 1290 3.96

H 40
780 - 0 70.6 47.14 109.54 225.92 335.46 804 2.40
35
Heavy Surface Casing Pressure Testing Calculations
Pressure Testing for the weakest grade
which is H 40 is done based on the following
equation:

( )
84 . 6
) 1000 ( 034 . 8 40 Pr
6 . 0 tan Re Pr
=
=
=
Factor Safety The
lbf H For Tension Testing essure
A Area Secntinal Cross ce sis Burst Tension Testing essure
s
10.14 A
s
(in
2
)
8.034
Additional Tension
(1000 lbf)
6.84 SF
36
Heavy Surface Casing Design Biaxial Calculations
Biaxial effect:




Where:
a
is the axial stress due to tension (psi

y
is minimum yield strength of the grade (psi)
Y
pa
is the effect yield strength (psi)
d
o
is the outer casing diameter (in)
d
i
in the inner casing diameter (in)




( )

|
|
.
|

\
|

(
(

|
|
.
|

\
|
=

=
y
a
y
a
y p
i o
a
Y
d d
Grade Weakest By Carried Weight Bouyant
o
o
o
o
o
o
t
o
5 . 0 75 . 0 1
4
5 . 0
2 2
37
Heavy Surface Casing Design Biaxial Calculations
Biaxial effect is calculated using the
following set of equations:







Where: A,B, C, F and G are empirical constants









3 13 2 7
6
3 16 2 10 5
10 36989 . 0 10 10483 . 0 030867 . 0 93 . 465
10 50609 . 0 026233 . 0
10 53132 . 0 10 21301 . 0 10 10679 . 0 8762 . 2
pa pa pa
pa
pa pa pa
Y Y Y C
Y B
Y Y Y A

+ + =
+ =
+ + =
A B F G
A B
A B
A B
A B
A B
Y
A B
A B
F
pa
/ ) (
/ 2
/ 3
1 /
/ 2
/ 3
/ 2
/ 3
10 95 . 46
2
3
6
=
(
(

|
.
|

\
|
+

|
|
.
|

\
|

+
(
(

|
.
|

\
|
+

=
38
Heavy Surface Casing Design Biaxial Calculations
2913.47
a

40000
y

38463.61 Y
p

53.21429 d
o
/t
The biaxial results for heavy surface casing:

Stress Calculations Coefficients Calculations
2.945766 A
0.045699 B
707.922 C
2.078155 F
0.032239 G
39
Heavy Surface Casing Design Biaxial Calculations
Model
> d
o
/t
Elastic
43.30674 > 53.2142857

From the results:







The collapse pressure remain unchanged (Elastic
Model)
A B
A B
t d
o
/ 3
/ 2
/
+
>
A B
A B
/ 3
/ 2 +






Where d
o
is the outer casing diameter, in
t is the thickness of casing, in

40
1
st
Heavy Intermediate Casing Design
41
1
st
Heavy Intermediate Casing Collapse Pressure
Depth (ft) Collapse Pressure (psi)
0 0
5800 2714.4
Collapse Pressure Vs. Depth
0
1000
2000
3000
4000
5000
6000
0 500 1000 1500 2000 2500 3000
Collapse Pressure (psi)
D
e
p
t
h

(
f
t
)
42
1
st
Heavy Intermediate Casing Burst Pressure
Depth (ft) Burst Pressure (psi)
0 5931.28
5800 3814.28
Burst Pressure Vs. Depth
0
1000
2000
3000
4000
5000
6000
7000
0 1000 2000 3000 4000 5000 6000 7000
Pressure (psi)
D
e
p
t
h

(
f
t
)
43
1
st
Heavy Intermediate Casing Tension Calculations
Selected grades based on collapse and burst
pressures and Tension Calculation:





The selected grades are safe and meet all
the loads
Grade
Grade
Weight
(lb/ft)
Buoyant
Weight
(1000 lbf)
Cumulative
Buoyant
weight
(1000 lbf)
Shock
Load
(1000 lbf)
Total
Tension
(1000 lbf)
Yield
Strength
(1000 lbf) SF
P 110 73.1 81.35 81.35 233.92 315.27 1225 3.89
L 80 65.2 251.15 332.50 208.64 541.14 1452 2.68
44
2
nd
Heavy Intermediate Casing Design
45
2
nd
Heavy Intermediate Casing Collapse Pressure
Depth (ft) Collapse Pressure (psi)
0 0
3074.57 1838.59
9420 1277.66
Collapse Pressure Vs. Depth
0
2000
4000
6000
8000
10000
0 500 1000 1500 2000
Collapse Pressure (psi)
D
e
p
t
h

(
f
t
)
46
2
nd
Heavy Intermediate Casing Burst Pressure
Depth (ft) Burst Pressure (psi)
0 2500
6705.64 3984.63
9420 2993.89
Burst Pressure Vs. Depth
0
2000
4000
6000
8000
10000
0 1000 2000 3000 4000 5000
Burst Pressure (psi)
D
e
p
t
h

(
f
t
)
47
2
nd
Heavy Intermediate Casing Grade Selection
Collapse Pressure Vs. Depth
0
2000
4000
6000
8000
10000
0 500 1000 1500 2000
Collapse Pressure (psi)
D
e
p
t
h

(
f
t
)
C
7
5

3
3
.
9

l
b
/
f
t
C 75 32lb/ft
C 75 32lb/ft
48
2
nd
Heavy Intermediate Casing Grade Selection
Burst Pressure Vs. Depth
0
2000
4000
6000
8000
10000
0 1000 2000 3000 4000 5000
Burst Pressure (psi)
D
e
p
t
h

(
f
t
)
C
7
5

3
3
.
9

l
b
/
f
t
C 75 32lb/ft
C 75 32lb/ft
49
2
nd
Heavy Intermediate Casing Tension Calculations
Grade
Depth
Interval (ft)
Grade
Weight
(lb/ft)
Buoyant
Weight
(1000 lbf)
Cumulative
Buoyant
weight
(1000 lb/ft)
Shock
Load
(1000 lbf)
Total
Tension
(1000 lbf)
Yield
Strength
(1000 lbf) SF
C 75 9420 - 7250 32 59.44 59.44 102.4 161.84 559 3.45
C 75 7250 - 2700 33.9 132.03 191.47 108.48 299.95 680 2.27
C 75 2700 - 0 32 73.96 265.43 102.4 367.83 559 1.52
L 80 2700 - 0 33.9 78.35 265.43 108.48 373.91 771 2.06





Grade C 75 of weight 32 lb/ft doesnt
satisfy tension load requirements so it is
replaced with grade L 80 of weight 33.9
lb/ft.
Pressure testing and biaxial loads will not
cause any change in the selected grades.
50
Heavy Casing Production Liner Collapse Pressure
Depth (ft) Collapse Pressure (psi)
9032 1311.96
9532 1267.75
Collapse Pressure Vs. Depth
9000
9200
9400
9600
1200 1250 1300 1350
Collapse Pressure (psi)
D
e
p
t
h

(
f
t
)
51
Heavy Casing Production Liner Burst Pressure
Depth (ft) Burst Pressure (psi)
9032 3135.96
9532 2953.01
Burst Pressure Vs. Depth
9000
9200
9400
9600
2800 2900 3000 3100 3200 3300 3400
Burst Pressure (psi)
D
e
p
t
h

(
f
t
)
52
Heavy Casing Production Liner Grade Selection
Collapse Pressure Vs. Depth
9000
9200
9400
9600
1200 1250 1300 1350
Collapse Pressure (psi)
D
e
p
t
h

(
f
t
)C 75
L

8
0
Burst Pressure Vs. Depth
9000
9200
9400
9600
2900 3100 3300 3500 3700 3900
Burst Pressure (psi)
D
e
p
t
h

(
f
t
)
C 75 L 80
53
Heavy Casing Production Liner Grade Selection
Grade
Depth Interval
(ft)
Grade
Weight
(lb/ft)
Buoyant
Weight
(1000 lbf)
Cumulative
Buoyant
weight (1000
lbf)
Shock
Load
(1000 lbf)
Total
Tension
(1000 lbf)
Yield
Strength
(1000 lbf) SF
L 80 9532 - 9250 15.5 3.74 3.74 49.6 53.34 358 6.71
C 75 9250 - 9032 15.3 2.86 6.60 48.96 55.56 331 5.96





Both grades are safe for production liner
54

Conductor Casing Design
The conductor casing is set at 150 ft for both
light and heavy casing designs.
Usually the conductor casing is driven for such
shallow depth and this is also practiced in ADCO
Conductor size is 18-5/8 in. for light casing and
30 in. for heavy casing.
J-55 and X-65 grades have been selected finally
for conductor pipe for light and heavy casing
designs respectively.

55

API Coupling Selections

Round short and long thread couplings are mostly
used in the casing design.
The same couplings are considered in both light
and heavy casing designs.
There strengths for each grade for all the
casings designed so far are compared with the
respective total tension load and it is found that
the safety factor is higher than 1.8
56

Economic Considerations
Design Features Cost $

Savings
Single grade 721500

143142 $
Combination grades 578358

20%
Light Casing Design Cost Analysis






Heavy Casing Design Cost Analysis

Design Features Cost $
Savings
Single grade 283584

27850 $
Combination grades 255734

10%
57


Conclusions
Collapse, burst, tension and biaxial design principles
are studied carefully to apply graphical methods for
casing grade selection.
Maximum load design principles and worst loading
conditions are applied for both casing designs
successfully, and combination grades are selected
for each casing string satisfying all constraints and
meeting all loads.
Cost analyses are performed for each casing design.
Environmental considerations are given emphasis in
both casing designs.
58