CASING COLLAPSE PERFORMANCE by Parviz Mehdizadeh Continental Oi1 Company Ponca City, Oklahoma (978/74 I. INTRODUCTION Several months ago, we experienced a casing collapse failure. Investigation of this failure indicated that the casing was made of slack quenched material which contained excessive residual stresses. It was concluded that the slack quenching and the excessive residual stresses lowered the collapse strength of the casing, thus contributing to its failure. The investigation described in this report was undertaken to assess the contribution of such manufacturing parameters as slack quenching end rotary straightening to the collapse performance of casings. II. COLLAPSE TESTING PROCEDURES Since testing method and sample size can affect the outcome of a collapse test, a brief investigation was conducted to determine the effect of these parameters on the collapse test data, The results shown in Figure 1 indicated a 10 percent increase in collapse pressure for test samples with lengths less than seven times the diameter of the tubing. It wasFigure 1, Collapse prossure vs the ratio of unrestrained length to outside diameter. Test specimens had Dit 15,5 and yield strength of 7585 ksi.also revealed that collapse tests in which the hydrostatic pressure acts axially on che full cross-sectional area of the specimen (closed-end samples) gave higher values for collapse pressure than “open-end” tests in which no axial stress is developed by the collapse pressure. Figure 2 shows the results of collapse tests obtained by the various test techniques using the same casing material (Reference 1), Regression analysis of the data produced the relation shown in Figure 2 between collapse pres- sure (P), normalized with respect to the compressive material yield strength (cy), and the diameter to wall thickness ratios (o/t).. The data in Figure 2 show that collapse pressures from short (2-30) open- end tests are about 10 percent greater than those obtained by the long closed-end test method. However, the collapse pressures from short (2-30) closed-end tests are about 25 percent greater than those obtained by long closed-end tests. As pointed out previously, the collapse data from long i open-end and long closed-end tests are very similar, as shown by the regres- sion lines for these tests in Figure 2. The above review of the collapse tests procedures indicated that collapse resistance determined by tests using short specimens, particularly "closed-end" type, are erroneously higher than the collapse resistance of casing under well conditions. Presently, most manufacturers use the short open-end test procedure to obtain casing performance data. This procedure has also been adopted by APT (see API Bulletin 5C2) as a standard method for collapse testing of“160 140 120 100 : cr ee co Bee etree cele he of wo-c, -pfe sha vol 3S RE Hoe BS bSe8 Bean wove abba srt70 \ Figure 2 Regression tines for collapse data otftained by the various test methods. Test designations are as : follows: 3D-CL: Specirren Length = 3 X Diameter; Closed End 3D-OP: Specirren Length = 3 X Diameter; Open End 8D.OP: Specirren Length = 8 X Diameter! Open End. 100-CL: Speci nen Length = 10 X Diameter; Closed End ‘The collapse gressure (P) is normalized with respect to compressive yield strength (CY) of the S-95 casings used in these tests (Ref, 1)... The numerical values for the regression line constants {A and B) are also shown in this { gure.pipes. Thus, the collapse data to be discussed in the remainder of this report was generated using short open-end test procedure. Figure 3 shows a schematic of the test arrangement. II], PARAMETERS THAT AFFECT COLLAPSE TEST RESULTS The collapse pressure obtained in a short open-end collapse test for a given diameter and grade of casing is influenced by the following specimen parameters: (a) Ratio of diameter to wall thickness (D/t). (b) The amount of ovality and eccentricity. (c) The magnitude and nature of the residual stress present in the casing material. (d) The paysical properties of the casing material. This investigation was conducted mainly to determine the effects of Factors (c) and (d) on the collapse strength. It was therefore necessary to normalize the data with respect to the other factors. The tests conducted in the present investigation fell in the transition and plastic collapse regions. Figure 4 shows the variation of collapse pressure with D/t ratio in the transition collapse region, Since the casing materials used in our tests had yield strengths in the range of 80-100 ksi, the average (318 psi) of the two slopes shown in Figure 4 was used io correct the transition collapse data with respect to O/t variation.1801 asdej00 pus-vado uawizods (s01aweIp €-Z) 140U 404 dries OneWaYDS “E aun“| con] D/t in the transition collapse region for N-60 grade of casings. Figure 4 Variation of collapse pressure with ‘curves. The solid line ond the dotted line correspond to 100 ksi The API 5C3 formulas were used to obtain the ‘and 80 ksi yield strength, respectively.Figure 5 shows the variation of collapse pressure with D/t ratio in the plastic collapse region for N-80 grade of casings. The slope of this curve in the 18-20 (D/t} range was used to correct the plastic collapse data with respect to D/t variation. IV. CHEMICAL COMPOSITION AND PHYSICAL PROPERTIES OF THE TEST MATERIAL Tables 1 anc 2 summarize the chemical composition and the mechanical properties cf the casing samples used in the present investigation. V. RESIDUAL STRESS MEASUREMENTS. The so-called "slit-ring method" was used to measure the residual stresses in the casing materials. This technique involves cutting a 2.0-inch wide ring from the casing, locating gage marks on the face of the ring, slitting the ring axially between the marks, and measuring the amount of opening or closing of the ring, The average residual stress can be calculated (Reference 2) by the following relation: ate So ane a where: S = Average circumferential residual stress, psi. a = Amount of ring opening or closing, inch. t = Average wall thickness, inch.nah seme [igtewe) : i i Figure 5 va Bulletin $C3,TABLE! CHEMICAL COMPOSITION OF THE CASING SAMPLES USED IN THE INVESTIGATION. WEIGHT PERCENT. Sample and Goup Designation Wa ° a $214 (Groups and V) 0340.38 0.80090 0.0120.016 0.02003 0.10.12 $214 (Groups 1, I1,and 1V) 0.36 1.20 019 0.026 018 $215 (Groups and 11) 027 1.33 0.007 0.025 024 $219 (Grours | and 11) 023 1.30 0013 0.028 $-220 (Groups I, 11,and 11) 0.26 ww 0.020: 0.022 or TABLE 2 MECHANICAL PROPERTIES OF THE CASING SAMPLES USED IN THE INVESTIGATION Sample Yietd Strength Tensile Strength Designation ___Group=Specimen psi psi % Btongation sai rea 84,000 104,800 2 2 83,400 101,300 2 | 1 100,000 413.200 26 75/8" ~ 26.4 Ibs 1-2 94801 108.300 26 N80 3 0,500 106,960 2 1 94,150 111,400 25 m2 93490 111.240 25 3 92,880 111240 23 1 82,900 113890 2 v-2 90570 114,470 2 3 85940 117570 2 sais 1 76000 101,500 2B 7.0" ~ 29 tbs 0 77,600 103,400 20 Restricted - Yield N-80 : . $219 1 86000 107,100 26 75/8" 26.4 bs u 91,200 110,100 2 Controted Yield N-60 s.220"* 1 95,250 113,500 a 75/8" ~ 33.7 hs 0 : : : Neo m : : “Mechanical properties of $:214 Group IV samples were not determined. These properties should be similar to those of Group V. **Mechanical properties of S:220 Groups II and 111 samples were not determined. These properties should be similar to thoze of Group |. gaR = Averege radius of the center line of the ring, inch. E = Modulus of elasticity, assumed as 30 x 10° in our calculations. Residual stress measurements using casing samples of different strength and fabrication methods indicated that the magnitude of the residual stress was independent of the ring width. Typical data for such experi- ments are siown in Table 3, On the basis of this type of data, 2,0-inch wide rings were used as standard test specimens throughout this investi- gation. TABLE 3 EFFECT OF THE RING WIDTH ON RESIDUAL STRESS MEASURENENTS FOR 7.0" 0.0., 29.0 LBS, RESTRICTED YIELD N-80 SEAMLESS CASING Sample Ring Width, Residual Stress Designation, Inch ps: $-215-1A* 26,532 $-215-1B 26,021 $-215-1C 23,620 $-215-1IA 26,352 $-215-11B 25,259 $-215-11C 26,170 $-215-1 , 23,713 $-215-11 26,204 $-215-1 23,879 S-215-I1 24,435 $-215-1 * 23,623 $-215-11 25,537 *A, B, C rings were cut from the same casing but slit at three locations 1209’ apart. 10VI. EFFECT OF SLACK QUENCHING ON COLLAPSE PERFORMANCE Slack quenching is a term which is used to describe the heat treatment gra- dient encountered during the quenching of low chemistry casing materials. Use of low chemistry casing material or slow rate of cooling during the outside Quenching process can result in a heat treatment gradient within the wall thickness of the casing, This, in turn, causes full martensitic transformation of the material which is closer to the 0.0. of the casing and partial transformation for the material near the I.D. The resulting microstructure would have a strength gradient varying from high strength at the 0.0. to low strength at the I.D. Figure 6 shows typical micro- structural gradient found in a slack quenched casing. The strength gradient within the wall thickness of a slack quenched casing is illustrated by the microhardness data shown in Figure 7. Table 4 shows the effect of slack quenching on the collapse strength of 7 5/8-inch 0.0., 26.40-pound, N-80 casings. The collapse test pressures Were normalized with respect to the nominal D/t of 23.25 for this grade of casing on the basis of discussions presented in Section III. The quench penetration parameter used in Table 4 denotes the percent of wall thickness having 100 percent martensitic microstructure, Thus, 100 percent penetration means that the materfal was fully quenched. Fifty percent penetration indicates that only half of the wall thickness experienced full transformation. unhs aR Baa Rea LEROY nk Figure 6 Microstructure of a slack quenched N-80 easing material near the O.D. (top) and 1.D. (bottor) of the casing. The square marks are depressions feft by the microhardness probe (see Figure 7). Note the fully martensitic microstructure near tho O.D. where the material was subjected to fast quenching rate vs the partially transformed structure near 1,0. whore the material was slack quenched. Mag. 400X——— CASING WALL——— OUTSIDE oa as | 720 {20 afb. M27T Po) INSIDE, al 292 282.292 262 ai Figure 7 Microhardness profile across the wall of a slack quenched casing sample, All hardness val Re scale, The dctted line delineates the boundary between the two microstructures shown in Figure 6.The residual stresses shown in Table 4 were measured using 2.0-inch wide slit-ring method described in the previous section. Duplicate collapse tests were conducted on representative samples of each group of materials, as shown in Table 4, The collapse test data were pooled to obtain the average collapse pressure for each group, as shown in the last column of the Table 4. In attempting to assess the effect of slack quenching, it is desirable to eliminate tke effect of other parameters, such as residual stress, that could also affect the collapse strength. We were not able to control the magnitude of residual stresses in the slack quenched samples, But the four test groups listed in Table 4 can be divided into two sub groups (I vs II and ITI vs IV) each having about the same level of residual stress, This enables us to coupare the effect of slack quenching within these two groups without interferences due to the residual stress parameters The comparison of the collapse data between the severely slack quenched Group I (4,054 psig) and fully quenched Group IT (5,588 psig) indicates that the collapse pressure of a fully quenched casing is about 40 percent higher than that of a severely slack quenched casing. The residual stress magnitude within test Groups I and II are considered to be about the same level in view of the variations observed in each group of test materials. Similarly, comparison of collapse data for test Groups III and IV with equivalent residual stress but different quench penetration parameters av)“ss0u18 eussaudwoo 01 5:2)2) "pur p seun6iy ut s10128} uolioas400 yrim soueps000€ Ut ‘GUISE O8-N "91 9°92 — .8/S £ 40} 3/9 Jeu0U aur 'S7'EZ = 1d 02 adSAL Way par!|EW0U SOMNSSO:d 95dE100 » uawypeds ye Jo reba “SE0.18 1enpIsO) eNUBsO]WNOAID » a1 veayong, eovse ry ose oov'e vez : ere oos'e wee e wee pve’ se Pree O56 over pauaubieas . sige oos'e zee Z _ Artioy pue sosez os save oos'e ezez veor ose'y we t veo 06 sese ooo vote ozo cove veEz e eol'y ee 86 ease vez povarysiess zeae cose 862 z ‘Asnioy pue sonsedoig ove'ez 7°? Cy 00's 9c722 PoypuenD —_epqwewDeyy pue son’ 09" zee t ing vorsedwog e09'z- 06 699'5 oos's avez eonwa4D e's 09's erez € 20) pue 6091 $6 ozé osc’ avez 1 s9jce4. 995 e9g oue's _ 001'S ave ey ves zere~ cot gigs 008 eLie payouen : ecg o02'9 evez ‘ aes 88 t- le oud cog wee cose ooz'e Bree ae $90 ° az 1909 ose vee pawuanp vey 002" ove t yes — 1 ET ROD TIL a % is Be yoay was | eH ames J04 a1nss814 sans voneneuey —esnssaig asdejog —_aunssoig 150 ssdeio "any penpisoyeny oun 1991109 ‘esdei109 SONISWO OBN S87 OY'92‘..8/G L JO HLONSULS Sd¥T109 HL. NO ONIHONIND ADVIS 40 193433 y Mev. Vaindicates an increase of about 12 percent in collapse strength for a fully quenched casing as compared to one that has a quench penetration of about half of its wall thickness. VII. EFFECT OF RESIDUAL STRESS ON COLLAPSE PERFORMANCE Analysis of the stress distribution within the wall of a casing (Refer- ence 3) subjected to internal or external pressure shows that the hoop stress is net uniformly distributed, The magnitude of the hoop stress at the inner surface of a casing under external or internal pressure is considerably higher than at the outer surface. Thus, under pressure, the material at the inner surface reaches the yield point before the material at the outer surface. Thus, for a casing with compressive residual stresses on the inner surface (tensile residual stresses on the ster surface), the collapse resistance decreases since the inner surface material reaches its yield stress at a lower value of collapse pressure than if no residual stress were present. It should de noted that circumferential residual stresses designated as tensile (as measured by our split-ring method and reported in this paper) are indicative of compressive residual stresses at the inner surface of the ring. Conversely, the compressive residual stresses measured by the split-ring method indicate the presence of tensile residual stresses on the inner surface of the ring. Hence, for a casing with compressive circumferential residual stress, the inner surface is in tension. In this case, with the application of external pressure, 8the residual tensile hoop stress at the inner surface must be reduced to zero before compressive hoop stress can build up. This type of residual stress distribution will therefore increase the collapse resistance of a casing. Two manufacturing operations are mainly responsible for introducing residual stresses in casings. These are the quenching, and the straightening processes. The non-uniform rate of cooling inherent in most practical quenching operations ‘nduces residual stress in the casing material. The magnitude of these quenching stresses is influenced by the chemical composition and wall thickness of the casing as well as the quenching process employed by the manufacturer, The main source of residual-stress, however, is the straightening process employed by most manufacturers to straighten casings after the heat treating process. Any type of straightening method introduces. some residual stress in the casing material that undergoes straightening operation. However, the results are much more pronounced with rotary straightening method employed by most casing manufacturers. Table 5 shows the range and nature of circumferential residual stresses found in the various grades of casings both prior to straightening, ‘due to the quenching process, and after rotary straightening. Note that the greater portion of residual stress is due to the straightening operation. ‘Also, the magnitude and nature of these stresses is a function of the casing D/t and the yield strength of the material. 16TABLES + MAGNITUDE AND NATURE OF THE CIRCUMFERENTIAL RESIDUAL STRESSES IN CASINGS PRIOR TO AND AFTER STRAIGHTENING OPERATION ‘Ave, Residual Stross? Ave, Residual Stress* 0D. Weight Before Straightening After Straightening Grade Inch LbsiFt Dh oi psi 95/8 47.00 20.8 4,050 23,300 75/8 29.70 20.33 9.970 45,170 7 26.00 19.33, 4810 34,250 76a) c370) 1073) 11,200 51,300 P:110(Dats From =O 5/B 35D 17.66 890 39,830 Reference 5) 7 2900 17.16 2,050 20,850 7 20.00 17.16 4,600 24,370 8 15.00 16.89 3,000 32,480 7 3200 18.45 0 24960 512 20.00. 15.23 1969 51,400 7 35.00 | 14.06 0 30,470 5 18.00 13.81 1.590 32,570 N80 (Data 75. 2640 © 23.76 2.178 25.60 From Ihis Investigation) 75/8 3370 *18.00 2.985 13.945 “All ciccumferential residual stresses were measured by split+ing method. Negative signs refer to compres! sive stress.The effect of residual stress on the collapse resistance of casings has been established fairly well by a number of prior investigations. Figure 8 shows the relation between the circumferential residual stress and the percent decrease in the collapse pressure as a function of diameter to the wall thickness ratio for casings made of 65-85 ksi yield strength material (Reference 2). The plotted data for P-110 casings obtained from Reference 4 indicates that for higher yield strength material, the curves tend to move upward. Since the data shown in Figure 8 were obtained 16-34 years ago, a limited number of collapse tests were conducted on presently produced casings to determine the nature and magnitude of the residual stresses and their effect on collapse resistance, Tables 6 and 7 contain the result of these tests. Table 7 shows that the collapse resistance of a 7 /8-inch, 26.4-pound, N-80 casing subjected to one pass through the rotary straightener decreased by about 27 percent due to the presence of 26 ksi residual tensile stress. This prediction is in agreement with the trend shown in Figure 8. However, we noted that an additional pass through the straightener resulted in a slight (6 percent) increase in the collapse pressure while at the same time increasing the magnitude of the residual stress. A similar trend was observed with the collapse test data for 7 5/8-inch, 33,7-pound, N-80 casing shown in Table 7, The first pass through the straighteer produced residual stresses of 10- 17 ksi magnitude, thus reducing the collapse resistance by about 9 percent, in agreement with the data shown in Figure 8. A second pass through 7Figure 8 Relationship between residual stress and decrease in collapse pressure as a function of diameter to wall thickness ratio, Solid lines correspond to casings samples with 65:85 ksi yield strength, Data points correspond ta P-110 casings, (Refs. 2 and 4), 18TABLE 6 EFFECT OF CIRCUMFERENTIAL RESIDUAL STRESS ON THE COLLAPSE STRENGTH OF 7 5/8" ~ 26.40 LBS, N-80 CASINGS (SAMPLE $-214)" Collapse Test? Corrected Collapse Average Specimen Pressure Pressure? Residual Stress Group! Designation Ave. D/t psig psig paaeen 23.43 6,300 6.369 W=No 1 21.73 6,000 5518 2232 ‘Straightening 24.12 5,100 5376 2 23.78 4.750 4920 23.49 5,600 5678 3 23.78 5,500 5,669 Ave, 5588 2282 4,600 465 ML — One Pass 1 22.96 5,000 4909 23,640 ‘Through Rotary 2398 3,600 3832 ‘Straightener 2 23.94 3,760 3.969 28,628 + 2394 3,800 4920 3 23.08 4,900, 24,634 Ave. 25,634 22.82 5,300 4962 V Two Passer 1 23.73 5,000 5,154 sigs Through 23.28 4,200 42 Rotary 2 23.27 3,800 3.806 32875 Straightener 23,05, 4,700 4639 3 23.42 4,000 31200 Ave.31,954 "See Tables 1 814 2 for chemical composition and mechanical properties. Duplicate tests for each specimen, *Corrected for 3/t variations per Figures 4 and § 18a,the straightener increased the collapse resistance by about 22 percent. In this case, however, the magnitude of the residual stress was reduced considerably. We do not presently have a concise explanation for the collapse improve- ments described above. Three possible explanations can, however, be offered at this time: (a) Additional passes through the rotary straightener reduce the ovality and thus improve the collapse resistance, (b) Deformation of the casing material as @ result of additional straightening distributes the residual stress more uniformly throughout the circumference and the length of cesing. In this case, the net circumferential residual stress measured by the split-ring method may increase, but the more uniformly distributed stresses would be less detrimental to the collapse resistance. This process appears to be the mechanism for the slight improvement in the collapse resistance noted Table 6. (c) Sufficient plastic deforma- tion of the casing material due to the additional straightening operations would relieve part of the residual stress, thus improving the collapse resistance significantly. This process probably accounts for the 22 percent increase in collapse pressure found for Group III specimens in Table 7. Whatever the actual mechanism or mechanisms may be, the additional straightening operation appears to offer one means of improving the collapse strength of casings. However, a full understanding of the improvement: mechanism involved in the process may await furthur investi- gations. There are, of course, other straightening processes that have much less detrimental effect on the collapse strength than the rotary straightening 19TABLE EFFECT OF CIRCUMFERENTIAL RESIDUAL STRESS ON. ‘THE COLLAPSE STRENGTH OF 7 5/8” ~ 33.7 LBS, N-80 CASINGS (SAMPLE $-220)! Specimen Ave, Collapse Test? Corrected Collapse? _—_—Residual Stress Group! Designa Dh — Prossuro.s Pressure, psig psi 18.06 10,000 10,223 3.570 1—No 1 18.07 10,000 10,227 Straightening 1792 6,700 6826 2 18.12 8,500 8,763 ‘Aw. 9,010 18.37 8,500 M1 Pass i 18.2 7,500 Through 18.44 Rotary 2 18.47 7,300 7804 0 Straightone Ave. 8,155, Ave. 13.945 MI ~ 2 Passos 17.87 10,000 10,090 2.890 Through 1 17.76 8.500 sis 3.540 Rotary 17.97 10,000 10,162 1.180 Straightener 2 17.79 11,000 11.037 3.560 Awe. 5.951 Ave. 2,793 See Tables 1 and 2 for chemical composition and mechanical properties. ' 2Duplicate tests for each specimen. >Corrected for D/t variation per Figures 8 and 9. TABLE 8 EFFECT OF STRAIGHTENING TECHNIQUES ON THE COLLAPSE RESISTANCE OF 7 5/8, 26.4 LBS, N-80 CASINGS, ‘Average Collapse No. of Residual Method of Pressure Data Stress Range Manufacturer ‘Straightening ___psia Points ksi a | Rotary “ Straightening 4,188 6 23:29 B Gog Straightening 4,650 6 173 a Rotary Straightening 4782 32 Not Available e Gag Straightening 5,336 19 Not Available 198processes. Table 8 shows that gag straightened casings have much higher collapse resistance than the rotary straightened casings. In fact, using proper control in the rotary straightening process (Reference 4) can result in a considerable reduction of the residual stress, thus improving the collapse strength. It should be noted again that the minimum API specified collapse pressure for the 7 5/8 0.D., 26.4-pound and 33.7-pound, N-80 casings used in this investigation are 3,400 psi and 6,560 psi, respectively. Thus, even casings with high residual stress can meet the collapse pressure require- ments, VIIT, ECONOMICS OF OBTAINING INCREASED COLLAPSE PERFORMANCE Presently, we have two means of "buying" increased collapse performance, j.e., use of higher strength and use of thicker wall (heavier) casings. Figure 9 shows the collapse strength and cost as a function of the minimum yield strength for 7,0-inch 0,D., 26-1b/ft casings. Note for example that an increase of about 30 percent in collapse performance would require a jump from K-55 to C-95 grade with an accompanying 30 percent increase in cost per foot of casing. Figure 10 shows the collapse performance and cost of 7.0-inch 0.D., N-80 casings as a function of the nominal weight per foot. Comparison of Figures 9 and 10 appears to indicate that an equivalent increase in collapse performance can be obtained cheaper through a change in weight 20} 1 L e at 3 ar ee pp an eee Figure 9 Min'mum cotlapse strength and cost as @ function of the minimum yield strength. (Cost figures have changed since this plot was prepared.) 2ff $ i i Er i Figure 10 Collapse performance and cost of 7-inch 0.0. N-B0 casings asa function of weight per foot. (Cost figures have changed since this plot was prepared.) 2la . .rather than the yield strength. However, the exact choice would probably depend upon casing string requirements other than collapse performance. Either method amounts to substantial increase in cost when additional collapse performance is desirable. On the basis of data presented in this report, we can conclude that fully quenched casings with low (3900 psi) residual stress levels would have minimum collapse strengths 20-30 percent higher than the present minimum API specified collapse strength. Table 9 shows a comparison of the casing string cost for a 16,000-foot Well using casings with API specified minimum collapse strength versus casings with 10 to 30 percent higher minimum collapse strengths. The improved minitum collapse conditions were simulated by reducing the collapse desicn factor in the program by 10 to 30 percent. Note that the use of casings with collapse strengths 39 percent higher than the present API specification could result in a 10 to 20 percent saving in the cost of the casing string when design conditions are controlled by collapse performance. Although all cost figures have increased since this report was written, the argument presented here is still valid and applicable tc the present prices. IX. ANEW METHOD OF COLLAPSE TESTING As pointed owt in the previous section, a significant improvement in casing design efficiency can be realized if fully quenched casings that are free from harmful residual stresses could be produced on an industry- wide scale. The know-how for producing these improved casings is well 22TABLE 9 COMPARISON OF CASING DESIGNS* COST VS MINIMUM COLLAPSE STRENGTH ‘TOTAL COST OF THE STRING ~$** 10% Higher 20% Higher 30% Higher No.of Sections API Spec. _Collpse_ - _Collapse_-_Collapse_ 9 85,700 82,800 : 8 : : 79,300 76,100 a 186,800 184,300 : : 6 : - 80,100 76,400 5 91,100 89,000 : : 4 : : 84,300 80,600 3 94,800 93,600 90,000 84,400 2 107,700 107.500 93,300 85,600 1 110,300 110,300 107,400 92,900 “Design Conditions Casing Size: 7.0" 0D, Setting Depth: 16,000 Ft. Collapse Conditions: External = 0.812 psiftt Intornal = pipe empty Burst Conditions: 6,000 psi surface pressure Exiornal gradient = 0.5 psitt Internal gradient = 05 psifft Tension Design Factor: Pipe = 1.5 Joint = 2.0 Casing Grade Limitations: N-80,C:95, P-110 (LT&BT) Environment Non-sulfide ** Cost Figures have changed 22aestablished and could be put into practice with very minor manufacturing modifications. Attainment of fully quenched rather than slack quenched casings requires better monitoring of steel chemistry and quenching process. Elivination of residual stress can be accomplished by proper control of rotary straightening operation (Reference 4) or additional rotary straightening. These collapse improvement techniques are practiced by a few casing manufacturers. This is partly due to the lack of awareness by the users to utilize casings with improved collapse performance and partly due to the difficulties encountered in the mill monitoring of the collapse properties of casings. AN] of the presently used collapse testing methods require that a specimen of certain length be prepared froma representative joint of casing and tested in a collapse chanber such as that shown in Figure 3. This process is time consuming, expensive, and destructive, thus unsuitable for a mill quality control. In conducting the present investigation, : some thought was, given to the development of an improved collapse test- ing method which overcame these difficulties. Figure 11 shows schematically the arrangement proposed for such a collapse testing system. The apparatus shown in Figure 11 can be clamped to the casing and exert uniform external pressure over length of casing equal to 1-3 times its diameter. The viability of this system was evaluated through the use of a conmercially available unit which is similar in construction to our proposed portable collapse tester. Table 10 shows the preliminary collapse data obtained by this “closed end" test method compared to data generated by the API Standard 5C2 open end collapse test method (Figure 3). The gage length of the tester 23fr CASING fe SPLIT STEEL CASE WITH LOCKING JAWS A—— RELEASE PRESSURE PRESSURE GAGE SPLIT PACKER To PRESSURE SYSTEM 4 Figure 1} Schematic drawing of the portable collapse tester. * 24TABLE 10 COMPARISON OF DATA FROM PORTABLE COLLAPSE. ‘TESTER AND API 5C2 OPEN ENO TEST METHOD, COLLAPSE PRE Sample Portable Collapse Corrected Portable ‘API 5C2 — Open Designation Tester (1/0 » 1.5) Lollapse Tester! End Tests (L/D = 4:5) 7.0", 29 tbs Restricted Yield n-80 5.2151 9,700 7980 . 7.20 : : 7800 S-215:2 9,400 7.710 8,780 9,600 7570 8,460 75/8", 26.4 tos Conteoited Yield Ngo $2191 7.300 4820 4,400 7.100 4700 4°30 $2192 71650 8,950 4'500 7/800 5,150 41500 s2193 7'360 5,180 5,000 7'700 5.080 5,000 "Estimated correction factors obtained from Figure 2: . ' For Sample $215 (D/t = 17.16), the L/D. change by a factor of 3 in closed-end tests vequires an 18% reduction in the collapse pressure. For Sample $-219 {D/t = 23.25), the L/D change by a factor of 3 in closed-end tests requires @ 34% reduc tion in the collapse pressure. ahaused in this investigation was 11 inches, resulting in a length to diameter ratio (L/D) of about 1.5 for the casings used in the tests. Therefore, as expected the collapse pressures obtained in this apparatus were much higher than those obtained by the API open-end method with L/D = 3. Hewever, when these values were corrected (Colunn 3 of Table 10) for the difference in the collapse length, by using the data in Figure 2, a reasonable agreement with the API test method is obtained. Obviously, more comparative tests using the portable collapse tester are required te establish the practical reliability of this system. The proposed test technique offers several advantages relative to the presently used test metliods shown in Figure 3, The method does not require the use of a prefabricated test sample. Thus, collapse tests can be conducted in the production line, saving the time and added cost of sample fabrication. Also, the collapse strength of the casings can be evaluated nondestructively by testing the casing to a minimum collapse requirement or test pressure setting. X. SUMMARY AND CONCLUSIONS The effect of slack quenching and circumferential residual stresses on the collapse performance of casings is reviewed in this paper. The collapse pressure of a fully quenched casing is 10-40 percent higher than the svack quenched casing, depending onthe slack quenching severity. Tensile circumferential residual stresses of 20-30 ksi magnitude due to rotary straightening found in most casings reduce their collapse strength by 10-40 percent. On the basis of our investigation, we estimate that 25fully quenched casings without harmful residual stresses would have minimum collapse properties 20-30 percent higher than the present API minimum collapse strengths. The know-how for commercial production of this type of casings is presently available ‘but is not used by all the casing manufacturers. . Our investigation indicates that the present API collapse requirements are based on the lower bound collapse performance data obtained from casings of different manufacturing backgrounds, including rotary straightened and slack quenched casings. Thus, the API minimum collapse requirements are based on the collapse performance of the worst quality casing that could have been produced at the time the specifications were established rather than any inherent collapse performance of the casings. Our investigation shows that severely slack quenched casings which had high circumferential residual stresses were able to meet the API collapse requirement. Thus, use of the API collapse specifications plus a safety factor in the design of casing strings have resulted in extremely conservative and costly collapse designs. We suggest the present API collapse specification be revised to reflect the collapse performance of the type of casings which could be manufactured by the present improved mill practices. In this report we have attempted,to outline two manufacturing parameters, j.e., slack quenching and residual stresses, which, if properly controlled, can improve the collapse performance of casings by 30 percent. Hardness checks and slit-ring tests can be used as quality control tools for monitoring these parameters. An improved method of collapse testing is also proposed. %XL. REFERENCES "Comparison of Casing Collapse Test Methods", by U. J. Arbter, et.al., A. 0. Smith Corporation, Milwaukee, Wisconsin, "casing Setting Depths Are Not Assured by Physical Properties of the Steel", W. M. Frame, Drilling and Production Practice API, 1939, p. 322. "Internal Pressure Design of Casing and Tubing Strings", L. C. Eichenberger and T. V. Miller, ASME Paper No. 72-PET-21, ASME Petroleum Mechanical Engineering and Pressure Vessels and Piping Conference, New Orleans, Louisiana, September 17-21, 1973. "Stress Effects of Rotary Straightening on Collapse Resistance of High Strength Casing", R. E. Zinkham, ASME Paper No. 57-PET-6, ASME Petroleum Mechanical Engineering Conference, Tulsa, Oklahona, September 22-25, 1957. a7