5-1 13 3/8" Surface casing design:

Surface casing 13 3/8 will be set at 3297 ft.

The following date will be used to design the casing.
Fracture gradient at 3297 ft 0.55 psi/ft 10.5 ppg.
Formation fluid density 0.451 psi/ft 8.67 ppg.
Mud weight when casing run 0.447 psi/ft 8.8 ppg.
Gas gradient expected 0.115 psi/ft.
Design factor DF Burst 1.1
Design factor 1.1
Design factor 1.95
MOP = Mix Over pull 100000 LB over pulls.

Casing availability: -

Wt Burst Collapse Tension 1000lb Body yield

Grade ID (in)
(lb/ft) (psi) (psi) (STC*1000) BTC 1000 lbs
K55 54.5 12.615 27.30 1130 547 1038 8.53
K55 61 12.515 3090 1540 595 962
N80 68 12.415 3450 2270 718 1.550
N80 72 12.347 5380 2670 1040 1693 1661
N80 98 11.937 6270 5910 2296 2144
C95 72 12.347 6390 2870 1204 1973
Table (5-1)

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 5.1.1 Burst loading:
Injection pressure = FG/constant + DF L constant
Injection pressure =
Fracture gradient / 0.052 + 1 Depth 0.052
=(0.55/ 0.052 + 1) 3297 0.052 = 1985 psi
Surface pressure = 1985 (3297 0.115) = 1606 psi
Back up pressure at 3297 ft =
3297 0.052 8.67 = 1486 psi

5.1.1- Burst loads summary:

Internal Back-up
Depth Resultant Design loading
load loading
(ft) (lb) *1.1
(lb) (lb)
0 1606 0 1606 1767

3297 1985 1486 499 549

Table (5-2)

The design loading can now be plotted on a pressure depth

graph as shown in chart (5 - A).

5.1.2 - Collapse loading:

Collapse pressure originates from the column of mud used to drill

the hole, and acts on the out side of casing. It will be highest at
the bottom and zero at the top due to mud hydrostatic pressure
effect from out side, and the inside of casing will be empty.
Maximum hydrostatic load due to mud
= 0.052 8.6 3297 =1509 psi.

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 Summary of collapse loads: -

External Back-up Resultant, Design

Depth, (ft)
loading, (lb) loading, (lb) (lb) loading *1.1
0 0 0 0 0

3297 1509 0 1509 1660

Table (5-3)

The design load can be also plotted on pressure depth graph as

shown in chart (5-B)

Choice of casing: -

Based on the design loading lines for both burst and collapse the
following string can be chosen.

Preliminary design

0 3297 ft N80 68 lb/ ft

NOTICE: The design should be kept as simple as possible.

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 5.1.3 -Tension loading: -

W = 3297 * 68 = 224196 lb
Casing design has to be simple as possible

F=P*A
Where: -
P = 0.052 *8.8 * 3 297 = 1509 PSI
A = / 4 (13.375 ^ 2 12.415 ^ 2) = 19.445 in^2
F = 1509 *19.445 = 29342 Lb

Tensile loading at each depth can now be calculated drill string

design: -
Tension, Over pull 100000, Apply DF *1.95,
Casing, (lb/ft) Depth, (ft)
(lb) (lb) (LB)
0 194854 294854 379965

N 80 68 3297 - 29342 70658

Table (5-4)

This information can be plotted as a graph as shown in chart (5-C).

It can be seen that the pipe body yield strength of the chosen casings
exceeds the tension design lines .STC couplings will allow efficient
join strength.

Where: -
F = 29342, W F = 194854

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 5.1.4 - Check axial Effects: -
Used the actual tension figures the reduction in collapse resistance should be calculate.

Casing, Depth, Tension, Pipe De-ratted

(lb/ft) (ft) (lb) yield, (lb) X Y collapse, psi
0 194854 1550000 0.125 0.925 2100

N80 68 3297 -29342 0.019 0.99 2270

Table (5-5)

X = axial load factor = Tension load / Body strength

X1= 194854 /1550000 = 0.125 Y = 0.925

X2= -29341/155000 = 0.0189 Y= 0.99

Where:-
X = axial load factor
Y =collapse strength rating factor

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 5.2 9 5/8" Design of Intermediate Casing:
5.2.1 Burst Conditions: -

The worst case is where Kick occurs while drilling below the
intermediate casing shoe, filling the string with both gas and
mud.
There are three conditions to be considered for burst loading:-
Kick pressure from gas and mud.
Injection pressure at casing shoe.
Maximum surface pressure at top of casing.

These three pressures can be expressed mathematically in the

relation ship: -
Ps + X (GM) + Y (Gg) =IP
Where: -
Ps = maximum surface pressure (usually BOP rating) 5000 psi.
X = Length of mud column, (Ft).
GM = Mud gradient (heaviest mud used below shoe),(PPG ).
Y = Length of gas column, (Ft).
Gg = Gas gradient, (psi /ft)
IP = Injection pressure, (psi).

Casing availability:

Tension, 1000
WT Burst, Collapse Body yield
Grade ID, inch (STC LBS
(lb/ft) (psi) (psi) 1000 lbs
*1000) BTS
N 80 43.5 8.755 4350 3250 1074 776 691
N 80 43.5 8.755 6330 3810 1074 825 1005
N 80 47 8.681 6870 4760 1161 905 1080
C 95 53.5 8.535 9410 7330 1458 1220 1477
P110 43.5 8.755 8700 4430 1388 1106 1381
P110 47 8.681 9440 5310 1500 1213 1491

Table (5 -7)

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 5.2.1 - Design will used the following data: -
9 5/8 casing setting depth 8857 ft.
Max- surface pressure BOP 5000 psi .
Facture gradient at shoe 0.702 psi/ft. 13.5 ppg.
Gas gradient expected 0.115 psi/ft. 2.2 ppg.
Formation fluid density 0.47 psi/ft. 9 ppg.
Mud weight when casing run 0.494 psi/ft. 9.5 ppg.
D.F Burst 1.1
D.F Collapse 1.1
D.F Tension 1.6 * 100000 LBS
Injection pressure = {(fracture gradient at shoe /0.052) + DF)}*
0.052 * casing setting depth.
I.P = {(0.702/0.052) + 1} * 0.052 *8857=6678 Psi
Back- up pressure due Formation fluid = 0.052 * 9 * 8857 = 4145
psi
Ps + (GM) x + (Gg) y = IP
Surface pressure + mud press pressure + gas pressure = pressure
at shoe
5000 + 0.494 x + 0. 115 y = 6678 1
X + y = 8857 2
Y = 8857 x
X = 1741 ft
0.494 x + 0.115 y = 1678
(0.494 * 1741) + 0.115 = 1678
860 + 0.115 y = 1678
0.115 y =818
Y = 7113 ft
X + y = 1741 + 7113 = 8854 ft
8854 *0.115 = 1018 psi
1678 1018 = 660 psi
660/0.45 = 1467 ft (mud column)
8854 1467 = 7387 ft (gas column)
The column he hydrostatic pressure due the gas column * gas
gradient.
The hydrostatic pressure due the gas=7387* 0.115 = 850 psi

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 The hydrostatic pressure due the mud = 1467 * 0.494 = 725 PSI
TOTAL = 850 +725 =1575 PSI.

Surface pressure = 6678 (8857 *0.115) =5659 psi

Back-up pressure due to formation = 1467 * 9 * 0.052= 687 psi
8857 * 9 * 0.052 = 4145 psi
3000 * 9 * 0.052 = 1404 psi
8857 40 = 8817 psi
8817 1467 7350 ft
3000 1467 = 1533 ft
1467 * 905 * 0.052 = 725 psi
7350 *0.115 = 176 psi
901 + 5000 = 5901 psi
5000 + 725 = 5725 psi
5725 + 845 = 6570 psi

Back-up
Internal Resultant, Design
Depth, (ft) External,
load, (psi) (psi) loading * 1.1
(psi)
0 5000 0 5000 5500
3000 5901 1404 4497 4947
8857 6570 4145 2425 2668
Table (5-8)

Burst loading plotted as shown in the chart (5 -D)

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 5.2.2 Collapse loading: -

Cement weight (lead = 12.5 ppg) (tail = 15.8 ppg)

8875 500 = 8357 ft
8357 * 12.5 * 0.052 = 5432 psi
500 8 15.8 8 0.052 = 411 psi
External pressure due to the cement = 5432 + 411= 5843 psi
Back - up pressure due to mud=8357*9.5* 0.052 = 4128 psi

8857*9.5*0.052= 4375 psi

External Design
Back _ up Resultant ,
Depth, Ft pressure, loading 1.1,
Internal, psi psi
psi psi
0 0 0 0 0
8357 5432 4128 1304 1434
8857 5843 4375 1468 1615
Table (5 9 )

Collapse loading plotted as shown in the chart (5 -E).

From the plots and calculation for burst and collapse and available
casing the following combination was selected: -

Preliminary design:

0 3000 N80 43.5 lb/ft

3000 8857 N80 47 lb/ft

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73 Casing Design Correction for Well (w5-8) in wafa field
2003-2004