Production Casing Design Considerations
Production Casing Design Considerations
Production Casing Design Considerations
Agenda
Introduction Casing Design Factors Casing Design Loads Pipe Performance Materials Selection Casing Connections Stimulation
NYSE: DVN
www.devonenergy.com
page 2
Introduction
Ensure the wells mechanical integrity. Optimize well costs. Provide operations personnel with maximum allowable loads.
NYSE: DVN
www.devonenergy.com
page 4
Directional plans Cement program Temperature profiles Base frack fluid, proppant type, and max proppant concentration Max anticipated frack surface pressure Produced fluid composition
NYSE: DVN
www.devonenergy.com
page 5
Load Cases
Dividing the pipe rating by a corresponding load results in a design factor. If the design factor is greater than the minimum acceptable design factor, then the pipe is acceptable for use with that load.
DF
DFmin
NYSE: DVN
www.devonenergy.com
page 7
Collapse
Tension Compression Von Mises Triaxial
1.1
1.4 1.2 1.25 Based on yield strength
NYSE: DVN
www.devonenergy.com
page 8
.002 0.2%
.005 0.5%
NYSE: DVN
www.devonenergy.com
page 9
Tubing Leak
This load case represents a high surface pressure on top of the completion fluid created by a tubing leak near the surface. Surface pressure is based on a gas gradient extending upward from the reservoir. Tubing leaks are evaluated with both static and flowing temperature profiles.
NYSE: DVN
www.devonenergy.com
page 11
Fluid gradient
This load case applies to wells that experience high pressure injection operations such as a fracing down casing. The load case models a surface pressure applied to a static fluid column. This is analogous to a screen-out during a frac job.
NYSE: DVN
www.devonenergy.com
page 12
Mud gradient Mix water gradient Pore pressure profile External Casing Pressure
NYSE: DVN
www.devonenergy.com
page 13
It assumes zero pressure on the inside of the pipe (such as fill over perfs and the well pressure blown down).
The external pressure used is the mud gradient from surface to the casing bottom.
NYSE: DVN
www.devonenergy.com
page 14
Pipe Performance
Per API the calculated number is rounded to the nearest 10 psi. The 0.875 factor represents the allowable manufacturers tolerance of minus 12.5% on wall thickness per API specifications.
NYSE: DVN
www.devonenergy.com
page 16
NYSE: DVN
www.devonenergy.com
page 17
Is based on four different equations based on the D/t ratio and the yield strength of the pipe Plastic collapse is based on a statistical regression analysis on empirical data from 2488 tests More information is in API Bulletin 5C3
NYSE: DVN
www.devonenergy.com
page 18
Axial strength of pipe body is calculated from the formula below: Fy = (/4) * (D2 d2) Yp Fy = Tension strength (lbs. rounded to the nearest 1,000) Yp = Yield strength of pipe ( psi) D = OD of pipe (inches) d = ID of pipe (inches)
NYSE: DVN
www.devonenergy.com
page 19
Calculations for joint strength of different API connections is found in API Bulletin 5C3. Joint strength of API connections is based on the ultimate strength and not the yield strength. Most (but not all) premium or proprietary connections are based on the yield strength of the connection.
NYSE: DVN
www.devonenergy.com
page 20
Materials Selection
NYSE: DVN
www.devonenergy.com
page 22
Mechanical Properties
NYSE: DVN
www.devonenergy.com
page 23
Chemical Requirements
NYSE: DVN
www.devonenergy.com
page 24
H2S exceeds 0.05 psia partial pressure Partial pressure = (ppm H2S)*(well pressure)/1,000,000 Total pressure exceeds 65 psia for a gas well or 265 psi for an oil well
NYSE: DVN
www.devonenergy.com
page 25
NYSE: DVN
www.devonenergy.com
page 26
Casing Connections
Connections
Connections represent less than 3% of the pipe length More than 90% of pipe failures occur in the connection Connections represent 10%-50% of the total tubular costs
NYSE: DVN
www.devonenergy.com
page 28
API Connections
STC 8 threads per inch Threads have rounded crests and roots LTC 8 threads per inch Threads have rounded crests and roots Thread section is longer so has better sealability and tensile strength than STC
NYSE: DVN
www.devonenergy.com
page 29
API Connections
Buttress 5 threads per inch Not symmetric for the load and stab flanks
NYSE: DVN
www.devonenergy.com
page 30
NYSE: DVN
www.devonenergy.com
page 31
NYSE: DVN
www.devonenergy.com
page 32
NYSE: DVN
www.devonenergy.com
page 33
Most (but not all) premium connections are based on yield strength
NYSE: DVN
www.devonenergy.com
page 34
Stimulation
Stimulation Considerations
NYSE: DVN
www.devonenergy.com
page 36
Thank You.
01.00.08
01.00.08 The other internal yield pressure case is injection down casing such as during a hydraulic fracture stimulation. The internal pressure is modeled by the applied surface pressure and the fluid gradient based on the fluid being pumped. This is analogous to a hydraulic fracture screenout downhole since fluid friction down the casing is not subtracted from the internal pressure profile. The external casing pressure profile is modeled with the mud gradient from surface to the top of cement. Then the gradient from the cement mix water from that point to the outer casing shoe. From the outer casing shoe to total depth (TD), the external pressure profile is the pore pressure profile. Production casing collapse loads assumes zero pressure on the inside of the pipe and a final mud weight gradient on the outside of the casing. Rated internal yield pressure of casing is calculated using the Barlow Equation below: P = 0.875 * [2*Yp*T]/D P= internal yield pressure or burst strength (psi) Yp = yield strength of the pipe (example P110 is 110,000 psi) T = nominal wall thickness (inches) D = nominal outer diameter of pipe (inches)
Per API, the calculated number is rounded to the nearest 10 psi. The 0.875 factor in the above equation represents the allowable manufacturers tolerance of minus 12.5% on wall thickness per API specifications. Collapse ratings on API tubulars are derived from four different equations based on the outside diameter / thickness ratio and the yield strength of the pipe. Axial strength of the pipe body is calculated from the formula below: Fy = (/4) * (D2 d2) Yp Fy = tension strength (lbs. rounded to the nearest 1,000) Yp = yield strength of pipe ( psi) D = OD of pipe (inches) d = ID of pipe (inches)
Calculations for joint strength can be found in API bulletin 5C3. Published joint strength of API connections is based on the ultimate strength of the pipe and not the yield strength. Most, but not all premium connections are based on the yield strength of the connection. API Spec 5CT is the Specification for Casing and Tubing. The different grades of API pipe specify a minimum and maximum yield strength. A maximum hardness is also specified from grades designed for sour service.
01.00.08 The chemical composition of the different grades of API casing is also specified. Grades designed to work in sour service have more stringent chemical requirements. Sour service is defined by the National Association of Corrosion Engineers or NACE, as an environment where the partial pressure of H2S exceed 0.05 psia. The total pressure must also exceed 65 psia for a gas well and 265 psia for an oil well. The NACE standard MR0175 and the ISO standard 15156 specify material to be used in sour service. In summary, API casing grades H40, J55, K55, M65, L80, C90 and T95 are good for all temperatures. N80 is good above 150 degrees F, P110 is good above 175 degrees F and Q125 is good above 225 degrees F. Casing connections represent less than 3% of the pipe length yet account for more than 90% of pipe failures. Also, the connection represents 10% to 50% of the total tubular cost. API connections STC (short thread and coupled) and LTC (long thread and coupled) each have 8 threads per inch and have rounded crests and roots. On LTC, the tread section is longer so it will have better sealability and tensile strength than STC. A buttress connection is another API connection that has 5 threads per inch. It is not symmetric for the load and stab flanks. There are several types of premium connections available, but most fall into one of the following categories: A metal to metal seal thread and coupled connection generally has the internal yield, collapse, and tension ratings equal to the pipe body. An integral joint connection has half the leak paths of thread and coupled connections. Also, the connection outer diameter (OD) is significantly smaller than a coupled connection. It also features a metal to metal seal. The joint strength of an integral joint connection is usually 70 to 80% of the pipe body. A flush joint connection is approximately the same OD as the pipe body. Its joint strength is usually only 45 to 60 % of the pipe body strength in tension. Prior to the hydraulic fracturing of a well, the maximum allowable surface fracture pressure must be calculated. The fluid gradients inside and outside the pipe are needed to make this calculation. Not only must the burst (internal yield) pressure of the pipe be considered when making this calculation but also the effect of the internal hydraulic fracturing pressure and hydraulic fracture injection rate on tension. The internal pressure during the hydraulic fracture causes a ballooning effect on the production casing that adds to the tension load. During the fracture, the production casing is cooled2 by the injection of fracture fluids, which also adds to
Fracture fluids stored at the surface will be near surface temperature, which is generally a much cooler temperature than the bottom hole temperature.
2
01.00.08 the tension load of the production casing. These additional tension loads must be taken into consideration when determining the maximum allowable hydraulic fracture pressure.