03 - Basic Well Design

CASING DETAILS
HOLE SIZES
Conductor (Pre-Driven)
30-inch 320 #/Ft Casing
Basic Well Design

Intermediate Casing
20-inch 94 #/Ft K-55 BTC 26-inch HOLE 800' TVD
Drilling Liner 1
13-3/8 inch 68.0 #/Ft L-80 VAM TOP
Tie Back 1
13-3/8 inch 68.0 #/Ft L-80 VAM TOP 17-1/2 inch HOLE 2600' MD
Perforated Liner 1
10-3/4 inch 45.5 #/Ft L-80 TC-II 12-1/4 inch HOLE 8000' MD
Perforated Liner 2
8-5/8 inch 24.0 #/Ft K-55 BTC 9-7/8 inch HOLE 10000' MD
Perforated Liner 3
7 inch 23.0 #/Ft K-55 BTC 7-7/8 inch CONTINGENCY HOLE
Tie Back 2
10-3/4 inch 45.5 #/Ft L-80 TC-II
WELL DESIGN
Topic Outline
 Well Design Objective
 Formation Parameters
• Definition of Hydrostatic Pressure

• Formation Pressure Concepts
• Rock Strength Determination
 Casing Depth Determination
 Casing String Design Objectives
 Wellhead and Casing Design Criteria
2
Well Design Objective
Contain and Control!

 Being able to contain the formation pressures and
temperatures at any drilling and operating condition of the
well.
 Being able to fully control the flow of the reservoir fluid.
Drill and construct wells with a 30-year operating life

expectancy
3
Topic Outline

4
Hydrostatic Pressure Definition
The force felt downward is still 3 lbs

but it is felt over a total surface area
of 1 square inch.
1 lb
Force = 3 lbs = 3 psi
Area 1 sq. in.
1 lb
1 lb
1”
1”
1
3
2
0 lb
5
Hydrostatic pressure is the pressure exerted due to the weight
of the fluid.
Phydrostatic = r x h x (1/144)
where Phydrostatic = hydrostatic pressure (psi)

r = density (lbs/ft3)
h = fluid height (ft)
6
In Oilfield nomenclature and units:
HP = hydrostatic pressure (psi), Phydrostatic,
FW = Fluid Weight (lbs/gal or ppg), r
TVD = True Vertical Depth (ft), h
Therefore from:
Phydrostatic = r x h x (1/144)
to:
HP = FW x TVD x (1/144) x 7.48 gal/ft3

or:
HP = FW x TVD x 0.052
7
TVD vs MD
Because fluid density is a function

of gravitational force and gravity
is a vertical component, the
bottomhole hydrostatic pressure
is the sum of all the vertical
components.
The sketch of a slant hole helps
us see why this is true. It shows 10’
that the mud column can be
thought of as a stack of blocks, 11’
with the weight of each block
pushing vertically downward on
those underneath it.
From this, we see that it is the

vertical height (or depth) of a mud
column, not its measured length,
that must be used in pressure
calculations.
8
Formation Pore Pressure and Effective
Confining Pressure Concepts
Origin of Pore Pressures
 All rocks in nature are under stresses. Beside tectonic stresses. Rocks
are under a compressive stress that comes from the weight of the
overlying strata.
 This stress is what brings about the development of formation pore
pressure
Overburden Pressure
 Pressure created by the weight of the overlying rocks and fluids is
called overburden pressure.
Formation Pore Pressure

 Overburden pressure may be divided into two components:
• The pressure of the fluid in the rocks = Formation Pore Pressure

• The portion of overburden pressure borne by the rock matrix =
Effective Confining Pressure (Effective Stress)
9
Formation Pore Pressure Concept
Effective Confining Pressure
 This is the pressure that forces the grains of the rock matrix together,
compacting the rock.
 This pressure largely controls the physical properties of the rock.

 Formation pressures approach a hydrostatic or water gradient in
normally pressured rocks.
 NORMAL PRESSURE GRADIENT
• The hydrostatic pressure gradient in a column of fresh water at
standard conditions is 0.433 psi/ft
• The presence of salts and the compression of fluids at high
pressure can increase the gradient to about 0.465 psi/ft
• Both are considered Normal Pressure Gradient.
10
Formation Pore Pressure Concept
 ABNORMAL PRESSURE
• The formation pressure is considered ABNORMAL when it is significantly
greater than normal (i.e., >0.433 psi/ft)
• This phenomenon may be caused by:
– Compaction:
Water expands with increasing depth and temperature. However, the
pore space in the rock tends to decrease with with increasing depth
(due to increasing geostatic loads)
– Trapped Fluid
Fluid trapped by a pressure seal
 SUBNORMAL PRESSURE
• The formation pressure is considered SUBNORMAL when it is significantly
below the normal.
• Subnormal formation pressures can reduce the hydraulic pressure required
to fracture a rock.
• The presence of subnormally pressured rocks often creates lost circulation
problems in drilling wells.
11
Fracture Pressure Concept
When hydraulic pressure is applied to a borehole, subsurface rocks may
fracture.
The pressure at which this occurs is called breakdown pressure or

fracture pressure.
Fracture pressure is an important consideration for selecting casing

seats.
A knowledge of the pressure at which formation fracture will occur at all

depths in the well is essential for well design and actual drilling.
There are various methods for estimating/predicting fracture pressure

and most of them are empirical or semi-empirical in nature (i.e., Eaton
Correlation, Hubbert and Willis Equation, etc.)
Most commonly, fracture pressures are estimated using offset Leakoff

Test data.
12
Leakoff Test
 A Leakoff Test (LOT) is a test that determines the pressure at which the
rock, at a certain depth, fractures.
 An LOT is done after a casing string is cemented in place, just before the
drilling of the next hole section is started.
• The next BHA is ran in the hole and drills out the cement left inside the
casing after the casing cementing job.
• It continues to drill out the casing shoe and a few feet (~5ft) past the
shoe, into the fresh formation.
• Before drilling is continued, the drilling fluid is conditioned so as to
ensure that the mud weight is uniform. Then the pipe ram and/or the
annular is closed and pressure is applied in the hole by pumping into
the well at a low, constant rate.
• Pressure may be applied to the drillstring but if the pressure drop
through the drillstring is significant, pressure may be applied through
the back side (i.e., the annulus between the casing and the drillstring).
• Pumping is continued until the rock fractures and begins to take mud,
causing a departure from the increasing pressure trend.
• The stabilized fracture pressure is then recorded after the pressure is
allowed to level off with time, with the pump still pumping at the same
constant rate.
13
Leakoff Test
Leak Off Test Example

700 2
600 Breakdown Pressure

Stabilized Injection Pressure
1.5
500
Pump Rate (bbl/min )

Pressure (Psig)
Instantaneous Shut
400 In Pressure
1
Closure Pressure
300
200
0.5
100
0 0
0 5 10 15 20 25 30 35 40
Time
Ref. LOT Procedure Document by Bob Swanson
14
Leakoff Test
Calculation of the Fracture Gradient from the LOT:
 FG (psi/ft) = [SIP +(TVD-GH) x MW x 0.052)]
(TVD - KB)
Where:
SIP = Stabilized Injection Pressure (psi)
TVD = True Vertical Depth (ft)
GH = Pump Pressure Gauge Height (ft)
MW = Mud Weight (lb/gal or ppg)
KB = Kelly Bushing Height (ft)
15
Leakoff Test
 The LOT data from offset wells can be used to verify the
selected depth at which each of the casing strings is planned
to be set.
 In sedimentary basins, the fracture gradient increases with
depth.
 In geothermal environment, the fracture gradient tends to
decrease with depth.
 Typical Geothermal Fracture Gradient Values*
Vertical Depth (ft) Fracture Gradient (psi/ft)
0 - 500 0.70
500 – 2,000 0.65
2,000 – 4,000 0.60
4,000 - TD 0.50
------------------------------------------------------
*Based on Salak, Bulalo, Tiwi, Sarulla and Salton Sea data

Ref. Unocal Geothermal Well Design Guidelines by Bob Swanson.
16
Topic Outline

17
Determining Casing Shoe Depths
The Fracture Gradient values from the offset LOT data can then be used to do a Well
Kick Simulation and come up with the recommended casing shoe depths for each of the
casing strings.
The Well Kick Simulation starts by setting the depth of the surface casing usually at a
depth where groundwater sources are isolated and yet doesn’t reach any zones of
potential flow (remember, there is no BOP installed in the well yet at this time).
Usually, for geothermal wells, the depth of the surface casing is set between 300’-350’.
Given the depth of the surface casing shoe, the next step is to determine (through a well
kick simulation) the maximum depth at which we could drill the intermediate hole
section without fracturing the surface casing shoe. This is called a “Design Down”
simulation. This simulation requires the following data input:
 Mud Weight used to drill the Intermediate hole section
 Fracture Gradient at the Shoe of the Surface casing
 Formation Pressure
 Kick Tolerance (volume and kick density)
 Gas Gradient
 Hole Size and Size of Drillpipe used
18
CASING SHOE DEPTH SIMULATOR

CASE 1: Surface Casing Design Down to
Determine Maximum Drill Depth of the
Intermediate Hole
30" Surface Casing Shoe (Initially Set at 300' TVD)
Design down
Inputs: MW
Formation Pressure
Frac Gradient at the shoe
Kick Tolerance (volume, density)
Gas Gradient
Drill Pipe Size
Hole Size
Output: Maximum Depth that could be drilled without

fracturing the shoe of the surface casing
19
The intermediate casing, at the same time, should be able to contain the
conditions while drilling to the target depth of the liner hole section.
The next step is therefore to do a “Design Up” simulation to determine what

will be the shallowest depth that the intermediate casing can be set to be
able to contain the conditions of drilling to the target depth of the liner hole
section (usually at the top of the reservoir).
This simulation requires the following data input:
 Mud Weight used to drill the liner hole section
 Fracture Gradient at the Shoe of the Intermediate Casing
 Formation Pressure
 Kick Tolerance (volume and kick density)
 Gas Gradient
 Size of Drillpipe used
20
CASING SHOE DEPTH SIMULATOR
CASE 1: Surface Casing Design Down to CASE 2: Design Up
Determine Maximum Drill Depth of the To determine the Minimum Depth
Intermediate Hole of the Intermediate Hole
30" Surface Casing Shoe (Initially Set at 300' TVD)

Design down
Inputs: MW
Formation Pressure
Frac Gradient at the shoe
Kick Tolerance (volume, density)
Gas Gradient
Drill Pipe Size = 5"
Hole Size = 17-1/2" Output: Shallowest Depth where
the Intermediate Casing
can be set
Design Up
Inputs: MW
Output: Maximum Depth that could be drilled without Formation Pressure
fracturing the shoe of the surface casing Frac Gradient at the shoe
Kick Tolerance
Gas Gradient
Drill Pipe Size = 5"
Hole Size = 17-1/2"
Depth of the Liner Hole at 3000' TVD

(Usually determined from Offset Well
Data, Identifying Top of the Reservoir)
21
Casing Seat Selection
Top - Down (Conservative)
Form’ PP /
s FG Trip Margin
 Generally 0.3 - 0.5
ppg over PP
 On Deep Wells may

switch to 150 - 200
psi over PP
Safety Margin
ppg under FG
 Kick Tolerance
Mud Wt (ppg)
Form’ PP /
s FG Trip Margin
ppg over PP

switch to 150 - 200
psi over PP
Safety Margin
ppg under FG
 Kick Tolerance
Mud Wt (ppg)
Form’ PP /
s FG1 Trip Margin
ppg over PP

switch to 150 - 200
psi over PP
Safety Margin
ppg under FG
 Kick Tolerance
Mud Wt (ppg)
Form’ PP /
s FG1 Trip Margin
ppg over PP

switch to 150 - 200
psi over PP
Safety Margin
2
ppg under FG
 Kick Tolerance
Mud Wt (ppg)
Form’ PP /
s FG1 Trip Margin
ppg over PP

switch to 150 - 200
psi over PP
Safety Margin
2
3
ppg under FG
 Kick Tolerance
Mud Wt (ppg)
Bottom - Up (Known Area)
Form’ PP /
s FG Trip Margin
3
ppg over PP

switch to 150 - 200
psi over PP
2
Safety Margin
1
ppg under FG
 Kick Tolerance
Mud Wt (ppg)
Additional Considerations
Differential Sticking - Straight Holes
 2000-2200 psi for normally pressured zones
 2200-2400 psi for abnormally pressured zones,

Conventional Fluid Loss
 >2400 psi for abnormally pressured zones,

Upgraded Fluid Loss required
Formation Considerations
 Weak zones, reactive shales
Government Regulations
Topic Outline

 Casing Depth Selection
29
Casing String Design Objectives
30
• Drill 26” hole to 800 ft.
• Run and Cement 20” Casing.
800’
800’
• Drill 17-1/2” hole to 2500 ft.

• Run and cement 13-3/8”
liner
• Run and cement 13-3/8”
2,500’ tie-back
800’
2,500’
• Drill 12-1/4” hole to 6500 ft.

• Run pre-perforated 10-3/4” liner
6,500’
800’
2,500’
6,500’
• Drill 9-7/8” hole to 10,000 ft.

• Run pre-perforated 8-5/8” liner
10,000’
800’
• Run and cement 10-

3/4” tie-back
2,500’
6,500’
10,000’
26” Hole
20” Casing
800’
17-1/2” Hole
2,500’ 13-3/8” Casing
12-1/4” Hole
6,500’ 10-3/4” Casing
9-7/8” Hole
10,000’ 8-5/8” Casing

37
30-inch Conductor Casing
 To provide a means to circulate drilling fluid and cuttings

to the flow line while drilling the 26” hole.
Conductor Pipe Options
 Shallow Cemented Conductors
• Set with a back hoe or auger from 20 ft to 50 ft.
 Driven Conductors
• Driven from 50 ft to more than 150 ft.
38
39
20-inch Intermediate Casing
 To provide adequate well control while drilling to the

desired depth of the 17-1/2” hole.
 A secondary objective that goes into the casing point

selection of the 20” intermediate casing is to be able to
improve the chance of achieving a quality cement job in
the 13-3/8 inch liner, the primary pressure containment
string of the well.
40
41
13-3/8-inch Drilling Liner
To serve as the primary well control casing string of the

well -- to contain all pressures encountered during drilling,
completion and production phases of the well.
 Adequate fracture pressure at the shoe - setting the

casing string within the clay-rich formation at the top of
the reservoir
• consistent hydrothermal alteration signature that
indicates top of the geothermal reservoir
 Ensure quality liner cement job around the liner shoe to

attain proper zonal isolation.
42
43
13-3/8-inch Tie-Back
 To provide pressure containment while drilling the well

to the planned TD.
44
45
10-3/4”, 8-5/8” and 7” Perforated Liners
 To provide mechanical support to the production

interval of the well and allow geothermal production
fluids to enter the wellbore.
The selection of the casing points of these strings would

mainly depend on the actual drilling conditions. These
liners shall be set in order to put behind pipe any
unstable formation and to reduce torque due to long
open sections.
46
47
10-3/4 inch Tieback
 Provide pressure containment for both the maximum

shut-in pressure and maximum production pressure (at
saturation temperature).
 Cover the 13-3/8” liner lap, thus, avoiding the risk of

future lap leaks during the service life of the well.
 Install a new pipe that is not subjected to any drilling

mechanical action, thus, ensuring quality gas tightness
and longer service life
48
Topic Outline

 Casing Depth Selection
 Casing Design Criteria and Wellhead
49
Casing Design Criteria
Example of Casing Size Selection
CASING DESCRIPTION SLIM HOLE STANDARD HOLE BIG HOLE
Conductor Pipe 20" 30" 40"
Surface Casing 13-3/8" 20" 30"
Intermediate Casing 9-5/8" 13-3/8" 20"
Drilling Liner 7" 9-5/8" 13-3/8"
Perforated Liner 1 5" 7" 10-3/4"
Perforated Liner 2 3-1/2" 5" 8-5/8"
Perforated Liner 3 None None 7"
Tieback Casing 7" 9-5/8" or 10-3/4" 13-3/8" or 16"
50
Casing Weight Selection
CASING OD BIT SIZE CASING WEIGHT WALL THICKNESS DRIFT DIAMETER

20" 17-1/2" 133 lb/ft 0.635" 18.542"
17-1/2" 94 lb/ft 0.438" 18.936"
16" 14-3/4" 84 lb/ft 0.495" 14.822"
13-3/8" 12-1/4" 72 lb/ft 0.514" 12.191" **
12-1/4" 68 lb/ft 0.480" 12.259"
10-3/4" 9-7/8" 45.5 lb/ft 0.400" 9.794"
9-7/8" 40.5 lb/ft 0.350" 9.894"
9-5/8" 8-1/2" 47 lb/ft 0.472" 8.525"
8-5/8" 7-7/8" 24 lb/ft 0.264" 7.972"
7" 6" 29 lb/ft 0.408" 6.059"
5" 4-1/8" 18 lb/ft 0.362" 4.151"
** Needs Special Drifting for 12-1/4” Bit 51

(Ref. Unocal Geothermal Well Design Guidelines)
Casing Grade Designation
 K-55
55,000 psi yield strength
Good for surface casing
Good for Intermediate Casing where flowing T < 450 0F
Good for Drilling Liner where flowing T < 450 0F
Good for Perforated Liner
 L-80
Good for Intermediate Casing where flowing T > 450 0F
Good for Tieback Casing where flowing T < 500 0F
 S-95 or T-95
Good for Tieback Casing where flowing T > 500 0F
52
 Yield Strength Reduction at High Temperatures

- 12% reduction at 300 0F
Example:
13-3/8”, L-80, 47 ppf, at 600 0F

YS600 = 80,000 x (1-.18) = 65,600 psi
53
Anticipated Loads
Axial
Tension
Load
External
Collapse
Pressure
Internal
Burst Pressure
Minimum Performance Property
 Minimum Performance Property
The Burst Rating, Collapse Resistance and Tensile

Strength of API Casings
API Bulletin 5C2 : Performance of Casing, Tubing and Drillpipe

API Bulleting 5C3: Formulas and Calculations for Casing,
Tubing, Drill Pipe and Line Pipe Properties
55
Collapse Design: Minimum Performance Property
 Collapse Design: (For commonly used casing in Geothermal)
CASING OD CASING WEIGHT CASING GRADE WALL THICKNESS D/t Ratio Collapse Eqn.
20" 133 lb/ft K-55 0.635" 31.50 1.1.3
94 lb/ft K-55 0.438" 45.66 1.1.4
16" 84 lb/ft L-80 0.495" 32.32 1.1.4
13-3/8" 72 lb/ft L-80 0.514" 26.02 1.1.3
68 lb/ft L-80 0.480" 27.86 1.1.3
10-3/4" 45.5 lb/ft L-80 0.400" 26.88 1.1.3
40.5 lb/ft L-80 0.350" 30.71 1.1.3
9-5/8" 47 lb/ft K-55 0.472" 20.39 1.1.2
8-5/8" 24 lb/ft K-55 0.264" 32.67 1.1.3
7" 29 lb/ft K-55 0.408" 17.16 1.1.2
5" 18 lb/ft K-55 0.362" 13.81 1.1.1
56
API 5C3
Collapse Pressure Formulas
57
Collapse Design Scenarios
 Reduction of internal pressure while drilling.
• Severe lost circulation (TLC)
 Considerable imbalance between the internal pressure

and the external pressure.
• Cementing operations
 Heat up of trapped water between casing strings,

thus, applying significant external pressure on the
inner casing.
• The external pressure for this case is extremely high. The issue is
addressed by attaining zero free water in cement design; and not
by the appropriate casing properties.
58
Example:
What is the collapse resistance of a 10-3/4” 45.5 lb/ft L-80
TC-II Casing?
Solution:
D = 10.75 in
t = 0.40 in
D/t = 26.88
From API 5C3 Table 1.1.3.1, Use Equation 1.1.3
PT = YP x F - G
D/t
where, from Table 1.1.3.1, F = 1.998 and G = 0.0434

Hence, PT = 80,000 x 1.998 - 0.0434 = 2474 psi
26.88
59
Recommended Design Safety Factors
 Safety Factor = Minimum Performance Property

Calculated Load
Minimum Burst Rating SF = 1.2

Minimum Collapse Resistance SF = 1.125
Minimum Tensile Strength SF = 1.25
Maximum Operating Pressure SF = 1.1
Wellhead Equipment Pressure Rating SF = 1.0
Thermally-Induced Stress SF = 1.0
Plastic Design, Minimum Tensile Load SF = 2.0
60
Topic Outline

61
Wellhead Design Criteria
Wellhead Equipment Design Requirements
 Maximum Shut-in Wellhead Pressure at ambient

temperature
 Maximum Flowing Wellhead Pressure and Temperature.
• Generally at saturated conditions.
62
Wellhead Equipment Design
Requirements
API 6A Working Pressure in psig from -20°F to 650°F

Rating - 20°F to 250°F 300°F 400°F 500°F 600°F 650°F
2M 2000 1955 1860 1735 1540 1430
3M 3000 2930 2785 2605 2310 2145
5M 5000 4880 4645 4340 3850 3575
ANSI B16.34 Working Pressure in psig from -20°F to 650°F

Class - 20°F to 250°F 200°F 300°F 400°F 500°F 600°F 650°F
150 290 260 230 200 170 140 125
300 750 750 730 705 665 605 590
600 1500 1500 1455 1410 1330 1210 1175
900 2250 2250 2185 2115 1995 1815 1765
1500 3750 3750 3640 3530 3325 3025 2940
63
Basic Geothermal Wellhead
Configurations
 External Pack-off Completion
 Expansion Spool Completion
 Casing Head Completion
64
External Pack-off Completion
65
Expansion Spool Completion
66
Casing Head Completion
67
Casing Accessories - Protectors
Pipe Deck - Offshore
Running Casing
Onshore / Offshore

03 - Basic Well Design

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CASING DETAILS

Basic Well Design

 Well Design Objective

• Definition of Hydrostatic Pressure

 Casing String Design Objectives

 Wellhead and Casing Design Criteria

Contain and Control!

 Being able to fully control the flow of the reservoir fluid.

Drill and construct wells with a 30-year operating life

 Well Design Objective

• Definition of Hydrostatic Pressure

 Casing String Design Objectives

 Wellhead and Casing Design Criteria

The force felt downward is still 3 lbs

where Phydrostatic = hydrostatic pressure (psi)

HP = FW x TVD x (1/144) x 7.48 gal/ft3

Because fluid density is a function

From this, we see that it is the

Formation Pore Pressure

• The pressure of the fluid in the rocks = Formation Pore Pressure

Formation Pore Pressure

The pressure at which this occurs is called breakdown pressure or

Fracture pressure is an important consideration for selecting casing

A knowledge of the pressure at which formation fracture will occur at all

There are various methods for estimating/predicting fracture pressure

Most commonly, fracture pressures are estimated using offset Leakoff

Leak Off Test Example

600 Breakdown Pressure

Pump Rate (bbl/min )

Calculation of the Fracture Gradient from the LOT:

 FG (psi/ft) = [SIP +(TVD-GH) x MW x 0.052)]

SIP = Stabilized Injection Pressure (psi)

TVD = True Vertical Depth (ft)

GH = Pump Pressure Gauge Height (ft)

MW = Mud Weight (lb/gal or ppg)

KB = Kelly Bushing Height (ft)

*Based on Salak, Bulalo, Tiwi, Sarulla and Salton Sea data

 Well Design Objective

• Definition of Hydrostatic Pressure

 Casing String Design Objectives

 Wellhead and Casing Design Criteria

 Mud Weight used to drill the Intermediate hole section

 Fracture Gradient at the Shoe of the Surface casing

 Kick Tolerance (volume and kick density)

 Hole Size and Size of Drillpipe used

CASING SHOE DEPTH SIMULATOR

30" Surface Casing Shoe (Initially Set at 300' TVD)

Output: Maximum Depth that could be drilled without

The next step is therefore to do a “Design Up” simulation to determine what

This simulation requires the following data input:

 Mud Weight used to drill the liner hole section

 Fracture Gradient at the Shoe of the Intermediate Casing

 Kick Tolerance (volume and kick density)

 Size of Drillpipe used

30" Surface Casing Shoe (Initially Set at 300' TVD)

Depth of the Liner Hole at 3000' TVD

 On Deep Wells may

 On Deep Wells may

 On Deep Wells may

 On Deep Wells may

 On Deep Wells may

 On Deep Wells may

 2000-2200 psi for normally pressured zones

 2200-2400 psi for abnormally pressured zones,