Basic Casing Design and

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Casing Point Selection

UTC Instructor
 Objectives
On completion of this module the engineer should be
able to…

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• Define the different types of casings.
• Describe the casing point selection process
• Describe the maximum load casing design method.
• Demonstrate the bottom up method of casing setting
depth initial estimation.
 Introduction
• Design Considerations
• Cost, (usually up to 17% of the total well cost)

• Bottomhole Pressure

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• Service Conditions (casing handling)

• Material Properties

• Internal Yield

• Collapse

• Tension
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 Statement of Standard
All casing and tubing shall be designed to withstand
all loads that can be imposed on them during
installation and the lifetime of the well.

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No well construction program shall be commenced
without an approved casing and tubing design.
 Mechanical Properties Of Steel
• API Standards
– Specification; API, 5A.

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– Bulletins; 5C2, properties of casing, tubing, drill pipe.
– Recommended; API. RP7G, care and use of tubular.

• H2S & CO2

• Exposure to more than 0.05 psia of H2S pressure and
CO2 corrosion can lead to failure,
– Common practice is the use chromium alloy (casing type L80
or Stainless steel)

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 Types of Casing Strings

• Conductor
• Surface

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• Intermediate
• Drilling Liner
• Production
 Types of Casing Strings
Conductor Casing
 Purpose
1. Provides mud returns to tanks.

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2. Divert flow in case of emergency.
3. Support subsequent casing loads.
 Installation
1. Driven
2. Jetted
3. Drilled and cemented
 Types of Casing Strings
Surface Casing
 Purpose

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1. Protect Fresh water aquifers.
2. Provide wellbore integrity,
- Provides a BOP seal
- Allows drilling into abnormal pressure safely by isolating
shallow hazards.
Definition: Casing set at or above 6500’ or in sub-normal pressure.
Setting depth is based on mechanical and regulatory considerations
 Casing Point Selection Criteria
Mechanical Considerations

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• Ability of the weakest exposed formation beneath the casing
(usually shoe FG) to withstand the load imposed by well control
operation.
• Likelihood of differential sticking occurring while running
casing.
 Types of Casing Strings
Intermediate Casing
 Purpose

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1. Provide mechanical integrity.
- Case off problem zones.
- Allows higher blowout protection as it is set in more
competent formations than surface casing (higher shoe strength)
Definition: Casing set to 6500’ or deeper in abnormal pressure.
Setting depth is based on mechanical considerations
 Types of Casing Strings
Drilling Liners
 Purpose

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1. Provide mechanical integrity as intermediate casing but at
lower cost.
Definition: Partial string of casing hung in previously set casing
string and is set to a depth greater than 6500’ or in abnormal
pressure.
Setting Depth is based on mechanical considerations
 Types of Casing Strings
Production Casing/Liners
 Purpose

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1. Provide isolation of the producing zone from other zones.
2. Withstand the anticipated loads during production and testing
operations for the wells life time.

Setting Depth is the last string across the production zone. This may
be a casing to surface or a liner that is hung.
 Casing Point Selection
• Why is Casing set in the Hole?

• Casing is set for two Drilling reasons;

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• To consolidate the hole already drilled, (steel filter cake)

• To provide the pressure control integrity to drill ahead.

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 Criteria For Selecting Casing
Depths
Each casing string is run as deep as possible based on

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kick tolerance, unless other reasons dictate it to be run
higher.

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Other Restrictions On Casing Shoe
Depth
• Wellbore Stability
Within the limit allowed by kick tolerance, we may restrict the
length of OH sections, to minimize deterioration of wellbore with

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time
• Mud Requirements
Formations may affect casing depth (reactive shale)
• Directional Requirements.

Directional Problems may alter casing points (drag, torque)

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 Casing Point Selection Criteria
Other factors affecting casing setting depth.
1. Underground fresh water zones

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2. Shallow hazards
3. Directional profile
4. Sidetrack requirement
5. ECD at shoe
 Special Criteria for Conductor
The Conductor pipe needs to be set deep enough to carry
subsequent axial loads from all other casing strings.

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• It also must withstand the bending loads from
environmental conditions.

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 Special Criteria for Surface Casing

The Surface Casing is usually set in the first competent

formation which is strong enough to close in on a kick.

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Special Criteria for Intermediate Casing

The Intermediate Casing is set as deep as possible to

allow sufficient shoe strength for drilling ahead.

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 Intermediate Casing - other
considerations
Intermediate casing may also be set for directional or
wellbore stability reasons

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• Reduce torques and drags in an extended reach hole.

• Case off possible differential sticking zones and

perform directional work below casing.

• Case off some problem zones prior to drilling ahead.

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 Special Criteria for Production Casing
The Production Casing is set through or just above the
reservoir, depending on the type of completion to be

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used.

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 Casing Point Selection Criteria
Information gathered prior to casing design.
• Estimated pore pressure and rock strength using offset data.

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• The minimum and maximum casing sizes to be run at TD that
would allow for logging testing and a completion program.
• The effects of geological uncertainties on casing setting depths
and the ability to safely circulate out the maximum anticipated
kick volume
 Casing Point Selection Criteria
After gathering Information
• Develop a pore pressure and fracture gradient versus depth plot.

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• Plan the well from TD up.
- Determine the maximum formation pressure at TD.
- Add a Trip margin and determine minimum weight at TD.
 Bottom Up Method
• Plot the pore pressure gradient curve
• Plot the Mud weight curve. The mud weight should balance the

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highest PP in the OH with a TM of 0.5 ppg.
• Plot the estimated actual FG curve, and the designed FG curve,
which is FG less allowance for Well control, surge or ECD.
• Start on the bottom on the mud weight curve and draw a
vertical line up to the designed FG curve. This is the initial
estimated production casing or liner.
• Cont…..
Casing Point Selection Criteria

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 Kick Tolerance

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 Kick Tolerance
Kick tolerance is the maximum
(SIDPP)
volume gas kick which can be
safely circulated out without
(SICP)

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causing formation failure at the
weakest point of the open hole
(usually deemed to be the casing
shoe).

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 Kick Tolerance
Kick tolerance is a measure of the size of a gas
kick that can be handled.
The following assumptions are made…

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 A gas influx comes from TD up to the casing point or stays at TD.
The kicking formation has a pore pressure equal to or greater than the mud
hydrostatic.
 Shut in casing pressure (SICP) = MAASP when the top of gas is at the
casing shoe, using the drillers method.
 Based on these assumptions, we calculate the volume of a gas kick. This is
.
the maximum size of gas influx, which is what we call KICK TOLERANCE

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 Kick Tolerance
More assumptions
 For an Exploration or Appraisal well, we can assume that the kicking

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formation may have a pore pressure gradient of 10% higher than the
mud gradient.
 i.e. A planned mud gradient of 0.5 psi/ft will assume a pore pressure
gradient at the kick depth of 0.55 psi/ft.
 For a development well in a known area, assume that the kicking
formation may have a pore pressure which is equal to the mud gradient.
 In this case any kick taken will be a swabbed kick.

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 The Well as a ‘U’-Tube - Static
The Pressure at Point 1 = Pressure at Point 2

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P1 = BHP = SIDPP + HPDS

P2 = BHP = SICP + HPA

P1

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 The Well as a ‘U’-Tube - Static
Therefore: P1 = P2
SIDPP@surf + HPDS = SICP@surf + HPA =>

SIDPP@surf = SICP@surf - HPDS + HPA =>

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SIDPP@surf = MAASP@surf – MgxTVDTD +(TVDTD – Hi)Mg + GgxHi
1st Step: Determine what the maximum height of influx can be when it reaches the casing
shoe*.

MAASP@surf  SIDPP@surf
Hi 
Mg  Gg
*Assumed that weakest formation is at the shoe

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 The Well as a ‘U’-Tube - Static
• To find MAASP@surf & SIDPP @surf:
– P@Shoe = MAASP@surf + Mg x TVDshoe = >

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MAASP@surf = P@Shoe - Mg x TVDshoe

– P@TD = SIDPP @Surf + Mg x TVDTD = >

SIDPP @Surf = P@TD - Mg x TVDTD

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 The Well as a ‘U’-Tube - Static
• Where:
When kick at the shoe : P@Shoe = MAASP @ shoe = Fg x TVDshoe

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When kick is at TD: P@TD = SIDPP@TD = {Mg+(10%Mg)} x
TVD TD
Kick Gradient

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 Hydrostatic Pressure
Pressure (psi)
0 1000 2000 3000 4000 5000 6000
0

1000

Hydrostatic Pressure
2000

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3000

4000
TVD (psi)

5000

6000

7000

8000

Hydrostatic Pressure
9000

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 Hydrostatic Pressure & SIDPP
Pressure (psi)
0 SIDPP@surf 1000 2000 3000 4000 5000 6000
0

SIDPP
1000
Hydrostatic Pressure

2000

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3000

4000
TVD (psi)

5000

6000

7000

8000

Hydrostatic Pressure
SIDPP
9000

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 Hydrostatic Pressure & SIDPP &
0
0 SIDPP@surf MAASP
1000 2000
Pressure (psi)
3000 4000 5000 6000

MAASP@surf
MAASP
1000 SIDPP
Hydrostatic Pressure

2000

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3000

4000
TVD (psi)

5000

6000 MAASP

7000

8000

Hydrostatic Pressure
SIDPP
9000

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 Hydrostatic Pressure & SIDPP &
0
0 SIDPP@surf
MAASP
1000 2000
Pressure (psi)
3000 4000 5000 6000

MAASP@surf

MAASP
1000
SIDPP
Hydrostatic Pressure
2000

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3000

4000
TVD (psi)

5000

MAASP@Shoe
6000

7000
MAASP@Surf = MAASP@Shoe - Hydro. P@Shoe

8000 SIDPP@TD

Mud Hydrostatic Pressure

9000

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MAASP@surf

MAASP
SIDPP
Hydrostatic Pressure

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MAASP@Shoe

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MAASP@Surf = MAASP@Shoe - Hydro. P@Shoe
 Kick tolerance
2nd Step: The height of influx represents a volume:

V@shoe = Hi@shoe x Annular Capacity@shoe

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So this is the influx volume which will cause the pressure
at the shoe to reach the maximum allowable value
when the kick reaches the shoe.

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 Kick tolerance
• However, we also have to consider the possibility that
the pressure at the shoe can reach the Maximum
allowable value when the kick enters the wellbore!!!

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• Therefore, we have to calculate the second kick
tolerance at TD.

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 Annular Gas Expansion
• Pressure reduces in gas as depth of gas
in well decreases.

• Gas expands as it rises and pressure is

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reduced (Boyle’s Law).

• Gas height increases, mud height

decreases.

So: P1V1 = P2V2

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 Kick Tolerance
3rd Step: Therefore, we can calculate V@TD & the height
of the influx at TD at that V@TD :

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P@Shoe x V@Shoe = P@TD x V@TD
P@Shoe x V@Shoe
V@TD 
And
P@TD

V@TD
H@TD 
Annular Capacity@TD
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 Kick Tolerance
The final kick tolerance is determined by which of either of
the two kick tolerances is the smallest:

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 If V@Shoe> V@TD , and if H@shoe >H@TD,then V@TD is the kick
tolerance

 If V@Shoe> V@TD , and if H@shoe < H@TD,then recalculate V@TD for

critical height H@Shoe at TD.

 If V@Shoe< V@TD, then we need to calculate a new volume using

the critical height (H@Shoe) as if it were around the BHA and DS.

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 Kick Tolerance Rule of Thumb
• If MAASP psi  target Vertical Depth in feet < 0.1,
kick tolerance is going to be low.

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• If MAASP psi  target Vertical Depth in feet > 0.1,
kick tolerance is probably going to be OK.

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 Kick Tolerance
Example 1:
Calculate the Kick Tolerance for the following scenario.
Casing shoe at 6000’ with a FG of 0.72 psi/ft, plan to drill to the

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next casing point at 8500’ with a mud gradient of 0.62 psi/ft in a
vertical exploration well. (Kick gradient 10%more than mud
gradient.)
Assume a gas gradient of 0.12 psi/ft at the casing shoe, and 12
¼” hole with 5” DP and 300’ of 8” drill collars.

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 Kick Tolerance
Example2:
Calculate the Kick Tolerance for the following scenario.
Casing shoe at 5000’ with a FG of 0.65 psi/ft, plan to drill to the

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next casing point at 7500’ with a mud gradient of 0.55 psi/ft in a
vertical exploration well. (Kick gradient 10%more than mud
gradient.)
Assume a gas gradient of 0.12 psi/ft at the casing shoe, and 12
¼” hole with 5 7/8” DP and 300’ of 8” drill collars.

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 Maximum Load casing Design
• This is a method for selecting specific casing based on
operational conditions and resulting stresses.

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• Concept: Design for most severe realistic load to minimize risk
of failure.
• Maximum load cases are based on geographical region,
geologic section and organizational philosophy.
 Maximum Load casing Design
• Design Cases:
– Burst

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– Collapse
– Tension

– Special considerations:
– H2S/CO2, Temperature, Multi-axial stress correction, Stability.
 Steps for Basic Casing Design
Burst Design Collapse Design Tension Design
Develop Maximum Develop Maximum Develop Maximum
Load case condition for Load case condition for Load case condition for
Collapse Tension

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burst

Calculate resulting Calculate resulting Calculate resulting

loads, (Design Line) loads, (Design Line) loads, (Design Line)

Multiply design line by Multiply design line by Multiply design line by

safety factor, (Load safety factor, (Load safety factor, (Load
Line) Line) Line)

For casing selected in For casing selected in

Select casing strings collapse design, check
with load capacity >/= burst design, check that
that load capacity >/=
Load line load capacity >/= Load
Load line
line
 Minimum Design Factors
DESIGN LOADS Surface & intermediate Production Tubing
casings, drilling liners casings/ liners

Collapse 1.0 1.1 1.125

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Burst
- normal service 1.1 1.1 1.1
- critical service 1.25 1.25 1.25
     
Tension
pipe body 1.3 1.3 1.3
connection 1.5 1.5 1.3

Compression 1.3 1.3 1.3

Triaxial 1.25 1.25 1.25

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 Casing Burst Design
Worst case scenario is gas filled above FG+SF
Load Line
Maximum pressure at casing shoe,dependent on FG. (Internal Pressure)

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Pinj  0.052(EMWfg  SF)Ds
The maximum internal burst loading pressure at surface is a
function of the injection pressure, and is given as:
Pisurf  Pinj @ shoe  Gg Ds
External pressure due to annular drilling fluid….0.465psi/ft

Pe  G f D
 Casing Burst Design
@ shoe Pbr @ shoe  ( Pinj @ shoe  Pe )

@ surface Pbrsurf  ( Pisurf  Pe )

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Design Line
Pressure with burst design factor of 1.1

@ shoe Pb  Pbr DFb

@ surface Pbsurf  Pbrsurf DFb
From the casing Tables choose appropriate casing
 Casing Collapse Design
Worst case scenario is full evacuation with Mud on the outside
Load Line
Maximum collapse pressure at shoe, (external pressure)

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Pe  0.052(  m ) D
The casing is empty and open to atmospheric pressure. This
will render the surface pressure to be 0 psi
Design Line
PC  ( Pe )1.1

From the casing Tables check casing collapse rating

 Casing Tension Design
Worst case scenario is stuck casing with an over pull 100,000 lbs applied
As per SLB casing manual, TVD should be used for gravity related

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Tensile load calculation. If Biaxial stress calculations are not being
made then a safety factor of 1.6 shall be used.

Load Line Design Line

Fwt  wLTVD  100,000lbs Fwtd  ( Fwt ) SF

From the casing Tables check casing tensile rating
Tensile load will change if pumps are on while pulling on casing.
 Casing Sizes Decision Tree
Casing size, in
16 18-5/8 20 24 30

Bit & hole

size, in 14-3/4 17-1/2 20 26

11-3/4 13-3/8
Casing size, in 16 20
11-7/8 14

Bit & hole

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size, in 10-5/8 12-1/4 14-3/4 17-1/2

Casing & liners 8-5/8 9-5/8 11-3/4 13-3/8

size, in 10-3/4
9-7/8 11-7/8 14

Bit & hole

size, in 7-7/8 8-1/2 8-3/4 9-1/2 10-5/8 12-1/4

Casing & liners

5-1/2 7-5/8
size, in 6-5/8 7 8-5/8 9-5/8
5-3/4 7-3/4

Bit & hole 8-1/2

4-1/2 4-3/4 5-7/8 6-1/8 6-1/2 7-7/8
size, in 8-3/4

Casing & liners

size, in 3-1/2 4 4-1/2 5 5-1/2 7
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Tubing size, in 1.9 2-1/16 2-3/8 2-7/8 3-1/2

 API CASING SPECIFICATIONS
• API Specifications (5A, 5AC and 5AX)

• Weight of Casing

• Nominal Weight Expressed in lb/ft or kg/mt ( Weight of CSG plus tool joint ).

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• Plain End Weight Expressed in lb/ft or kg/mt ( Weight of CSG w/out tool joint) .

• Length of Casing
Range Length (ft) Average length (ft)

1 16 -25 22

2 25 -34 31

3 Over 34 42

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 API CASING SPECIFICATIONS
• Colour Grade Identifications

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 Maximum Load Case - Example
• Scenario for burst- Gas filled at shoe fracture pressure and normal pressure gradient
outside.
• Scenario for collapse- Total evacuation, drilling mud in the annulus.
• Scenario for tension- no biaxial and triaxial calculations applied.

Exploration Well

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9 5/8" Casing 47 ppf N-80 setting depth 9500' TVD
Mud weight casing will be set in is 12.5 ppg
Normal pressure gradient is 0.465 psi/ft
Gas gradient is 0.12 psi/ft
Fracture gradient at shoe 16 ppg
Burst design factor 1.1
Collapse design factor 1.0
Tension design factor 1.6

61 UTC Instructor
 Maximum Load Case – Example 2
• Scenario for burst- Gas filled at shoe fracture pressure and normal pressure gradient
outside.
• Scenario for collapse- Total evacuation, drilling mud in the annulus.
• Scenario for tension- No biaxial and triaxial calculations applied.

Development well

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-13 3/8" Casing /Setting depth 5000' MD/3500’TVD
-Mud weight casing will be set in is 10 ppg
-Normal pressure gradient is 0.465 psi/ft
-Gas gradient is 0.12 psi/ft
-Fracture gradient at shoe 14.5 ppg
-Burst design factor 1.1
-Collapse design factor 1.0
-Tension design factor 1.6

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 Kick Tolerance
Example:
Calculate the Kick Tolerance for the following scenario.
Casing shoe at 3500’ with a FG of 0.72 psi/ft, plan to drill to the

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next casing point at 8500’ with a mud gradient of 0.56 psi/ft in a
vertical exploration well. (Kick gradient 10%more than mud
gradient.)
Assume a gas gradient of 0.12 psi/ft at the casing shoe, and 12
¼” hole with 5 1/2” DP and 300’ of 8 1/4” drill collars.

63 UTC Instructor