Casing Failure PreventionEast Texas Gas Producer’s Assoc.

9 March 2010

2

The Ideal Casing String

• For as long as needed, it will:

– Safely carry all applied loads,

– and be free from leaks.Until the next string is set…

…to the life of the well

3

Three Steps are Required to Achieve the Ideal…

• Design: The engineer decides casing sizes, weights, grades and connections for each hole section (usually choosing from available ‘standard’ options).

• Manufacturing and Procurement: Someone builds the casing (and coupling stock), someone threads the connections, someone buys the casing and someone delivers it to the rig.

• Installation: Rig crew and casing crew pick it up one joint at a time and run it.

A breakdown in any one of these steps can result in a casing failure!

Design

Manufacturing

Installation

The discussion today will focus on:

•Common failure modes•Underlying causes•Steps to minimize the risk of failure

4

Casing Failures

Failure ModesCasing Failures

PRESSUREBurstCollapseConnection Leaks

TENSIONTube FractureConnection FractureConnection Jump OutBuckling

BRITTLE FRACTUREEnvironmental Cracking“Naturally” Brittle Material

FATIGUEConnections

OTHERGallingBTC Disengagement

5

Failure ModesCasing Failures

PRESSUREBurstCollapseConnection Leaks

TENSIONTube FractureConnection FractureConnection Jump OutBuckling

BRITTLE FRACTUREEnvironmental Cracking“Naturally” Brittle Material

FATIGUEConnections

OTHERGallingBTC Disengagement

6

Failure ModesCasing Failures

PRESSUREBurstCollapseConnection Leaks

TENSIONTube FractureConnection FractureConnection Jump OutBuckling

BRITTLE FRACTUREEnvironmental Cracking“Naturally” Brittle Material

FATIGUEConnections

OTHERGallingBTC Disengagement

√

7

Pressure RelatedBurst and Collapse

• Failure MechanismOverload failures where pressure (burst

or collapse) exceeds load capacity

• Recognition– Appearance: Plastic deformation

(ductile material)– Orientation: Longitudinal– Location: Sections with highest loads

8

BURST FAILURE

COLLAPSE FAILURE

9

Axial and Pressure Loads Interactively Affect One Another

-2000

2000

4000

6000

8000

10000

-700 -600 -500 -400 -300 -200 -100 100 200

Triaxial Ellipsefor 7"- 23.0 lb/ftN-80 Casing

Bur

st S

tren

gth

(psi

)C

olla

pse

Stre

ngth

(psi

)

(1000 lbf)

Compression Tension

500300 400 600 700

-8000

-10000

-6000

-4000

Axial Force

-2000

2000

4000

6000

-500 -400 -300 -200 -100 100 200

Compression Tension

500300 400

-8000

-6000

-4000

Remember…..Pressure and Tension are not independent.

Connections 10

Internal Pressure (PI)Internal Pressure (PI)

Why Connections Leak:1. Inadequate Bearing Pressure

Bearing Pressure (PB)If bearing pressure (PB) exceeds internal pressure (PI), then no leak.

If internal pressure (PI) exceeds bearing pressure (PB), then leak.

Connections 11

Bearing Pressure (PB)

Why Connections Leak:2. Leak Path Across Seal(s)

A leak path is present on this pin seal. The seal will leak regardless of how much bearing pressure is forcing the two components together.

Connections 12

API Connections Have Built-In (Helical) Leak Paths

These tortuous paths are plugged with the solids in thread dope during makeup.

API ROUND THREAD

PIN

BOX

API BUTTRESS

PIN

BOX

Connections 13

Preventing Leaks

• Leak Paths (other than helical)

• Inadequate Bearing Pressure

Adequate Bearing Pressure is assured by:--Proper dimensions--Proper makeup

Found in visual inspection. Removed from the string.

Pressure Related Failures Failure drivers

– Design error: Applied load > rated load capacity

– Material problem:Load capacity < rated load capacity

– Casing wear– Inspection problem:– Manufacturing flaw,

thin wall joint or thread dimensions

– Improper make up

Mitigations Steps– Use appropriate design factors

to account for higher than anticipated loads.

– Inspect material for manufacturing flaws, thin wall, grade and thread dimensions.

– Minimize casing wear by: reducing side loads, use of casing friendly hardbanding and reducing rotations of drill string.

– Make up connections to generate desired bearing pressure.

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Failure ModesCasing Failures

PRESSUREBurstCollapseConnection Leaks

TENSIONTube FractureConnection FractureConnection Jump OutBuckling

BRITTLE FRACTUREEnvironmental Cracking“Naturally” Brittle Material

FATIGUEConnections

OTHERGallingBTC Disengagement

√

15

16

Failure Generally Associated with Tensile Loads

TENSILE FRACTURE IN THE

TUBE

TENSILE FRACTURE IN THE

PIN THREADS

THREAD “JUMPOUT”

In API tensile tests to failure, 148 of 162 (91%) of round threaded connections failed by jumpout.

Only 9% failed by fracture.

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BOX

PIN

How Jumpout Happens

BOXBOXBOX BOX

NOT ENGAGED

ENGAGED-JUMPED OUT

Much of the thread deformation (strain) on jumpout is elastic, so only minor thread damage occurs (at thread crests).

Many times, jumped-out threads have been successfully rejoined downhole by setting down and turning right.

18

Jumpout - The Main Reason API Adopted the Buttress Thread Form

BOX

PIN

API BUTTRESS THREAD FORM

3 degreesVs. 30 degrees for the round thread form

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Casing Buckling• Sudden, rapid axial collapse of a casing

section that occurs when forces that destabilize the section exceed forces that stabilize it.

• Factors affecting buckling:– State of tension or compression including

temperature and pressure affects– Stability forces

(PI x AI) - (PO x AO) • Section stable if:

F > (PI x AI) - (PO x AO) • Section buckled if:

F ≤ (PI x AI) - (PO x AO)

where: F is the amount of tension (+) or compression (-) (lbs)PO is the annular pressure (psi)AO is the outer circumference of the casing (in)PI is the pressure inside the casing (psi)AI is the inner circumference of the casing (in)

F ≤(PI x AI) - (PO x AO)

Buckled

F >(PI x AI) - (PO x AO)

Stable

Tension FailuresFailure drivers

– Design error: Applied load > rated load capacity

– Material problem:Load capacity < rated load capacity

– Casing wear– Inspection problem:

Manufacturing flaw, thin wall joint or incorrect thread dimensions.

– Improper make up– Casing buckling

Mitigation steps– Use appropriate design factors

to account for higher than anticipated loads

– Inspect material for manufacturing flaws, thin wall and grade.

– Minimize casing wear by reducing side loads, use of casing friendly hardbanding and reducing rotations of drill string.

– Gauge connections and make up properly.

– Adjust tension and TOC to eliminate buckling.

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Failure ModesCasing Failures

PRESSUREBurstCollapseConnection Leaks

TENSIONTube FractureConnection FractureConnection Jump OutBuckling

BRITTLE FRACTUREEnvironmental Cracking“Naturally” Brittle Material

FATIGUEConnections

OTHERGallingBTC Disengagement

√

21

22

BRITTLE FRACTURE (Hydrogen Induced)

This brittle coupling fracture occurred in an H2S (hydrogen sulfide) environment. The mechanism is called Sulfide Stress Cracking (SSC)

Whether or not such a failure will happen depends on many factors that work together in complex interrelationships:

H2S concentrationTime of exposure

Tensile stress levelMetallurgical properties

TemperatureOther factors

Microscopically, Sulfide Stress cracks tend to be branched and run along grain boundaries.

Free hydrogen ions from the chemical reaction with H2S entered the steel in this coupling and made it brittle, leading to the failure. But some materials begin life brittle…

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BRITTLE FRACTURE(“Naturally” Induced)

This N80 casing joint was never exposed to hydrogen sulfide. Rather, it came brittle off the production line due to improper metallurgy and/or heat treatment.

Under impact loading, the pipe cracked and parted (much like laboratory glass piping is cut) when a crack started at the bottom of a slip cut, and rapid, brittle fracture occurred. Such a material is called “NOTCH-SENSITIVE.”

Slip cuts

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SAFE

Why Tough Material is Better Than BrittleMATERIAL “A” - BRITTLE, NOTCH-SENSITIVE

MATERIAL “B” - TOUGH

Will fail by tearing apart like a piece of taffy, not shattering like a piece of glass!

DEFECT SIZE

TEN

SILE

STR

ESS

RAPID, BRITTLE FRACTURE

MATERIAL “A”

MATERIAL “B”

Can safely carry a larger defect at a given stress…

Can safely carry a higher stress with a given defect,

Tougher materials are safer & more “forgiving”

In impact loading

In fatigue loading

In hydrogen sulfide

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Fundamentals of Casing Material Selection for Sour and Corrosive Service

Fundamentals!

Recall the failure mechanism Sulfide Stress Cracking (SSC)

Free hydrogen generated in the H2S-Steel corrosion reaction causes otherwise ductile metal to become brittle and crack.

26

Curves give H2S concentration in NaCl solution. (After Hudgins, McGlasson, Mehdizadeh, and Rosborough)

How Hardness and H2S Concentration Affect SSC

(5% NaCl solutrion. Carbon steel specimens @ 130% yield stress)

H2S PPM

8000

3000

15

5

1

0.1

H2S PP @ 10,000 psi

80

30

0.15

.05

.01

.001

NACE definition of “sour:”

H2S Partial Pressure ≥ 0.05 psia. (5 PPM @ 10,000 psi)

10

15

20

25

30

35

40

0.1 1 10 100 1000 104

HA

RD

NE

SS

(HR

C)

TIME TO FAILURE (HOURS)

DAY WEEK MONTH YEAR

0.1 ppm

1.0 ppm

15

3000

8000

90 minutes

Six months

As hardness decreases, time to failure increases.

As concentration decreases, time to failure increases.

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NO SSC

SSC

Temperature and SSC

For a given grade, as minimum temperature increases, liklihood of

SSC decreases.

This explains why P110 (for example) may be fine

for a deep liner in sour service, but be

unacceptable in the same hole near the surface.

P110 range of possible YS

NACE Minimum Temperature for P110

28

Curves give stress as a percent of yield strength. (After Hudgins, McGlasson, Mehdizadeh, and Rosborough)

How Hardness and Tensile Stress Affect SSC(300 ppm H2S in 5% NaCl solutrion. Carbon steel specimens)

As Tensile Stress decreases, time to failure increases.

15

20

25

30

35

40

45

0.1 1 10 100 1000

HA

RD

NE

SS

(HR

C)

TIME TO FAILURE (HOURS)DAY MONTHWEEK

40%

130%

100%

80%

60%

Why Group 2 sour service grades

(M65,L80,C90,T95) have restricted

maximum hardness

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A Corrosion Engineer Selecting a Sour Service Material Will Consider Many Factors:

a. H2S concentrationb. Chloride levelsc. CO2 concentrationd. pHe. Temperaturef. Oxygen content of the flowstreamg. Sulfur content of the flowstreamh. Gas/Oil Ratioi. Water content of the flowstreamj. Fluid velocityk. Cost of alternativesl. Anticipated life of the well

The analysis is complex and the result will be a compromise that’s very dependent on “Local Conditions.”

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Typical Chemistry of Steels

ClassificationCarbon Steels

Low Alloy Steels

Stainless Steels

Nickel Based Alloys

Element (% Wt.)Carbon 0.3 - 0.5 0.3 - 0.5 <0.25 <0.3Manganese 0.5 - 2.0 <2 <2 <2Molybdenum ---- <1 <4 <10Chromium ---- <2 9 - 26 <25Nickel ---- <1 <25 40 - 70Iron >97 >95 40 - 85 2 - 40

Typical Cost Ratios1 1.5 3 - 10 $$$!

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400

300275

475

0.15 1.5 10 1000 10000

200

800

15002000

NIC 62 (C-276)

NIC 42 (G3, SM2550)

22 CR, 25 CR(DUPLEX SS)

13 CR (420 MOD SS)

9 Cr

Partial Pressure H2S (psia)

Tem

pera

ture

(deg

F) 400 deg F

300 deg F

A Guide for the Application of Corrosion Resistant Alloys (CRA)

$1.5-2

$2-3

$6-7

$12-14

$16-20

If L80 Type 1 costs $1

Not for Material Selection! (talk to your corrosion engineer)

Prices will vary widely with conditions in the metal markets.

Higher temperature benefits SSC, but

accelerates weight-loss corrosion.

Questions

32