The equations of the “Casing and cementing” lessons in “Drilling engineering”, with their conditions and units, and what each symbol means in them.
Inside diameter and mass per metre of a casing pipe
d=D−2t,m=ρsteelπ(D−t)t
SI
Holds when: The cross-section area of the wall, 4π(D2−d2), equals π(D−t)t. This is the mass of a plain pipe. The nominal weight in a catalogue is a little greater, because it includes the couplings or the upset (thickened) ends. These are nominal sizes. Real sizes differ within the tolerances of the standard.
any consistent units: the pressure and the yield strength in the same units (MPa or psi), t and D in the same units
Holds when: The pipe is thin-walled, and the stress is taken as uniform across the wall (the derivation is in the advanced section). The pressure outside is zero. In a well, the pipe feels the difference between the internal and the external pressure. This is a rating of the pipe body. The pressure that the connection holds may be lower.
Collapse pressure: yield and elastic loss of stability
pY=2Yp(D/t)2D/t−1,pE=1−ν22E⋅(D/t)(D/t−1)21
any consistent units of pressure and modulus
Holds when: A long, perfectly round pipe with a uniform wall, zero pressure inside and no axial load. The standard reduces the theoretical pE by about 29% to allow for ovality and uneven wall thickness. Between the two limits it applies empirical formulas for “plastic” and “transition” collapse. The boundaries between these ranges depend on the grade.
Weight of a metre of string when the fluids inside and outside differ
w=g[m(1−ρsteelρout)+(ρin−ρout)Ain]
SI
Holds when: A vertical string and fluids at rest. This is the same formula as in the lesson on drill string design (the effective force), where the volume of steel of the pipe with couplings is taken as m/ρsteel. With the same fluids inside and outside, the second term disappears, and we get w=mgkb with the buoyancy factorkb=1−ρm/ρsteel. In an inclined hole the hook load also depends on the friction against the wall.
Drop of the level in the annulus when the float valve fails
y=LemptyAin+AannAin,Δp=ρmgy
SI; in metric units Δp[MPa]=0.00981ρm[g/cm3]y[m]
Holds when: The mud in the string and in the annulus has the same density, and the well is not being topped up at this time. The levels equalise completely. The areas are constant along the unfilled part and along the depth of the drop.
SI; it is convenient to calculate ∑(ρ−ρm)h in g/cm³·m and to multiply by 1000
Holds when: A vertical string and fluids at rest. When mud circulates, the friction of the flow against the pipe adds to the weight. The areas are the same along the length. For a string of sections with different thickness, Aout hardly changes, and Ain is taken for the section where the column stands.
Holds when: Both pressures are taken at the same depth and at the same moment. The profiles inside and outside must be compatible, that is, they must exist together in one operation. The pressures are gauge pressures: atmospheric pressure acts on both sides of the wall and cancels. The pressure of a column of fluid is calculated from the vertical depth, and the length of the pipe sections from the length along the hole.
Depth of the mud level in the string during lost circulation
L=hloss(1−ρmρloss)
any units of length; the densities in the same units
Holds when: The well is open at the wellhead, and the mud is at rest and has the same density throughout. The formation takes mud while the pressure of the column above it is higher than the pressure in the formation: ρm(hloss−L)=ρlosshloss. While the level falls, the pressure on the formations above it decreases, and they may start to flow. Then the string will hold gas, not an empty space.
Holds when: The well is closed and full of gas from the formation to the wellhead. This is the worst case. When a small pocket of gas is circulated out, the pressures are much lower (Well kill methods). The gas density is taken as constant along the well, and taken with a margin on the low side: the lighter the gas, the higher the pressure at the wellhead. For this calculation the fracture pressure is taken with a margin on the high side: an underestimated value here underestimates the load. If there is a rock in the open hole that is weaker than the rock under the shoe, it sets the limit.
Holds when: We check the conditions in every cross-section of the string, for every load case. The ratings already include the minimum yield strength (the stress at which the steel starts to stretch permanently) and the tolerance on the wall thickness, but not wear, corrosion or axial load. The values of the factors are set by regulatory documents and company standards.
SI; the force in newtons, 1 MN = 10⁶ N ≈ 102 tonnes-force ≈ 224.8 thousand pounds-force
Holds when: The string hangs freely, with mud of the same density inside and outside. The hole is vertical. In an inclined hole, we take the projection of the length on the vertical instead of the length, and friction against the wall adds a load when the crew pulls the string or moves it up and down. This is the weight of the string in the fluid. The true axial force in the pipe body below the wellhead is a little smaller (see the advanced section), so the estimate is on the safe side.
Holds when: Bending: the pipe follows the axis of the hole. We add the force σbendAs to the axial load as the equivalent of bending, and we check the sections with sharp curvature. Shock: an instant stop and an elastic wave in a long string. This is an upper estimate. With smooth work the force is much smaller. Pressure test: the bottom of the string is closed with a plug, and the pressure acts on the whole area of the inside cross-section.
Holds when: The von Mises yield condition (a rule for when steel yields under combined stresses) for the hoop and axial stresses. The radial stress is not included (the derivation is in the advanced section). The formula is used for tension. The favourable effect of compression is not taken as a margin. Bending is not included in σa. Internal pressure, if there is any, is taken into account separately.
the formulas of the standard are written in psi: convert the yield strength to psi (1 MPa = 145.04 psi), and convert the result back to MPa
Holds when: We choose the regime by D/t: yield up to (D/t)YP, plastic up to (D/t)PT, transition up to (D/t)TE, and elastic above. The boundaries are given below. The plastic-regime formulas are empirical, from tests of pipes. The numerator of the elastic formula is the theoretical value reduced by about 29% to allow for imperfections of shape. The pipe has no axial load and no internal pressure. We allow for tension by putting Ypa in place of Yp.
Holds when: The coefficients are valid only with Yp in psi. The boundaries of the regimes: (D/t)PT=C+Yp(B−G)Yp(A−F), (D/t)TE=3B/A2+B/A. The boundary (D/t)YP is the point where the yield formula and the plastic formula give the same value.
True axial force in a string of one wall thickness
Fa(z)=gm(L−z)−pLAs
SI
Holds when: A vertical string of one wall thickness with an open bottom, and fluid of the same density inside and outside. If the bottom is closed by a float valve and the pressures inside and outside differ, the force on the end face is poutAout−pinAin, where Aout and Ain are the areas of the outer and inner cross-sections. In a string of sections with different walls, the pressure also acts on the steps at the changes.
any consistent units of stress and pressure; radii in the same units
Holds when: An elastic pipe with a uniform wall. Under pressure, the highest equivalent stress is on the inside surface. Tension is positive. Shear stresses from torsion are not included. The condition describes the start of yield, not loss of stability: the collapse of thin-walled pipes is checked separately.
Holds when: The part is fixed at both ends and stays straight (no buckling). The changes of temperature and pressures are averaged along the length of the free part. The steel is elastic.
kg and kg/L: the volumes come out in litres, and the density in kg/L = g/cm³
Holds when: The volumes of the components add up. Dissolving and chemical shrinkage on mixing are not included. Additives that dissolve in water are counted by their own density. The error is small, because the amounts are small. There is no entrained air in the slurry. In foaming, the density is lower than the calculated one, so the crew checks it on the rig with a pressurised mud balance.
Holds when: The filtrate grows in proportion to t, as in filtration through a growing cake (filtration theory). When the sample dehydrates in minutes, this is only a conventional index for comparing recipes.
Holds when: The cross-section of the hole is round. In a washout (a place where the hole has been washed wider than the bit made it), Dhole is its diameter. 100% means that the string is exactly in the middle, and 0% means that it touches the wall.
Ratio of the speeds on the narrow and the wide side of an eccentric annulus
vwidvnar=(2−SOSO)(n+1)/n
dimensionless
Holds when: Each part of the circumference of the annulus is treated as a narrow flat slot with its own width, and the pressure gradient along the length is the same for all parts (the narrow-slot approximation). The flow is laminar, and the fluid is a power-law fluid with no yield stress. In a mud with a yield stress, the flow on the narrow side can stop altogether. The width of the slot on the narrow side is proportional to SO, and on the wide side to 2−SO (as fractions of the nominal gap).
Holds when: The volumes of the slurry do not change during pumping (we neglect compressibility and shrinkage). The margin covers the inaccuracy of the hole volume. If the hole turns out smaller, the cement will rise higher than planned.
Holds when: Nominal inside diameters. The real volume differs by fractions of a per cent, so the crew expects the bump near the calculated volume. Pumps are counted by strokes with a volumetric efficiency, or by a flow meter. The compression of the mud and the string under pressure adds a little volume.
metric: MPa, g/cm³, m; 0.00981 MPa is the pressure of a column of 1 m of fluid with a density of 1 g/cm³
Holds when: The heights are vertical. The columns are counted from the wellhead to the depth of the shoe. If ppump comes out negative by the formula, there is no pressure at the pumps: the fluid in the string goes down faster than it is pumped (free fall, the next section).
Holds when: The pressure in the void is taken as atmospheric. In reality there is a partial vacuum there, which holds the fall back a little: the void is slightly smaller than calculated. We ignore the inertia of the fluids: at each moment the flow rate is the one at which the heads balance. The fluid being pumped lies at once on top of the column. The rathole is filled with mud and does not take part in the flow. The volume of the head and the piping (0.2 m³) is not included: it only shifts the displacement by 0.2 m³.
dB/m; amplitudes in the same units; 1 dB/ft = 3.28 dB/m
Holds when: The amplitude of the casing wave decays exponentially: on every metre of path it falls by the same factor. Both receivers see the same casing wave, and the losses on the stretches of path through the mud are equal for them. So these losses cancel in the ratio A1/A2. In the second formula the reference is free casing in the same well: the same diameter and wall thickness of the pipe, the same mud and the same tool.
Holds when: The reference A100 is taken in the same casing and in the same cement. A lightweight set cement weakens the wave less even with full bond, so the lead slurry needs its own reference. The index averages over the whole circumference: a channel over part of the circumference and a uniformly weak cement give the same BI. The travel time is constant, and arrivals through the rock do not fall into the window where the amplitude is measured (otherwise the readings are false; see the next section).
Wellhead pressure limit in a squeeze without fracturing
pwhmax=pf−Δpmargin−0.00981i∑ρihi
MPa; 0.00981 MPa is the pressure of a 1 m column of fluid with a density of 1 g/cm³
Holds when: The calculation is for rest. While we pump down the pipe, friction reduces the pressure at the bottom for the same wellhead pressure. So during pumping the pressure at the bottom stays below the limit, and in the pauses it just reaches it. The fracture pressure is taken from tests of this formation or a neighbouring one, if there are any, and not from a forecast. The heights are vertical: in a deviated well the columns are counted by the true vertical depth.
Holds when: The fluids do not mix. The same fluids stand at the same height in the pipe and in the annulus. Then the pressures at the end of the pipe are equal, and there is no flow. The cross-section of the hole is constant (taken from the caliper log, a log that measures the diameter of the hole). The tool joints are ignored. They reduce the annulus slightly, so with the pipe in the hole the cement stands a little higher than calculated. The deviation of the hole is ignored. The pipe drains as it is pulled out, and all the cement stays in the wellbore.
Holds when: The delay round the circumference varies as τcosφ (the displacement is small compared with the radius of the casing), and the arrivals from all sides are equally strong. The signal is narrow-band: a sine wave of frequency f. For a short pulse the weakening is of the same order. The ray approximation is used, as in the formula for the travel time of the head wave.
Holds when: A plane wave at normal incidence. The attenuation in the steel itself and the spreading of the beam are ignored. They make the decay faster behind any material, so real times are shorter than calculated, and the tool finds the difference between materials by calibration. Behind the casing there is a layer that is thick compared with the wavelength. A thin layer or a microannulus changes the picture. Real processing fits a model to the whole record, with the transducer and the mud taken into account. The formula explains the principle.
speed of the longitudinal wave along the pipe (the speed of sound along it, as in a rod), E/ρsteel, about 5100 m/s; in massive steel the wave is faster, about 5900 m/s, m/sCasing design
Young's modulus of steel, about 207,000 MPa, PaCasing design
E,α,ν
Young's modulus (about 207,000 MPa), the coefficient of linear expansion (about 12⋅10−6 1/°C) and Poisson's ratio (0.3) of steel, Pa, 1/°C, —Casing design
tensile strength of the pipe body; for a connection, its tensile strength (the pull-out load, at which the thread starts to pull out of the coupling), MNCasing design
F(z)
tensile force in the cross-section at the depth z, NCasing design
Δpfr.ann,Δpfr.str
friction losses in the annulus and in the string at the given rate, MPaPrimary cementing
Δpfr.str,Δpfr.ann
friction losses in the string and in the annulus at the rate Q, MPaPrimary cementing
path of the wave along the casing to the near receiver: the 0.914 m spacing minus the shift caused by the two stretches of path through the mud, which gives about 0.9 m, mRemedial cementing, cement plugs and cement evaluation
pressure inside and outside the pipe, MPaCasing design
piy
internal yield pressure (burst): the internal gauge pressure at which the hoop stress in the wall (the stress around the circumference of the pipe) reaches the yield strength, MPaCasing: purpose, types, properties and standards
internal yield pressure of the pipe, MPaCasing design
pL
fluid pressure at the depth of the shoe, PaCasing design
pne
external excess pressure, the collapse load, MPaCasing design
pne,pni,F
external and internal excess pressure and axial force in the cross-section considered, MPa, MPa, MNCasing design
pni
internal excess pressure, the burst load, MPaCasing design
pout,pin
pressure outside and inside the string at the depth z, MPaCasing design
pp
pore pressure of the highest-pressure formation of the next interval, at the depth h, PaCasing design
pressure inside the string at the depth of the shoe, PaCasing design
pstr(ztop)
the hydrostatic pressure of the column in the string at the shoe, when its top has gone down to the depth ztop (above it there is a void), MPaPrimary cementing
pwh
pressure inside the string at the wellhead, PaCasing design
reduced yield strength: the yield strength of a pipe that is also being pulled. It is lower than Yp, and we use it instead of Yp to calculate the collapse pressure of a pipe in tension, MPaCasing design