Casing Failure Prevention East Texas Gas Producer s Assoc. 9 March 2010

Casing Failure Prevention East Texas Gas Producer s Assoc. 9 March 2010

The Ideal Casing String For as long as needed, it will: Safely carry all applied loads, Until the next string is set and be free from leaks. to the life of the well 2

Three Steps are Required to A breakdown in any one of these Achieve the Ideal steps can result in a casing failure! Design: The engineer decides casing sizes, Design weights, grades and connections for each hole section (usually choosing from available standard options). Common Manufacturing Manufacturing failure modes and Procurement: Someone builds the casing (and coupling stock), someone threads the Underlying causes connections, someone buys the casing and someone Steps delivers it to to the minimize rig. Installation the risk of failure Installation: Rig crew and casing crew pick it up one joint at a time and run it. The discussion today will focus on: 3

Casing Failures 4

Failure Modes Casing Failures PRESSURE Burst Collapse Connection Leaks TENSION Tube Fracture Connection Fracture Connection Jump Out Buckling BRITTLE FRACTURE Environmental Cracking Naturally Brittle Material FATIGUE Connections OTHER Galling BTC Disengagement 5

Failure Modes Casing Failures PRESSURE Burst Collapse Connection Leaks TENSION Tube Fracture Connection Fracture Connection Jump Out Buckling BRITTLE FRACTURE Environmental Cracking Naturally Brittle Material FATIGUE Connections OTHER Galling BTC Disengagement 6

Failure Modes Casing Failures PRESSURE Burst Collapse Connection Leaks TENSION Tube Fracture Connection Fracture Connection Jump Out Buckling BRITTLE FRACTURE Environmental Cracking Naturally Brittle Material FATIGUE Connections OTHER Galling BTC Disengagement 7

Pressure Related Burst and Collapse BURST FAILURE Failure Mechanism Overload failures where pressure (burst or collapse) exceeds load capacity Recognition Appearance: Plastic deformation (ductile material) Orientation: Longitudinal Location: Sections with highest loads COLLAPSE FAILURE 8

Remember.. Pressure and Tension are not independent. Axial and Pressure Loads Interactively Affect One Another Burst Strength (psi) 10000 8000 6000 4000 2000 Compression Tension -700-600 -500-400 -300-200 -100 100 200-2000 Collapse Strength (psi) -4000-6000 -8000-10000 Axial Force (1000 lbf) 300 400 500 600 700 Triaxial Ellipse for 7"- 23.0 lb/ft N-80 Casing 9

Why Connections Leak: 1. Inadequate Bearing Pressure Bearing Pressure (PB) If bearing pressure (PB) exceeds internal pressure (PI), then no leak. Internal Pressure (PI) If internal pressure (PI) exceeds bearing pressure (PB), then leak. Connections 10

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. Why Connections Leak: 2. Leak Path Across Seal(s) Bearing Pressure (PB) Connections 11

API Connections Have Built-In (Helical) Leak Paths PIN BOX API BUTTRESS These tortuous paths are plugged with the solids in thread dope during makeup. PIN API ROUND THREAD BOX Connections 12

Preventing Leaks Leak Paths (other than helical) Found in visual inspection. Removed from the string. Inadequate Bearing Pressure Adequate Bearing Pressure is assured by: --Proper dimensions --Proper makeup Connections 13

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. 14

Failure Modes Casing Failures PRESSURE Burst Collapse Connection Leaks TENSION Tube Fracture Connection Fracture Connection Jump Out Buckling BRITTLE FRACTURE Environmental Cracking Naturally Brittle Material FATIGUE Connections OTHER Galling BTC Disengagement 15

Failure Generally Associated with Tensile Loads In API tensile tests to failure, 148 of 162 (91%) of round threaded connections failed by jumpout. Only 9% failed by fracture. TENSILE FRACTURE IN THE PIN THREADS TENSILE FRACTURE IN THE TUBE THREAD JUMPOUT 16

How Jumpout Happens Many times, jumped-out threads have been successfully rejoined downhole by setting down and turning right. BOX BOX BOX BOX BOX PIN NOT ENGAGED ENGAGED- JUMPED OUT Much of the thread deformation (strain) on jumpout is elastic, so only minor thread damage occurs (at thread crests). 17

Jumpout - The Main Reason API Adopted the Buttress Thread Form Vs. 30 degrees for the round thread form 3 degrees BOX PIN API BUTTRESS THREAD FORM 18

Stable F>(P I x A I ) - (P O x A O ) 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 (P I x A I ) - (P O x A O ) Section stable if: F > (P I x A I ) - (P O x A O ) Section buckled if: F (P I x A I ) - (P O x A O ) where: F is the amount of tension (+) or compression (-) (lbs) P O is the annular pressure (psi) A O is the outer circumference of the casing (in) P I is the pressure inside the casing (psi) A I is the inner circumference of the casing (in) Buckled F (P I x A I ) - (P O x A O ) 19

Tension 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 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. 20

Failure Modes Casing Failures PRESSURE Burst Collapse Connection Leaks TENSION Tube Fracture Connection Fracture Connection Jump Out Buckling BRITTLE FRACTURE Environmental Cracking Naturally Brittle Material FATIGUE Connections OTHER Galling BTC Disengagement 21

BRITTLE FRACTURE (Hydrogen Induced) Free hydrogen ions from the chemical reaction with H 2 S entered the steel in this coupling This and brittle made coupling it brittle, fracture leading occurred to in the failure. But some materials an begin H 2 S (hydrogen life brittle sulfide) environment. The mechanism is called Sulfide Stress Cracking (SSC) Microscopically, Sulfide Stress cracks tend to be branched and run along grain boundaries. Whether or not such a failure will happen depends on many factors that work together in complex interrelationships: H 2 S concentration Time of exposure Tensile stress level Metallurgical properties Temperature Other factors 22

Slip cuts 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. 23

Why Tough Material is Better Than Brittle MATERIAL A - BRITTLE, NOTCH-SENSITIVE MATERIAL B - TOUGH Tougher Can safely materials are safer & more RAPID, forgiving carry a higher BRITTLE stress with a FRACTURE given defect, Will fail by tearing apart like a piece of taffy, not shattering like a piece of glass! TENSILE STRESS SAFE In impact loading In fatigue loading In hydrogen sulfide MATERIAL B MATERIAL A Can safely carry a larger defect at a given stress DEFECT SIZE 24

Fundamentals! Fundamentals of Casing Material Selection for Sour and Corrosive Service Recall the failure mechanism Sulfide Stress Cracking (SSC) Free hydrogen generated in the H 2 S-Steel corrosion reaction causes otherwise ductile metal to become brittle and crack. 25

How Hardness and H 2 S Concentration Affect SSC 40 35 (5% NaCl solutrion. Carbon steel specimens @ 130% yield stress) As hardness decreases, time to failure increases. As concentration decreases, time to failure increases. NACE definition of sour: H 2 S Partial Pressure 0.05 psia. (5 PPM @ 10,000 psi) HARDNESS (HRC) 30 25 20 90 minutes Six months 0.1 ppm 1.0 ppm 15 H 2 S PPM 8000 3000 15 5 1 H 2 S PP @ 10,000 psi 80 30 0.15.05.01 15 3000 0.1.001 8000 10 0.1 1 10 100 1000 104 DAY WEEK MONTH YEAR Curves give H 2 S concentration in NaCl solution. (After Hudgins, McGlasson, Mehdizadeh, and Rosborough) TIME TO FAILURE (HOURS) 26

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. NO SSC P110 range of possible YS SSC NACE Minimum Temperature for P110 27

How Hardness and Tensile Stress Affect SSC Why Group 2 sour service grades (M65,L80,C90,T95) have restricted maximum hardness As Tensile Stress decreases, time to failure increases. HARDNESS (HRC) 45 40 35 30 25 (300 ppm H2S in 5% NaCl solutrion. Carbon steel specimens) 40% 60% 80% Curves give stress as a percent of yield strength. (After Hudgins, McGlasson, Mehdizadeh, and Rosborough) 20 100% 130% 15 0.1 1 10 100 1000 DAY WEEK MONTH TIME TO FAILURE (HOURS) 28

A Corrosion Engineer Selecting a Sour Service Material Will Consider Many Factors: a. H 2 S concentration b. Chloride levels The analysis is complex and the result c. CO 2 concentration will be a compromise that s very d. ph dependent on Local Conditions. e. Temperature f. Oxygen content of the flowstream g. Sulfur content of the flowstream h. Gas/Oil Ratio i. Water content of the flowstream j. Fluid velocity k. Cost of alternatives l. Anticipated life of the well 29

Typical Chemistry of Steels Carbon Steels Classification Low Alloy Steels Element (% Wt.) Stainless Steels Nickel Based Alloys Carbon 0.3-0.5 0.3-0.5 <0.25 <0.3 Manganese 0.5-2.0 <2 <2 <2 Molybdenum ---- <1 <4 <10 Chromium ---- <2 9-26 <25 Nickel ---- <1 <25 40-70 Iron >97 >95 40-85 2-40 Typical Cost Ratios 1 1.5 3-10 $$$! 30

Not for Material Selection! (talk to your corrosion engineer) A Guide for the Application of Corrosion Resistant Alloys (CRA) Higher temperature benefits SSC, but accelerates weightloss corrosion. $12-14 NIC 42 (G3, SM2550) $16-20 NIC 62 (C-276) Temperature (deg F) 475 400 300 275 $1.5-2 22 CR, 25 CR (DUPLEX SS) $2-3 $6-7 13 CR (420 MOD SS) 300 deg F 400 deg F Prices will vary widely with conditions in the metal markets. 800 2000 1500 9 Cr 200 0.15 1.5 10 1000 10000 Partial Pressure H2S (psia) If L80 Type 1 costs $1 31

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