Equations to Calculate Collapse Strength for High Collapse Casing

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Yuanhua Lin1 State Key Laboratory of Oil and Gas Reservoir Geology and Exploitation(SWPU),Chengdu,Sichuan610500,Chinae-mail:yhlin28@Yongxing Sun1 State Key Laboratory of Oil and Gas Reservoir Geology and Exploitation(SWPU),Chengdu Sichuan610500,China; Drilling&Production Engineering TechnologyResearch Institute(CCDC), Guanghan,Sichuan618300,Chinae-mail:yohancesun@Taihe ShiKuanhai Deng State Key Laboratory of Oil and Gas ReservoirGeology and Exploitation(SWPU),Chengdu,Sichuan610500,ChinaLiexiang HanHaifang Sun Drilling&Production Engineering TechnologyResearch Institute(CCDC), Guanghan,Sichuan618300,ChinaDezhi ZengHongjun Zhu State Key Laboratory of Oil and Gas ReservoirGeology and Exploitation(SWPU),Chengdu,Sichuan610500,China Equations to Calculate Collapse Strength for High Collapse CasingAs wells are drilled deeper,the external pressures applied to well casing become greater. Conventional America Petroleum Institute(API)casing strength cannot meet the strength criteria of high pressure,high temperature,and high H2S(HPHTHS)gas wells which are called“3-high”gas wells.When high collapse casing(HCC)is applied in oilfields,it has obviously improved collapse properties in excess of API ratings.HCC shows a very high resistance to tension load,internal pressure,and collapse,as well as being highly resistant to sulfide stress corrosion cracking(SSCC),and it also can be used for deep and sour gas and oilfields.For imperfections of the API5C3collapse formula,the joint API/ISO work group ISOTC67SC5WG2b have proposed the current API Bulletin5C3, and a new collapse strength model with manufacturing imperfections,such as ovality,ec-centricity,residual stress,etc.,improves the casing strength calculation accuracy and increases the benefits for casing strength design,rather than just using API Bulletin5C3. The study on the new ISO collapse model has found that it is inappropriate to predict the collapse strength of the high collapse casing.As a result,on the basis of my work group results,a new high collapse model for predicting the collapse strength of all HCC has been presented.Numerical and experimental comparisons show that the“new high col-lapse model”predicts higher accuracy than that of ISO,and this will make great improvements in the casing design of deep and ultradeep wells on the basis of HCC mate-rial safety,which was guaranteed.[DOI:10.1115/1.4023734]1IntroductionAs wells are drilled deeper,the external pressures applied to well casings become greater.Thus,a well casing must have adequate collapse strength to withstand these horizontal pressures without deformation.With the high pressure,high temperature, and high H2S(HPHTHS)gas wells increasing,conventional API casing strength cannot meet the strength criteria of HPHTHS,the so called“3-high”gas wells.In these wells,failures of high strength grades for deep well service have been reported in recent years.Furthermore,it is well known that the plastic creep forma-tion made of rock salt,gypse,and clay shale will give rise to a much higher external collapse pressure on casing,and this results in a much higher collapse strength of oil country tubular goods (OCTG)grades(such as140and150ksi grades)which are required to meet deep well service requirements.High collapse (HC)casing applied in oilfields has improved collapse properties well in excess of API ratings.These properties are achieved by strict mill control incorporating a unique production technique in-clusive of quenching and tempering,as well as being highly resist-ant to sulfide stress corrosion cracking and can be used for deep and sour gas and oil service.The influence of manufacturing technology and imperfections on casing collapse strength is not considered in API Bulletin5C3 [1].In addition,the API5C3collapse strength equations(pre-sented in ISO/TR10,400:2007[2]Annex E)cannot be used to predict the collapse strength of high strength pipe or other proprie-tary products.For these cases,the joint API/ISO work group ISOTC67SC5WG2b has proposed the current API Bulletin5C3 and has presented a new ISO collapse strength model with manu-facturing imperfections,such as ovality,eccentricity,residual stress,etc.The new ISO collapse strength model improves the casing strength calculation accuracy and benefits a lot from casing strength design,rather than just using API Bulletin5C3[ISO/TR 10,400(first edition2007-12-15)][2].With the improvement of the production technology and devel-opment of OCTG quality control,various manufacturing imper-fections have been tightly controlled.The predictive collapse strength by API5C3:1994is too conservative and some collapse strength values are much higher than that of API5C3,because API5C3collapse strength equations are relatively poor predictors1Corresponding authors.Contributed by the Pressure Vessel and Piping Division of ASME for publication in the J OURNAL OF P RESSURE V ESSEL T ECHNOLOGY.Manuscript received April16,2012;final manuscript received February4,2013;published online June11,2013.Assoc. Editor:Wolf Reinhardt.of true collapse strength [3–11].In addition,the API 5C3collapse strength equations (presented in ISO/TR 10,400:2007Annex E)cannot be used to predict the collapse strength of high strength pipe or other proprietary products.For these cases,the joint API/ISO work group ISOTC67SC5WG2b has proposed the current API Bulletin 5C3and released the document of ISO/TR 10,400(first edition 2007-12-15)[2].The study on the new ISO collapse model has found that it is unsuited to be used to predict all the collapse strength of high col-lapse casing.So,on the basis of my work group results [11,12],a new OCTG high collapse model for predicting the collapse strength of all high HCC has been presented.Lots of numerical and experimental comparisons show that the “new high collapse model”prediction’s accuracy is higher than that of ISO,and this will make great improvements in the casing design of deep and ultradeep wells on the basis of guaranteed high collapse casing material safety.(China National Petroleum Corp.(CNPC)legisla-tion defines high pressure,high temperature,and high H 2S wells as those with an undisturbed bottom hole of 150 C or greater,a well bottom pressure of 105MPa or greater,and a H 2S gas vol-ume of 3%or greater.)2HCC Strength Prediction2.1Imperfections of API 5C3Collapse Formula.The min-imum collapse pressures given in API Bulletin 5C3are calculated by means of yield strength collapse pressure Eq.(1)[2]:P yp ¼2r yD t À1D 2(1)Equation (1)can be used to compute the yield collapse pressure where the diameter-thickness ratio (D =t )is less than D =t ðÞYP .Where D =t ðÞYP is the upper bound of the diameter-thickness ra-tio in yield collapse stage.Plastic collapse pressure Eq.(2)[2]:P pc ¼r y A c D tÀB c 0B @1C A 264375ÀC c(2)Equation (2)can be used to compute the plastic collapse pres-sure where the diameter-thickness ratio (D =t )ranges from D =t ðÞYP to D =t ðÞPT .Where D =t ðÞPT is the upper bound of the diameter-thickness ra-tio in plastic collapse stage;A c ,B c ,and C c are the steel grade coef-ficients used to compute the collapse pressure.Transition collapse pressure Eq.(3)[2]:P pt ¼r y F c D ÀG c 0B @1CA(3)Equation (3)can be used to compute the transition collapse pressure where the diameter-thickness ratio (D =t )ranges from D =t ðÞPT to D =t ðÞTE .Where D =t ðÞTE is the upper bound of the diameter-thickness ra-tio in elastic-plastic collapse stage;F c and G c are the steel grade coefficients used to compute the collapse pressure.And elastic collapse pressure Eq.(4)[2]:P e ¼46:95Â1060D t DtÀ1 2"#(4)Equation (4)can be used to compute the elastic collapse pres-sure where the diameter-thickness ratio (D =t )is greater than D =t ðÞTE .For all of the above equations’details (such as D =t ðÞYP ,D =t ðÞPT ,D =t ðÞTE ,and the steel grade coefficients A c ,B c ,C c ,et al.)see Annex E in ISO/TR 10,400:2007[2].When determining the appro-priate equation to be used for calculating collapse resistance for a particular D /t ratio and minimum yield strength,the D /t ranges should be first determined by relative equations.The API 5C3collapse strength equations (presented in ISO/TR 10,400:2007Annex E)cannot be used to predict the collapse strength of high strength pipe or other proprietary products.2.2ISO New Collapse Strength Equation.Theoretical stud-ies of the effect of ovality on tubular collapse resistance consis-tently indicate that an ovality of 1%to 2%can make a reduction in collapse resistance on the order of 25%.However,experimental/empirical investigations indicate a much smaller effect.Test data indicate that ovality is the only one of many pipe parameters (including residual stress,isotropy,shape of stress-strain curve/microstructure,and yield strength)that influences collapse resist-ance.Review of industry collapse data indicates that the ovality is not the dominant parameter affecting collapse strength.A work-group on collapse resistance concluded that the effect of ovality on tubular collapse had been handled during the adjustment of average collapse predictions to minimum performance values and that oval-ity should not be awarded the status of an independent variable in an API equation for collapse performance.The design collapse strength for pipe under external pressure is only as follows (per F.6“Summary”P184ISO/TR 10,400first edition 2007-12-15)[2]:P ISO ¼P e Àiso þP y Àiso ÀÁÀP e Àiso ÀP y ÀisoÀÁ2h n þ4P e Àiso P y Àiso H t Ã1=2o.21ÀH t ðÞ½ (5)whereP y Àiso ¼k y Àiso Â2r y t =D ðÞ1þ2D ðÞ½(6)P e Àiso ¼0:825Â2E .1Àv 2ÀÁD =t ðÞD =t ðÞÀ1½2n o (7)H t Àiso ¼0:127l ov þ0:0039l ec À0:440l rs =l fyÀÁ(8)H t -iso is a decrement factor taking into consideration the imper-fections,such as ovality,eccentricity,residual stress;H t -iso ¼0.22for a cold rotary straightened (CRS)product and 0.20for a hot ro-tary straightened (HRS).k y -iso is the down-rating factor for design yield collapse (shown in ISO10400:2007P185)and k y -iso is de-pendent on steel grade,hot or cold straightened process.The difference between ISO 10,400and API Bulletin 5C3is that ISO 10,400considers the manufacturing imperfections of ovality,eccentricity,and residual stress,as well as the influence of different manufacturing techniques on casing collapse strength.The specified collapse strength calculated by the new ISO model is called design collapse strength,because it is used to design OCTG strength for oil field applications.Recently,manufacturers created non-API standard thick-wall casing and non-API standard high collapse casing to meet the project criteria,the collapse strength can be predicted by the new ISO collapse formula instead of API 5C3.Moreover,ISO 10,400does not rely on the full-size specimen collapse evaluation,and only a few number of full-scale collapse results are used to validate the evaluation.The maximum ovality and eccentricity calibrated in ISO 11,960:2009[13]is,respectively,0.5%and 12.5%,when H t -iso is 0.22,the minimum ratio of residual stress to yield strength is 10.8%,which requires the manufacturers to control tightly the ovality and eccentricity of casing,or to reduce the residual stress of casing.2.3New HCC Strength Equation.It has been shown from ISO TC67SC5WG2b work and SWRI [2]in their document 18-5C3-TP-1[14]that steels with lower residual stress and a sharp kneed stress-strain curve could contribute greater collapse per-formances (shown in Fig.1).Other factors such as the ovality and eccentricity do affect collapse performances but not so much dominating collapse strength with the modern manufacturing technology of the oil tubular goods.In Fig.1the collapse ratio is defined as the ratio of real residual stress (RS)and yield strength (YS)of casings;Smls stands for seamless;EW stands for electric welded,YS stands for yield strength;Ten stands for tensile strength;RS stands for residual stress;and Pc stands for the collapse strength of casing.From Fig.1,it is known that J55RS is 18ksi and YS is 63ksi.So the collapse ratio of J55casing is equal to 0.286(18/63).By parity of reasoning,the collapse ratio of N80high collapse casing is equal to 0.038(4/105).By comparing the collapse ratio of J55casing with the N80high collapse casing,it is known that the N80high collapse casing has greater collapse performances than J55casing.In other words,steels with lower residual stress and a sharp kneed stress-strain curve could contribute greater collapse performances.Another factor affecting casing collapse behavior is the ratio of yield strength to tensile strength.A lower ratio of yield strength (r y )to tensile strength (r t )for the casings with same yield strength has higher collapse strength.A typical example of that is J55and K55casing.Those two steels (J55and K55casing)have the same nominal yield strength (r y )but the tensile strength (r t )of K55is higher than J55,which imparts K55much higher col-lapse strength than J55.The main difference between ISO 10,400and the new HCC strength equation is that the yield stress and decrement factor H t -new term,where in ISO/TR 10,400(first edition 2007-12-15)[2]the yield stress through the wall of OCTG,is drastically underestimated.P new ¼p e Ànew þp p Ànew ÀÁÀp e Ànew Àp p ÀnewÀÁ2h n þ4p e Ànew p p Ànew H t ÀnewÃ1=2o.21ÀH t Ànew ðÞ½ (9)p e Ànew ¼2E =1Àv 2ÀÁD =t ðÞD =t ðÞÀ1½ 2n o (10)P p Ànew¼2k yc r y ffiffiffi3p lnD =t D =t À2(11)H t Ànew ¼0:127l ov þ0:0039l ec À0:440l rs ðÞ=l fy þr t ÀÁþh n(12)where h n in Eq.(12)is the shape factor of stress and strain curves and it is generally equal to zero under the better processing condi-tion;k yc is the decrement factor for yield strength.3Numerical and Experimental ComparisonsThe purpose of DEA-130[14]was to perform collapse testsand carefully document the pipe samples and test data.The partic-ipants of DEA-130consisted of 12end-users,three industry/government agencies and 11pipe manufacturers.The program was performed by four engineering companies and was directed by a Steering Committee,which was made up of representatives of the end-users and agencies.All tests were for long specimens (L /D !7),and in each case the relevant strength and geometry properties (yield stress,average outside diameter,average wall thickness,eccentricity,ovality,and residual stress)were accu-rately measured prior to collapse testing.The test fixture consists of two seal end plates with the diameter closely matching the outside diameter of the sample and a solid steel mandrel that is sized to fit inside the sample with the length of the mandrel approximately matching the pipe sample length.The mandrel is connected to the seal plates by means of threaded fasteners.Figure 2shows arrangement of the test sample and fix-ture in a pressure vessel [14].DEA-130was structured to provide proprietary benefit to participating companies,while it also pro-vided public benefit to the industry through the acquisition of a collapse database on modern pipe for use by API and ISO.The mean deviation (MD),standard deviation (SD),and coeffi-cient of variation (COV)of the actual collapse strength-to-pre-dicted collapse strength ration (Q&T only)are shown in Table 1.It can be found that using Eq.(9)to calculate HCCcollapseFig.1Typical stress-strain curves (SSCs)for collapseratioFig.2Collapse test setupstrength can get higher calculation accuracy than that of API and ISO.Based on theoretical analysis and comparison of calculated results obtained by Eqs.(9)–(12),with the complete collapse tests of steel pipe casing and tubing completed by SWRI in the docu-ment 18-5C3-TP-1[14],the calculated results are compared to test collapse in Fig.3for high collapse grades.In Fig.3the verticalaxis is collapse strength,and the horizontal axis is the ratio of the pipe’s outer diameter to pipe wall thickness (D /t ).Table 2shows comparisons of HCC calculation results computed by Eqs.(9)–(12)with full-scale collapse test data.Figure 4shows that the ratio of P test to P hc is normally distrib-uted,which indicates that the new high collapse model proposed in the paper can better predict collapse strength of HCC,on theTable 1The predictive accuracies (Q&T only)P test /API Bulletin5C31994P test /ISO104002007P test /Eq.(9)Dataset (DEA-130)Axial forceMD COV SD MD COV SD MD COV SD HCC (29samples)No1.4100.0240.1591.4260.0210.1471.2890.0310.179Fig.3Comparison of full-scale collapse test data with calcula-tion results Table 2Comparison of HCC calculation results with full-scale collapse test data a No.Specified D (in.)r y (ksi)Grade Process Test D (in.)Test t (in.)OV (%)EC (%)P test (psi)P hc P test /P hc 607110A EW 7.070.4050.1460.8161032310075 1.07617110A EW 7.070.4040.3020.6121004210075 1.04627110A EW 7.080.4030.3250.8821021110075 1.06637110A EW 7.060.4030.4640.8191001810075 1.04767.75125Q Smls 7.820.5980.227 1.9052122018084 1.24777.75125Q Smls 7.820.60.226 2.5722395618084 1.4011310.7580N Smls 10.840.3980.18 2.0713******* 1.1111410.7580N Smls 10.830.4010.249 1.61436983099 1.2211510.7580N Smls 10.830.40.22 1.56235423099 1.1612913.37580N Smls 13.450.4820.17 4.334022815 1.2313013.37580N Smls 13.440.4850.166 6.2935212815 1.2713113.37580N Smls 13.450.4860.3028.11934372815 1.2413513.375110P Smls 13.440.480.212 1.60332082955 1.1013613.375110P Smls 13.440.4730.271 1.53730802955 1.0513713.375110P Smls 13.430.4810.196 3.22333522955 1.1513813.37595A Smls 13.470.5230.647 2.36538133496 1.1113913.37595A Smls 13.460.5280.618 2.45840103496 1.1614013.375110P Smls 13.460.5020.396 3.06536373581 1.0314113.375110P Smls 13.450.5050.269 4.0373******* 1.0814213.375110P Smls 13.450.5140.303 4.75740563581 1.15143 1.3625125Q Smls 13.730.6420.218 1.77583176743 1.26144 1.3625125Q Smls 13.720.6470.289 1.53776206743 1.15145 1.3625125Q Smls 13.730.6470.2 1.98778496743 1.191461680N Smls 16.090.5310.231 2.32926691870 1.441471680N Smls 16.080.520.291 4.72325501870 1.381481680N Smls 16.080.5120.234 4.68224131870 1.3014916110P EW 16.070.5740.274 1.0713******* 1.0715016110P EW 16.090.5720.3340.62629032937 1.0015116110PEW16.080.5740.310.532315029371.08aSmls stands for seamless;EW stands for electric welded,OV stands for ovality,EC stands for eccentricity,P hc stands for design collapse pressure(psi).Fig.4Histogram for the ratio of full-scale collapse pressure to calculation results computed by Eqs.(9)–(12)condition that ovality is less than0.4%,nonuniform wall thickness is less than4.0%,and the measured yield strength of material is greater than nominal yield strength by10%.Since the HCC collapse test is difficult and costly,the collapse strength data available are cited in the paper.Extensive full-scale collapse data are needed to validate the new high collapse model proposed in this paper to further improve and complete the calcu-lation accuracy;thus providing reliable references for casing design.4ConclusionsOn the basis of the new ISO collapse model,a new high col-lapse strength equation has been presented that considers manu-facturing imperfections such as ovality,eccentricity,and residual stress in its calculation.It will improve the high collapse strength calculation accuracy and provide important reference to optimize casing strength design.Equation(9)better reflects the HCC actual manufacturing tech-nology because it considers influence of manufacturing imperfec-tions on OCTG collapse strength,which will be good for high collapse strength design,rather than just using API bulletin5C3 or ISO,because not only does it avoid the material loss but also guarantees the safety and reliability of casing material. Numerical and experimental comparisons showed that Eq.(9) calculation accuracy is better than that of API and ISO.So,Eq.(9)can be used as a lower bound design equation,which will make great improvements in deep and ultradeep wells casing designs on the basis of guaranteeing casing material safety. AcknowledgmentResearch work was co-financed by the National Natural Sci-ence Foundation of China(No.51074135,No.51274170,No. 51004084),and thanks to Mr.Young W.Kwon at Battelle for his helpful discussions.NomenclatureP yp¼API5C3Bulletin collapse pressure,psiP pc¼API5C3Bulletin plastic collapse pressure,psiP pt¼API5C3Bulletin transition collapse pressure,psiP ISO¼ISO design collapse pressure,psiP new¼new HCC strength equation design collapse pressure,psi P e-iso¼ISO design elastic collapse term,psiP y-iso¼ISO design yield collapse term,psiP e-new¼new HCC strength equation design elastic collapse term, psiP p-new¼new HCC strength equation design full-wall yield col-lapse term,psiD¼specified outside diameter,in.t¼specified pipe wall thickness,in.E¼Young’s modulus,30Â106psiH t-iso¼decrement factor of ISO new collapse strength equationto take the pipe imperfection into considerationH t-new¼decrement factor of new HCC strength equation to takethe pipe imperfection into considerationk y-iso¼down-rating factor for ISO design yield collapse(shown in ISO10400:2007P185)k yc¼decrement factor for yield strength,0.9¼Poisson ratio,0.28l fy¼mean true yield strength,psil ov¼mean ovality,%,l ov¼100(D maxÀD min)/D avel ec¼mean calculated eccentricity as a percent,l ec¼100(t cmaxÀt cmin)/t cavel rs/l ty¼residual stress ratiol rs¼residual stress,psir y¼yield strength,psir t¼tensile strength,psih n¼shape factor of stress and strain curvesReferences[1]Bulletin on Formulas and Calculations for Casing,Tubing,Drill Pipe and LineProperties,API Bulletin5C3,6th ed.,1994.[2]“Petroleum and Natural Gas Industries-Formula and Calculation for Casing,Tubing,Drill Pipe and Line Pipe Properties,”ISO/TR10400,2007.[3]Chen,Q.,Marley,M.,and Zhou,J.,2011,“Remaining Collapse Capacity ofCorroded Pipelines,”ASME Conf.Proc.OMAE2011.[4]Klever,F.J.,and Tamano,T.,2006,“A New OCTG Strength Equation for Col-lapse Under Combined Loads,”SPE,90904,pp.2–6.[5]Pattillo,2007,“Effect of Length:Diameter Ratio on Collapse Test Results andFrame Design,”SPE105602-MS.[6]Paumier,L.,and Mesnage,O.,2011,“PSI Armour Wire for High Collapse Per-formance of Flexible Pipe,”ASME Conf.Proc.OMAE2011.[7]Van den Abeele,F.,Bar,J.,and Jakani,S.,2011,“Buckling and Unstable Col-lapse of Seamless Pipes and Tubes,”ASME Conf.Proc.IPC2010,8th Interna-tional Pipeline Conference,Vol.3.[8]Reichel,T.,Pavlyk,V.,Beissel,J.,Kyriakides,S.,and Jang,W.-Y.,2010,“Improved Collapse Resistance of Large Diameter Pipe for Deepwater Applica-tions Using a New Impander Technology,”ASME Conf.Proc.IPC2010,8th International Pipeline Conference,Vol.2.[9]Paumier,L.,Averbuch,D.,and Felix-Henry,A.,2009,“Flexible Pipe CurvedCollapse Resistance Calculation,”ASME Conf.Proc.OMAE2009,Vol.3: Pipeline and Riser Technology.[10]Machida,H.,Takahashi,Y.,and Nakagawa,Y.,2008,“Plastic Collapse Evalua-tion for Multiple Circumferential Flaws in a Pipe,”ASME Conf.Proc.PVP2008,Vol.1:Codes and Standards.[11]Sun,S.,2010,“Equation for Calculation Casing Through-Wall Yield CollapsePressure,”SPE126580-MS.[12]Sun,Y.-X.,Lin,Y.-h.,Wang,Z.-S.,Shi,T.-h.,Liu,H.-b.,Liao,P.,and Shen,X.-d.,2011,“A New OCTG Strength Equation for Collapse Under External Load Only,”ASME J.Pressure Vessel Technol.,133,p.011702.[13]Petroleum and Natural Gas Industries-Steel Pipes for Use as Casing or Tubingfor Wells,”ISO11960,2009.[14]“SWRI18-5C3-TP-1of DEA-130Modernization of Tubular Collapse Perform-ance Properties,”API/HSE/MMS Participant Report,October2002.。