Advanced Casing & Tubing Design Training Course

1. Introduction to Advanced Casing and Tubing Design

1.1 Fundamentals of Well Tubular Design

• Role of casing and tubing in well construction including (barrier function, structural support, and production enablement)

• Evolution of design methodologies including (historical approaches and modern analytical methods)

• Impact of well design on field economics including (capital costs, operational efficiency, and intervention requirements)

• Integration with other disciplines including (drilling engineering, completion engineering, and reservoir management)

• Introduction to API TR 5C3 and ISO 11960 standards for tubular design and performance

1.2 Casing and Tubing Functions

• Primary casing functions including (zonal isolation, wellbore stability, and pressure containment)

• Tubing design considerations including (production requirements, artificial lift compatibility, and intervention access)

• Casing seat selection including (pressure regression analysis, formation integrity evaluation, and pore pressure determination)

• Tubular program optimization including (telescoping ratios, clearance requirements, and drift diameter considerations)

• Well integrity principles including (barrier philosophy, verification methods, and long-term monitoring)

2. Advanced Load Case Analysis

2.1 Mechanical Properties and Performance Limits

• Material strength characteristics including (yield strength, tensile strength, and elastic limits)

• Performance envelopes including (triaxial stress analysis and combined loading effects)

• Safety factors determination including (risk-based approaches, environmental factors, and regulatory requirements)

• Understanding API specifications for tubular performance including (minimum performance properties and testing requirements)

• Manufacturing processes and their impact on mechanical properties including (seamless vs. welded, heat treatment, and cold working)

2.2 Burst Load Analysis

• Burst pressure calculation methods including (Barlow's formula, API methods, and FEA approaches)

• Internal yield pressure determination including (elastic and plastic deformation considerations)

• External pressure effects including (differential pressure scenarios and trapped annular pressure)

• Biaxial and triaxial stress effects including (combined loading and axial stress impact)

• Burst design factors including (operational scenarios, worst-case evaluations, and uncertainty management)

2.3 Collapse Load Analysis

• Collapse modes including (yield strength collapse, plastic collapse, elastic collapse, and transition collapse)

• API TR 5C3 collapse rating methodologies including (simplified equations and numerical methods)

• Impact of manufacturing variations including (ovality, eccentricity, and wall thickness variations)

• Collapse resistance in deviated wells including (bending stress effects and dogleg severity impact)

• Environmental degradation effects including (corrosion, temperature, and hydrogen embrittlement)

2.4 Tensile Load Analysis

• Tension limit determination including (body yield, connection strength, and combined load effects)

• Self-weight calculations including (buoyancy effects and fluid density considerations)

• Bending stress analysis including (dogleg severity, build rates, and wellbore tortuosity)

• Surface and operational loads including (slips effect, handling procedures, and workover considerations)

• Shock loading considerations including (jarring operations and sudden pressure changes)

2.5 Advanced Combined Load Analysis

• Triaxial stress analysis including (von Mises criteria and maximum distortion energy theory)

• Advanced yield criteria including (Tresca criterion and modified von Mises approaches)

• Non-uniform loading including (partial pressurization, localized heating, and contact forces)

• Dynamic loading considerations including (pressure testing, temperature cycling, and vibration)

• Computer modeling techniques including (finite element analysis and probabilistic approaches)

3. Material Selection and Connection Design

3.1 Tubular Materials and Metallurgy

• Carbon steel grades including (H40, J55, N80, P110, and Q125)

• Corrosion resistant alloys including (13Cr, super 13Cr, duplex, and Inconel)

• Mechanical properties including (yield strength, tensile strength, hardness, and toughness)

• Sour service considerations in accordance with NACE MR0175/ISO 15156 including (SSC resistance and HIC resistance)

• High temperature performance including (yield strength degradation and creep resistance)

3.2 Connection Types and Selection

• API connections including (round thread, buttress thread, and extreme line)

• Premium connections including (metal-to-metal seals, torque shoulders, and specialty threads)

• Connection performance attributes including (tension efficiency, pressure integrity, and fatigue resistance)

• Specialized connections including (expandable tubulars, multilateral junctions, and intelligent completions)

• Connection qualification per ISO 13679 and API RP 5C5 including (testing protocols and acceptance criteria)

3.3 Thread Compound and Make-up Considerations

• Thread compound selection including (standard, environmental, and high-temperature applications)

• Make-up torque calculations including (friction factors, shoulder effects, and stress limitations)

• Computer-controlled make-up including (torque-turn monitoring and acceptance criteria)

• Connection management including (handling procedures, inspection requirements, and field repair)

• Quality assurance protocols including (thread inspection, dimensional verification, and make-up verification)

4. Designing for Challenging Environments

4.1 HPHT Well Design

• HPHT classification and challenges including (temperature effects on materials and thermal expansion)

• Material selection for HPHT including (specialized alloys and heat treatment requirements)

• Thermal stress analysis including (casing elongation, buckling potential, and annular pressure buildup)

• Cement design considerations including (thermal cycling, expansion properties, and set time)

• HPHT well integrity verification including (pressure testing, cement evaluation, and monitoring systems)

4.2 Deviated and Extended Reach Wells

• Buckling analysis including (sinusoidal, helical, and post-buckling behavior)

• Torque and drag considerations including (friction factors and well trajectory optimization)

• Running and rotation limitations including (critical rotational speed and resonance phenomena)

• Centralizer program design including (placement strategy and stand-off requirements)

• Weight transfer in highly deviated sections including (sliding friction and weight stacking)

4.3 Subsalt and Mobile Formation Applications

• Salt creep effects including (loading rate, temperature influence, and stress relaxation)

• Casing design for mobile formations including (higher collapse ratings and clearance considerations)

• Salt layer crossing strategies including (stiffness matching, special connections, and material selection)

• Long-term integrity monitoring including (casing deformation detection and remedial options)

• Case histories of subsalt well designs including (Gulf of Mexico and Middle East applications)

4.4 Deepwater Applications

• Deepwater-specific challenges including (temperature effects, hydrostatic pressure, and fatigue loading)

• Riser to wellhead transition including (stress concentration management and fatigue analysis)

• Subsea wellhead loading including (bending moment limitations and conductor design)

• Vortex-induced vibration including (prediction methods and mitigation strategies)

• Fatigue analysis per API RP 2RD including (S-N curves and cumulative damage calculation)

5. Failure Analysis and Prevention

5.1 Casing and Tubing Failure Mechanisms

• Mechanical failures including (burst, collapse, tensile parting, and connection failure)

• Environmentally assisted cracking including (SSC, CSCC, and hydrogen embrittlement)

• Erosion and wear mechanisms including (sand production, tool rotation, and fluid velocities)

• Corrosion mechanisms including (sweet, sour, galvanic, and microbial)

• Thermal fatigue including (temperature cycling and expansion/contraction effects)

5.2 Failure Prevention Strategies

• Material selection optimization including (corrosion resistant alloys, coatings, and inhibition)

• Design factor adjustment including (risk-based approaches and reliability-centered design)

• Connection selection criteria including (gas tightness, fatigue resistance, and tensile efficiency)

• Operational procedures including (running practices, pressure testing protocols, and workover considerations)

• Condition monitoring including (caliper surveys, pressure monitoring, and annular fluid sampling)

5.3 Root Cause Analysis Methodology

• Investigation protocols including (data gathering, metallurgical analysis, and operational review)

• Failure analysis techniques including (visual inspection, non-destructive testing, and microstructural examination)

• Stress analysis including (stress distribution modeling and critical point identification)

• Environmental factor assessment including (fluid analysis, temperature profiling, and microbiological testing)

• Recommendations development including (redesign considerations, operational modifications, and monitoring programs)

6. Economics and Optimization

6.1 Cost Analysis and Optimization

• Material cost considerations including (grade selection, connection type, and dimensional optimization)

• Installation cost factors including (running time, specialized equipment, and personnel requirements)

• Life-cycle cost analysis including (initial investment, intervention frequency, and remediation costs)

• Risk-based optimization including (failure probability, consequence assessment, and risk mitigation)

• Value engineering approaches including (fit-for-purpose design and standardization opportunities)

6.2 Decision-Making Tools and Methods

• Decision tree analysis including (uncertainty quantification and expected monetary value)

• Monte Carlo simulation including (probabilistic inputs and confidence intervals)

• Multi-criteria decision analysis including (weighted scoring and prioritization techniques)

• Sensitivity analysis including (tornado diagrams and critical parameter identification)

• Cost-benefit optimization including (marginal analysis and diminishing returns assessment)

7. Cementing Considerations for Tubular Design

7.1 Cement-Tubular Interface

• Cement sheath integrity including (stress analysis and failure mechanisms)

• Cement bond evaluation including (acoustic and ultrasonic measurement techniques)

• Thermal effects including (expansion coefficient mismatch and stress development)

• Microannulus prevention including (expandable cement systems and flexible cement designs)

• Long-term integrity considerations including (cyclic loading effects and remedial options)

7.2 Advanced Cementing Technologies

• Cement system selection including (conventional, lightweight, and heavyweight systems)

• Specialized cement additives including (expansion agents, fibers, and flexible polymers)

• Zonal isolation strategies including (stage cementing, external casing packers, and swellable packers)

• Remedial cementing techniques including (squeeze cementing and expandable casing patches)

• Quality assurance procedures including (lab testing, job simulation, and post-job evaluation)

8. HSE in Tubular Design and Operations

• Well control considerations including (kick tolerance analysis, casing pressure ratings, and blowout scenarios)

• Environmental protection including (barrier verification, leak detection, and remediation plans)

• Personnel safety including (handling procedures, running operations, and pressurization risks)

• Regulatory compliance including (governmental requirements, industry standards, and operator specifications)

• Emergency response planning including (well control events, casing failure scenarios, and contingency procedures)

9. Quality Assurance and Quality Control

9.1 Tubular Specifications and Inspection

• API and ISO requirements including (specification compliance and verification methods)

• Dimensional inspection including (OD, ID, wall thickness, and ovality measurements)

• Non-destructive testing including (electromagnetic, ultrasonic, and radiographic methods)

• Thread inspection including (profile verification, surface finish, and standoff measurements)

• Documentation and traceability including (mill certificates, heat numbers, and unique identifiers)

9.2 Field Operations QA/QC

• Pre-running inspection including (visual examination, drift testing, and thread protection)

• Running procedures including (handling guidelines, make-up practices, and torque monitoring)

• Installation verification including (tally verification, depth correlation, and cement evaluation)

• Post-installation testing including (pressure testing, casing inspection logs, and cement evaluation logs)

• Documentation requirements including (as-built records, test reports, and non-conformance management)

10. Case Studies & Group Discussions

• Regional case studies from Middle East operations including (HPHT wells, deviated wells, and challenging formations)

• Failure analysis examples including (root cause identification, lessons learned, and preventative measures)

• Design optimization scenarios including (material selection, connection choices, and design factor determination)

• Problem-solving exercises including (load case analysis, material selection, and failure prevention)

• The importance of proper training in successful casing and tubing design and installation operations