Casing Design Training Course

1. Introduction to Casing Design

1.1 Casing Design Fundamentals

• Purpose and functions of casing including (wellbore stability and zone isolation)

• Types of casing strings including (conductor casing and production casing)

• Casing design workflow including (data gathering and load analysis)

• Key design factors including (safety factors and economic considerations)

• Introduction to API 5C3 and ISO 11960 standards for casing design

1.2 Well Planning Considerations

• Geological factors affecting casing design including (formation pressure profiles and formation strength)

• Well trajectory influences including (directional considerations and dogleg severity)

• Operational constraints including (rig capabilities and handling limitations)

• Regulatory requirements including (barrier philosophy and compliance considerations)

• Risk assessment methodology including (risk identification and mitigation strategies)

2. Casing and Tubing Properties

2.1 Casing Materials and Manufacturing

• Steel grades and properties including (yield strength and tensile strength)

• Manufacturing processes including (seamless pipes and electric resistance welded pipes)

• Heat treatment effects including (normalized casing and quenched and tempered casing)

• Metallurgical considerations including (chemical composition and carbon equivalence)

• Quality control during manufacturing including (non-destructive testing and mechanical testing)

2.2 Casing Dimensions and Specifications

• Size designation system including (nominal outside diameter and actual dimensions)

• Wall thickness options including (standard weights and special weights)

• Dimensional tolerances including (diameter tolerances and wall thickness variations)

• Internal yield pressure ratings including (Barlow's formula and API ratings)

• Collapse resistance ratings including (API collapse formulas and plasticity factors)

3. Load Analysis and Design Principles

3.1 Basic Load Conditions

• Burst pressure calculations including (internal pressure and external pressure differentials)

• Collapse pressure determination including (hydrostatic pressure and cement pressure)

• Axial load analysis including (tension loads and compression loads)

• Biaxial load effects including (combined loading conditions and triaxial stress analysis)

• Temperature effects including (thermal expansion and property degradation)

3.2 Advanced Load Analysis

• Buckling considerations including (sinusoidal buckling and helical buckling)

• Bending stress analysis including (dogleg severity effects and contact forces)

• Wear mechanisms including (mechanical wear and corrosion effects)

• Fatigue loading including (cyclic stresses and cumulative damage)

• Dynamic loading including (surge and swab pressures and jar impacts)

4. Casing Design Methodology

4.1 Design Process and Workflow

• Data gathering and organization including (offset well data and geological information)

• Design criteria establishment including (regulatory requirements and company standards)

• Load case identification including (critical scenarios and contingency operations)

• Iterative design approach including (preliminary sizing and detailed analysis)

• Design verification including (safety factor validation and sensitivity analysis)

4.2 Safety Factors and Risk Assessment

• Industry standard safety factors including (API recommended values and regional requirements)

• Risk-based design approach including (risk assessment matrix and mitigation measures)

• Sensitivity analysis including (parameter uncertainty and impact evaluation)

• Reliability-based design including (probabilistic methods and failure assessment)

• Fit-for-purpose considerations including (optimizing design based on operational requirements)

5. Casing Design for Various Well Types

5.1 Vertical and Directional Wells

• Design considerations for vertical wells including (standard load cases and simple designs)

• Directional well challenges including (dogleg severity and contact forces)

• Extended reach wells including (friction reduction and buckling prevention)

• S-shaped wells including (tension and compression transitions and neutral points)

• Hook load predictions including (string weight and drag effects)

5.2 Horizontal and Multilateral Wells

• Horizontal section design including (buckling prevention and wear considerations)

• Landing string design including (tension capacity and rotational capability)

• Multilateral junction considerations including (mechanical integrity and pressure ratings)

• Window exit reinforcement including (stress concentration and material selection)

• Torque and drag analysis including (friction factors and rotational limitations)

6. Specialized Casing Design Applications

6.1 High-Pressure High-Temperature Wells

• HPHT design challenges including (material limitations and property degradation)

• Temperature effects on material properties including (yield strength reduction and expansion coefficients)

• Connection selection for HPHT including (premium connection types and gas-tight ratings)

• Special metallurgy considerations including (hydrogen sulfide resistance and carbon dioxide tolerance)

• Middle East HPHT case studies including (deep gas wells and high-pressure limestone formations)

6.2 Hostile Environment Applications

• Corrosive environment design including (H₂S service and CO₂ presence)

• Material selection for corrosion resistance including (CRA selection and coating options)

• Sour service requirements including (NACE MR0175 compliance and hardness limitations)

• Shallow gas considerations including (conductor design and diverter systems)

• Salt zone considerations including (creep effects and isolation strategies)

7. Connections and Accessories

7.1 Casing Connections

• Connection types including (API connections and premium connections)

• Connection performance characteristics including (torque capacity and pressure integrity)

• Make-up considerations including (torque application and thread compounds)

• Connection selection criteria including (gas-tight requirements and tensile efficiency)

• Connection qualification testing including (API 5C5 testing and connection-specific protocols)

7.2 Casing Accessories and Specialty Equipment

• Centralizers including (bow-spring centralizers and rigid centralizers)

• Float equipment including (float collars and float shoes)

• Stage cementing equipment including (stage collars and external casing packers)

• Liner hangers including (mechanical hangers and hydraulic hangers)

• Specialty items including (landing nipples and polished bore receptacles)

8. Casing Running and Installation

8.1 Pre-Installation Planning

• Torque and drag modeling including (friction factors and hook load predictions)

• Running procedure development including (speed limitations and rotation considerations)

• Fluid management including (equivalent circulating density and surge/swab control)

• Contingency planning including (fishing operations and stuck pipe scenarios)

• Logistics and material handling including (yard management and pipe inspection)

8.2 Installation Best Practices

• Casing handling including (lifting procedures and thread protection)

• Make-up practices including (torque application and position monitoring)

• Running techniques including (floating techniques and fill-up control)

• Cementing considerations including (cement placement and displacement efficiency)

• Post-installation verification including (pressure testing and cement evaluation)

9. HSE Considerations in Casing Design

• Well integrity assurance including (barrier philosophy and verification methods)

• Blowout prevention including (casing depth selection and kick tolerance)

• Environmental protection including (groundwater isolation and zonal containment)

• Operational safety including (handling procedures and pressure testing)

• Long-term integrity including (corrosion monitoring and intervention planning)

10. Quality Control in Casing Design

• Material quality verification including (mill certification and inspection requirements)

• Design quality assurance including (peer review and validation processes)

• Installation quality control including (procedural compliance and verification testing)

• Documentation requirements including (design basis and as-built records)

• Continuous improvement practices including (lesson learned application and design optimization)

11. Case Studies & Group Discussions

• Analysis of casing failures including (Middle East field examples and root cause identification)

• Problem-solving sessions for challenging design scenarios including (HPHT wells and corrosive environments)

• Regional applications including (depleted reservoirs in the Arabian Gulf and geomechanically challenging formations)

• Optimized designs including (material selection strategies and cost reduction approaches)

• The importance of proper training in successful casing design