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c ' ! b d b i A REPORT SAND82-0863 Unlimited Release UC-66c


Printed February 1983

Euler Buckling of Geothermal Well Casing

SAND--82-0863
DE83 010292

Robert P. Rechard, Karl W. Schuler

Prepared by
Sandia National Laboratories
Albuquerque, New Mexico 87 185 and Llvermore, California 94550
for the United States Department of Energy
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SAND82-0863

EULER BUCKLING OF GEOTHERMAL WELL C A S I N G

R. P. Rechard
K. W. S c h u l e r

A p p l i e d Mechanics D i v i s i o n
Sandia N a t i o n a l L a b o r a t o r i e s
A l b u q u e r q u e , New M e x i c o 87185

HOTICE
PORTIONS OF THIS REPQRT ARE ILLEGIELE.
tt has been rcprosfuced from the best
available copy to permit the broadest
possible avatfability, - . -. _ . . - - .
ABSTRACT

Geothermal w e l l o p e r a t o r s have expressed concern over t h e


v u l n e r a b i l i t y of u n s u p p o r t e d c a s i n g t o b u c k l i n g f r o m t h e r m a l
elongation. I n t h i s r e p o r t , we p r e s e n t p r e l i m i n a r y n u m e r i c a l
and t h e o r e t i c a l c a l c u l a t i o n s , which i n d i c a t e t h e b u c k l i n g
phenomenon s h o u l d n o t b e s e r i o u s i n N-80 c a s i n g i f t h e s t r i n g
i s t e n s i o n preloaded. B u c k l i n g w o u l d b e d e t r i m e n t a l f o r ' K-55
casing. The e f f e c t o f w a l l c o n t a c t was f o u n d t o b e b e n e f i c i a l
f o r c l o s e l y c o n f i n e d p i p e s t r i n g s and o f n o d e t r i m e n t when h o l e
gaps a r e l a r g e . The weakness o f A P I s c r e w j o i n t s i n b e n d i n g
appears t o be t h e s t r u c t u r a l l i m i t a t i o n . The a n a l y s i s assumed
s t r e s s e s above y i e l d c o n s t i t u t e d f a i l u r e , t h a t t h e r m a l
e x p a n s i o n was s t r a i n c o n t r o l l e d , and t h a t t h e c a s i n g was
continuous. E x c e s s i v e i n t e r n a l p r e s s u r e i n s t a b i l i t y was
ignored. The t e m p e r a t u r e v a r i a t i o n c o n s i d e r e d was b e t w e e n
c e m e n t i n g c o n d i t i o n s o f 100-200°F (40-95°C) and s h u t - i n
c o n d i t i o n s o f 425-450°F ( 2 2 0 - 2 3 0 ° C ) .
"
CONTENTS

Page

INTRODUCTION. ................. . 1

Geothermal Well C o n s t r u c t i o n . . . ...... 1


Well Casing Design. . . . . . . . . . . . .
Temperature Environment . . . . . . . . . . . .
5
6
Casing I n s t a b i l i t y . . . . . . . . .... 11

ANALYSIS. . . 17
T h e o r e t i c a l Model . . . .
N u m e r i c a l Model . . . . . .
.. .. .. . .. . . .. . 17

Addition o f Constant Stress . . . ..


A n a l y t i c Summary. . . . . . . . . . . . . . . .
30
33
33
RESULT IMPLICATIONS . . . . . . . . . . . . . . . 35
T h e r m a l l y Induced E u l e r Buckling. . . . . . . . 35
Joint Behavior.,. . . . . . . . . . . . . . . 37
SUMMARY AND CONCLUSIONS . . . . . . . . . . . . 39

REFERENCES. . . . . . . . . . . . . . . . . . . . 41
APPENDIX A - Nomenclature . . . . . . . . . . . . . 43

APPENDIX B - Derivation o f Equations. . .. 45

iii
I L L U STR AT IO NS

Figure Page

1. T y p i c a l G e o t h e r m a l W e l l C o n s t r u c t i o n and
Casing Temperature P r o f i l e . ........... 3

2. I d e a l i z e d C o n d i t i o n s Causing Casing B u c k l i n g
w i t h Temperature Excursion. . . . . . . . . . . . 7

3. P r e l i m i n a r y GEOTEMP C a l c u l a t i o n s o f
Temperature C o n d i t i o n s D u r i n g Cementing . . . . . 9

4. P o s t u l a t e d B u c k l i n g F a i l u r e Modes: a) Local,
P l a s t i c Deformation, b) E u l e r b u c k l i n g ,
c ) E u l e r B u c k l i n g w i t h Subsequent Wall Contact,
and d ) H e l i c a l B u c k l i n g ............. 12

5. Q u a l i t a t i v e P l o t o f T e m p e r a t u r e Change V e r s u s
Unsupported Length D e p i c t i n g B u c k l i n g Regions . 14

6. D e f i n i t i o n o f Terms: a ) L i n e S k e t c h and
b ) F r e e Body Diagram. .............. 19
7. Locus D e l i n e a t i n g E u l e r B u c k l i n g R e g i o n : ?lot
o f T e m p e r a t u r e Change ( A T ) V e r s u s N o r m a l i z e d
Unsupported Length (L/D). ............ 21

8. Maximum S t r e s s ( u ) V e r s u s T e m p e r a t u r e Change
( A T ) f o r 1 3 - 3 / 8 i n c h 54.5 p p f C a s i n g Assuming
U n s u p p o r t e d L e n g t h s ( L / D ) o f 50, 100, and 200 . 25

9. Maximum D e f l e c t i o n V e r s u s T e m p e r a t u r e Change
( A T ) for 1 3 - 3 / 8 i n c h 54.5 p p f C a s i n g Assuming
U n s u p p o r t e d L e n g t h s ( L / D ) o f 50, 100, and 200 26

10. D e f o r m e d C a s i n g Shapes w i t h W a l l C o n s t r a i n t
P r e d i c t e d b y MARC and T h e o r e t i c a l M o d e l s ,at
a ) A T = 80'F, b ) MARC R e s u l t s a t A T = 300 F,
a n d c ) A n a l y t i c R e s u l t s a t AT = 300°F ...... 27

11. Maximum S t r e s s ( u ) V e r s u s A T f o r 1 3 - 3 / 8 i n c h
54.5 p p f C a s i n g f o r U n s u p p o r t e d L e n g t h ( L / D )
o f 100 w i t h Wall Contact: a ) A n a l y t i c Model,
b ) MARC Computer Code, and c ) C o n s t a n t S t r e s s
Addition. .................... 29

i v
.
c

INTRODUCTION

D r S l l i n g f o r g e o t h e r m a l e n e r g y b e g a n as e a r l y as t h e 1 9 2 0 ' s
i n t h e Geysers f i e l d i n n o r t h e r n C a l i f o r n i a , b u t a s e r i o u s
e f f o r t t o h a r n e s s g e o t h e r m a l e n e r g y f o r power g e n e r a t i o n was
n o t begun i n t h e U n i t e d S t a t e s u n t i l t h e 1 9 7 0 ' s . On a n a t i o n a l
scale, t h e r e i s t h e g e o l o g i c p o t e n t i a l t o d e v e l o p 20,000 MW o f
e l e c t r i c a l energy. The g e o t h e r m a l e n e r g y i n d u s t r y p e r f o r m a n c e
i n t h e l a s t 1 0 y e a r s and t h e g e o l o g i c p r o s p e c t s i n d i c a t e t h e
i n d u s t r y has t h e p o t e n t i a l f o r g r o w t h and can make a
c o n t r i b u t i o n i n s u p p l y i n g t h e e n e r g y needs o f t h e n a t i o n .
T h e r e a r e numerous s i m i l a r i t i e s b e t w e e n c o n v e n t i o n a l o i l
and gas w e l l s and g e o t h e r m a l w e l l s i n c o n s t r u c t i o n and
operation. However, i m p o r t a n t d i f f e r e n c e s do e x i s t ( w h e t h e r
f r o m d r y steam, d r y h o t r o c k , h o t w a t e r , o r g e o p r e s s u r i t e d
f l u i d reservoirs). F l u i d f l o w r a t e s a r e an o r d e r o f m a g n i t u d e
l a r g e r than i n the petroleum industry. The h i g h t e m p e r a t u r e s
e n c o u n t e r e d a f f e c t t h e d r i l l b i t , d r i l l i n g mud and t h e cement
performance. R e s e r v o i r c a l c u l a t i o n s m u s t i n c l u d e an e n e r g y
b a l a n c e as w e l l as a mass b a l a n c e . F i n a l l y , d i f f i c u l t geology,
c o r r o s i v e e n v i r o n m e n t s , and t h e r m a l s t r e s s e s i n d u c e d i n t h e
w e l l c a s i n g p r e s e n t t h e c a s i n g d e s i g n e r w i t h a new s e t o f
f a i l u r e modes t o c o n s i d e r .

Geothermal W e l l C o n s t r u c t i o n

This introduction i s intended t o provide the reader


u n f a m i l i a r w i t h g e o t h e r m a l w e l l c a s i n g d e s i g n and c o n s t r u c t i o n
necessary background i n f o r m a t i o n . However, i t a l s o s e r v e s t o
r e m i n d t h e r e a d e r t h a t a l t h o u g h t h e c a s i n g s e l e c t i o n i s based
on t h e w o r s t case d e s i g n c r i t e r i a f r o m b u r s t , c o l l a p s e ,
tension, etc., s t r e s s e s f r o m many d i f f e r e n t l o a d s c a n b e
p r e s e n t s i m u l t a n e o u s l y -and c o n t r i b u t e t o c a s i n g f a i l u r e . More
comprehensive d i s c u s s i o n s o f t h e v a r i o u s f a c t s o f Geothermal
w e l l s a r e a v a i l a b l e (e.g. Edwards e t a l . , 1982).
F i g u r e 1 shows a s c h e m a t i c o f a g e o t h e r m a l w e l l w h i c h w i l l
be used f o r d i s c u s s i o n . T e m p e r a t u r e p r o f i l e s o f t h e c a s i n g and
u n d i s t u r b e d f o r m a t i o n a r e a l s o shown. Figure 1 contains well
f e a t u r e s f r o m s e v e r a l t y p e s o f g e o t h e r m a l f i e l d s and t h u s
c a n n o t t r u l y b e c l a s s i f i e d as l l t y p i c a l . l l
The w e l l i s shown v e r t i c a l , b u t f r e q u e n t l y geothermal w e l l s
are d i r e c t i o n a l l y d r i l l e d . Appropriate d r i l l s i t e s are
difficult t o l o c a t e i n t h e r o u g h t e r r a i n o f t e n f o u n d above
geothermal f i e l d s . I t i s a l s o d e s i r a b l e t o d r i l l a t an a n g l e
t o i n t e r s e c t more f r a c t u r e s . Geothermal r e s e r v o i r s f r e q u e n t l y
o c c u r i n f r a c t u r e d r e s e r v o i r s b e l o w 3000 f t ( 9 0 0 m ) ; hence
fractures are primarily vertical.
Most g e o t h e r m a l r e s e r v o i r s a r e b e l o w t h e d r i l l mud
h y d r o s t a t i c p r e s s u r e which causes l o s t c i r c u l a t i o n problems
d u r i n g d r i l l i n g and c e m e n t i n g . Also, low geothermal r e s e r v o i r
p r e s s u r e s make d e t e c t i o n o f s t e a m or h o t w a t e r b e a r i n g
fractures d i f f i c u l t . The u s e o f a i r r e d u c e s t h e d r P l l f l u i d
d e n s i t y and g r e a t l y s p e e d s u p d r i l l i n g . However, t h e d r i l l b i t
l i f e i s g r e a t l y reduced because o f t h e h i g h t e m p e r a t u r e s
encountered. The n e a r s o n i c v e l o c i t i e s p r o d u c e d w h i l e c a r r y i n g
t h e c u t t i n g s up t h e o u t s i d e o f t h e d r i l l p i p e a l s o causes
excessive erosion o f t h e d r i l l pipe.
The s t a n d a r d c o m p o n e n t s o f t h e w e l l c a s i n g p r o g r a m a r e
conductor pipe, s u r f a c e casing, i n t e r m e d i a t e c a s i n g and
production casing. The p r o d u c t i o n c a s i n g i s o f t e n s e t as a
production l i n e r with a tieback. P r o d u c t i o n c a s i n g and
p r o d u c t i o n l i n e r s a r e d e s i g n e d w i t h t h e same c r i t e r i o n as
i n t e r m e d i a t e c a s i n g and d r i l l i n g l i n e r s e x c e p t t h a t
c o n s i d e r a t i o n o f d r i l l i n g wear i s n o t r e q u i r e d . The w e l l
construction d i f f e r s s l i g h t l y from conventional o i l wells i n
t h a t each c a s i n g i s cemented t o t h e s u r f a c e .
Conductor p i p e i s t h e f i r s t s t r i n g o f p i p e t o be
installed. I t a i d s i n p r e v e n t i n g washouts around t h e d r i l l

2
GEOTHERMAL WELL SCHEMATIC
AND CASING TEMPERATURE

Q526'F 50°F
- 350°F-
100
I
I

200c
THE SURFACE

TEMPERATURE
INTERMEDIATE PROFILES
0 -UNDISTURBED
13-3/8 INCH FORMATION

BUTTRESS JOINTS
-CEMENT-SET
TEMPERATURE
I'
0 -0PERATINa CASING
TEMPERATURE
-SHUT-IN CASING
TEMPERATURE
5001

J
8001 L 100 200

TEMPERATUREOF
300 400 Ll
500

F i g u r e 1. T y p i c a l G e o t h e r m a l We1 1 C o n s t r u c t on and C a s i n g
Temperature P r o f i l e .

3
. z

r i g s , provides a conduit f o r d r i l l i n g f l u i d s t o surface p i t s ,


and h e l p s s u p p o r t w e l l h e a d e q u i p m e n t . Conductor p i p e i s s e t
s h a l l o w and i s n o t u s u a l l y c o n s i d e r e d a p r e s s u r e s t r i n g .
The s u r f a c e c a s i n g i s t h e f i r s t t r u e c a s i n g s t r i n g . As a
p r i m a r y s t r u c t u r a l member i t p r o v i d e s s u p p o r t f o r s u b s e q u e n t
casing strings. To a v o i d b u c k l i n g p r o b l e m s f r o m t h e
compressive loads applied, i t i s o f t e n cemented t o t h e s u r f a c e
even i n c o n v e n t i o n a l w e l l s . S u r f a c e c a s i n g must a l s o p r o v i d e
sufficient hole stability, protection to aquifers, solid
support f o r t h e r e s e r v o i r pressure, and p r e s s u r e i n t e g r i t y i n
t h e e v e n t o f a b r u p t p r e s s u r e i n c r e a s e s ( b l o w o u t s and k i c k s ) .
S u r f a c e c a s i n g i s s u b j e c t e d t o d r i l l i n g wear w h i c h r e q u i r e s
heavy casing. Common s e t t i n g d e p t h s a r e b e t w e e n 1000 a n d 2500
f t ( 3 0 0 t o 760 m).
I n a c o n v e n t i o n a l w e l l , i n t e r m e d i a t e c a s i n g can be exposed
t o h i g h bottom h o l e pressures which r e q u i r e s s u b s t a n t i a l b u r s t
resistance. High c o l l a p s e r e s i s t a n c e i s a l s o r e q u i r e d f o r t h e
deeper casing. Heavy muds and cement s l u r r i e s r e q u i r e d f o r
deep d r i l l i n g can c r e a t e h i g h c o l l a p s e l o a d s s h o u l d l o s t
c i r c u l a t i o n zones empty t h e p i p e . These c o n d i t i o n s d i c t a t e
heavy casing. As w i t h s u r f a c e s t r i n g s , i n t e r m e d i a t e c a s i n g and
d r illi n g 1 i n e r s a r e s u b j e c t e d t o m e c h a n i c a l damage f r o m
d r i l l i n g wear.
T h e c a s i n g s i z e s shown i n F i g u r e 1 a r e commonly s e l e c t e d
v a l u e s i n many g e o t h e r m a l f i e l d s . However, a standard casing
program i n t h e p r o m i n e n t Geysers geothermal f i e l d c o n s i s t s o f
26 a n d / o r 20 i n c h ( 6 6 0 o r 508 mm) d i a m e t e r c o n d u c t o r p i p e ,
13-3/8 i n c h ( 3 4 0 mm) s u r f a c e c a s i n g , and 9 - 5 / 8 i n c h ( 2 4 4 mm)
i n t e r m e d i a t e c a s i n g or l i n e r ( w i t h o r w i t h o u t a t i e b a c k s t r i n g
of e i t h e r 9-5/8 o r 10-3/4 i n c h ( 2 4 4 o r 273 mm) c a s i n g )
(Capuano, 1979). Because s u p e r h e a t e d s t e a m i s p r o d u c e d , a
p r o d u c t i o n c a s i n g i s n o t needed. An open h o l e i n t h e r e s e r v o i r
i s usually stable.

4
-
--a s i n g Des&
Well C

The p r o p e r s e l e c t i o n o f t h e t y p e , size, and s e t t i n g d e p t h


o f t h e w e l l c a s i n g i s b a s e d on t h e e x p e c t e d w e l l o p e r a t i o n
c o n d i t i o n s and t h e d r i l l i n g s i t e g e o l o g y . The u s u a l p r a c t i c e
i s t o c o n s i d e r t h e w o r s t c a s e o r maximum l o a d i n d e t e r m i n i n g
the required casing configuration. C o m p l i c a t i o n s due t o c a s i n g
nesting are usually ignored. A l i s t o f c a s i n g f a i l u r e modes
i n c l u d e s (Snyder, 1979):

*Metal failure: burst, collapse, tension, or corrosion,

* M e c h a n i c a l damage: d r i l l p i p e wear, w e l d i n g p r o b l e m s ,
t h r e a t damage, o r l e a k a g e and p e r f o r a t i o n ,

.Casing i n s t a b i l i t y : l a t e r a l deflection (buckling) from


e x c e s s i v e c o m p r e s s i v e l o a d s (e.g t h e r m a l e x p a n s i o n ) o r
i n t e r n a l pressure,

*Cement f a i l u r e s : v o i d s f r o m l o s t c i r c u l a t i o n zones' o r
cement t o o l p r o b l e m s , cement d i s s o l u t i o n and c o r r o s i o n
p e r m i t t i n g f l u i d movement b e t w e e n c a s i n g and f o r m a t i o n , or
poor high-temperature s l u r r y behavior,

*Thermal s t r e s s f a i l u r e s : compression and/or t e n s i o n


f a i l u r e s ( t e l e s c o p i n g ) , leakage i n couplings from c y c l i c
l o a d i n g , e x c e s s i v e b e n d i n g l o a d s i n dog l e g s , s t r a i n b e y o n d
ultimate.

T h i s t a b u l a t i o n p r e s e n t s p o s s i b l e f a i l u r e modes.
U n f o r t u n a t e l y l i t t l e d e t a i l e d p u b l i c i n f o r m a t i o n e x i s t s on
geothermal w e l l c a s i n g f a i l u r e s . The a n a l y s t can o n l y
p o s t u l a t e t y p e s and f a i l u r e mechanisms and t h u s t h e d a n g e r
e x i s t s t h a t an i m p o r t a n t o r more l i k e l y f a i l u r e mechanism has
been o v e r l o o k e d .
I t s h o u l d b e n o t e d t h a t t h e f a i l u r e modes l i s t e d a r e n o t
independent. For--example, a cement f a i l u r e c o u l d c a u s e
i n s u f f i c i e n t l a t e r a l s u p p o r t and r e s u l t i n c a s i n g i n s t a b i l i t y
when h i g h i n t e r n a l p r e s s u r e s o c c u r r e d . The r e s u l t i n g l a t e r a l
d e f l e c t i o n c o u l d i n t u r n r e s u l t i n e x c e s s i v e d r i l l p i p e wear
d u r i n g t h e d r i l l i n g o p e r a t i o n and s u b s e q u e n t b u r s t o f t h e
casing during the production operation.

5
I n o i l o r gas w e l l c a s i n g d e s i g n , t h e major concern
addressed i s metal f a i l u r e from b u r s t , collapse, or tension.
However, t h e presence o f thermal loads i n geothermal w e l l
casing g r e a t l y increases the opportunity f o r casing
instability. C a s i n g s t a b i l i t y can b e i m p r o v e d by:
1) cementing t h e e n t i r e s t r i n g t o p r o v i d e l a t e r a l support o r
2 ) a p p l y i n g a t e n s i o n l o a d i n t h e uncemented s e c t i o n s . Fully
cementing t h e casing s t r i n g i s t h e usual choice.
Unfortunately, poor formation c o n d i t i o n s f r e q u e n t l y e x i s t i n
geothermal areas. The r e s e r v o i r i s u s u a l l y b e l o w h y d r o s t a t i c
p r e s s u r e a n d can b e h i g h l y f r a c t u r e d . Consequently, lost
c i r c u l a t i o n w h i l e d r i l l i n g w i t h mud o r c e m e n t i n g c a s i n g i s
common. I t i s t h u s i m p o s s i b l e t o e n s u r e a c o m p l e t e cement j o b
i n many i n s t a n c e s . F a i l u r e o f stage cementing t o o l s i n
g e o t h e r m a l w e l l s i s f r e q u e n t and a l s o c r e a t e s u n s u p p o r t e d
t u b u l a r s e c t i o n s ( S n y d e r , 1979). Buckling failures o f the
c a s i n g f r o m t h e r m a l e x p a n s i o n w h e r e cement f a i l u r e s h a v e
occurred i s the subject o f t h i s r e p o r t (Figure 2 ) .

TemDerature Environment

The t e m p e r a t u r e e n v i r o n m e n t i s i m p o r t a n t i n f o r m a t i o n f o r
the thermal analysis. f i g u r e 1 presents a hypothetical
temperature environment. The s u r f a c e and b o t t o m h o l e
t e m p e r a t u r e s a r e as s u r m i s e d b y t h e w e l l o p e r a t o r s i n The
G e y s e r s f i e l d (Pye, 1980; J e n k i n s and S n y d e r , 1979), but the
a c t u a l t e m p e r a t u r e p r o f i l e s t h r o u g h o u t t h e s t r a t i g r a p h y and
c a s i n g a r e unknown. I n F i g u r e 1 casing temperatures are
assumed t o v a r y l i n e a r l y . The u n d i s t u r b e d f o r m a t i o n p r o f i l e i s
shown w i t h one e l b o w . A f e w p r o f i l e s a v a i l a b l e f r o m The
Geysers f i e l d c o n t a i n two k i n k s : t h e second elbow o c c u r s
w i t h i n t h e f i r s t 500 f t ( 1 5 0 m ) .
For w e l l s completed i n low-pressure hot-water o r steam
r e s e r v o i r s , t h e c a s i n g s a r e t h o u g h t t o b e cemented a t a
t e m p e r a t u r e b e t w e e n 100-2OO'F (40-95°C). T h i s assumes t h e

6
i .

HOT WATER, STEAM

CEMENT SHEATH

ENLARGED HOL

PIPE DIAMETER

Fig ure 2 . I d e a l i z e d Conditions Causing Casing Buck, l i n g with


Temperature Excursion.

7
c a s i n g i s n o t p u r p o s e l y a l l o w e d t o h e a t up b e f o r e cementing.
Upon c o m p l e t i o n , t h e w e l l i s t e m p e r a t u r e c y c l e d between
p r o d u c i n g c o n d i t i o n s o f a p p r o x i m a t e l y 325-400°F (160-205°C) and
s h u t i n c o n d i t i o n s o f 425-450°F (220-235°C). The c y c l i n g i s
due t o a i r p o l l u t i o n s t a n d a r d s w h i c h l i m i t t h e v e n t i n g o f
geothermal w e l l s . C y c l i n g c a n o c c u r 2 t o 3 t i m e s p e r week i f
t h e s t e a m c o n t a i n s a p o l l u t a n t s u c h as h y d r o g e n s u l f i d e ( H 2 S ) .
When t h e w e l l r e q u i r e s r e m e d i a l w o r k , t h e casing temperature i s
r e d u c e d t o a r o u n d 100°F ( 4 0 ° C ) w i t h c o o l w a t e r . These a r e
approximate values only.
A temperature p r o f i l e i s very useful i n v i s u a l i z i n g t h e
t e m p e r a t u r e change t o w h i c h each t y p e o f c a s i n g i s s u b j e c t e d .
Accurate i n f o r m a t i o n o f t h i s t y p e would g r e a t l y a i d t h e design
and a n a l y s i s o f t h e c a s i n g i n t e g r i t y . As seen i n F i g u r e 1, t h e
c a s i n g can b e s u b j e c t e d t o l a r g e t e m p e r a t u r e changes.
C o n s e q u e n t l y l a r g e t h e r m a l s t r e s s e s must be a n t i c i p a t e d . It i s
seen t h a t t h e more s e v e r e t e m p e r a t u r e changes o c c u r n e a r t h e
s u r f a c e d u r i n g t h e c y c l i n g b e t w e e n p r o d u c t i o n and s h u t - i n .
However, t h e w h o l e c a s i n g s t r i n g can b e s u b j e c t e d t o l a r g e
t e m p e r a t u r e changes a f t e r c e m e n t i n g and whenever t h e w e l l m u s t
b e quenched.
An a c c u r a t e c e m e n t - s e t temperature i s essential t o t h e
t h e r m a l s t r e s s a n a l y s i s because t h i s i s t h e t e m p e r a t u r e t h e
c a s i n g becomes c o n s t r a i n e d . The GEOTEMP c o m p u t e r p r o g r a m
(Wooley, 1980; M i t c h e l l , 1982) b e i n g developed under c o n t r a c t
t o S a n d i a w i l l be h e l p f u l i n more c a r e f u l l y d e f i n i n g t h e
temperature regime o f t h e w e l l casing. P r e l i m i n a r y GEOTEMP
t e m p e r a t u r e c a l c u l a t i o n s a r e shown i n F i g u r e 3. Radial
t e m p e r a t u r e s a t 200 f t ( 6 0 m) depth under t h r e e geothermal
f l u i d flow c o n d i t i o n s are depicted f o r a Geysers w e l l . The
c e m e n t i n g c o n d i t i o n s a r e l o w e r t h a n g e n e r a l l y assumed b y
operators. V e r i f i c a t i o n o f t h e GEOTEMP p r o g r a m i s n o t
c o m p l e t e , b u t t h e t e m p e r a t u r e d i f f e r e n c e shown c o u l d b e
s i g n i f i c a n t and needs t o b e more c a r e f u l l y e x a m i n e d .
c

PROFILES TAKEN FROM GEOTEMP ANALYSIS

100 1 I t I I

20 INCH
13 3/8 INCH
n
B 5/8 INCH
5 u

-
Y

90 t

A
06 h INJECTION COOLING 250 gal/rnin
-
0 3 h SHUT IN AFTER INJECTION
A 5 h CONDITIONING 400 gal/rnin
2 h CEMENTING

n 10' I I I I

r (FEET)
RADIAL TEMPERATURES AT 200 FOOT DEPTH

Figure 3 . Preliminary GEOTEMP C a l c u l a t i o n s o f Temperature


Conditions During Cementing.

9
.
c a s i n g i s n o t p u r p o s e l y a l l o w e d t o h e a t up b e f o r e cementing.
Upon c o m p l e t i o n , t h e w e l l i s t e m p e r a t u r e c y c l e d between
p r o d u c i n g c o n d i t i o n s o f a p p r o x i m a t e l y 325-400°F (160-205°C) and
s h u t i n c o n d i t i o n s o f 425-450°F (220-235°C). The c y c l i n g i s
due t o a i r p o l l u t i o n s t a n d a r d s w h i c h l i m i t t h e v e n t i n g o f
geothermal wells. C y c l i n g c a n o c c u r 2 t o 3 t i m e s p e r week i f
t h e s t e a m c o n t a i n s a p o l l u t a n t s u c h as h y d r o g e n s u l f i d e (H2S).
When t h e w e l l r e q u i r e s r e m e d i a l w o r k , the casing temperature i s
r e d u c e d t o a r o u n d 100°F (40'C) with cool water. These a r e
approximate values only.
A temperature p r o f i l e i s very useful i n v i s u a l i z i n g the
t e m p e r a t u r e change t o w h i c h each t y p e o f c a s i n g i s s u b j e c t e d .
Accurate i n f o r m a t i o n o f t h i s type would g r e a t l y a i d t h e design
and a n a l y s i s o f t h e c a s i n g i n t e g r i t y . As seen i n F i g u r e 1, the
c a s i n g can be s u b j e c t e d t o l a r g e t e m p e r a t u r e changes.
C o n s e q u e n t l y l a r g e t h e r m a l s t r e s s e s must be a n t i c i p a t e d . It i s
seen t h a t t h e m o r e s e v e r e t e m p e r a t u r e c h a n g e s o c c u r n e a r t h e
s u r f a c e d u r i n g t h e c y c l i n g b e t w e e n p r o d u c t i o n and s h u t - i n .
However, t h e w h o l e c a s i n g s t r i n g c a n b e s u b j e c t e d t o l a r g e
t e m p e r a t u r e c h a n g e s a f t e r c e m e n t i n g and whenever t h e w e l l m u s t
b e quenched.
An a c c u r a t e c e m e n t - s e t temperature i s essential t o the
t h e r m a l s t r e s s a n a l y s i s because t h i s i s t h e t e m p e r a t u r e t h e
c a s i n g becomes c o n s t r a i n e d . The GEOTEMP c o m p u t e r p r o g r a m
(Wooley, 1980; M i t c h e l l , 1982) b e i n g developed under c o n t r a c t
t o S a n d i a w i l l b e h e l p f u l i n more c a r e f u l l y d e f i n i n g t h e
temperature regime o f t h e w e l l casing. P r e l i m i n a r y GEOTEMP
t e m p e r a t u r e c a l c u l a t i o n s a r e shown i n F i g u r e 3. Radial
t e m p e r a t u r e s a t 200 f t . (60 m ) depth under t h r e e geothermal
f l u i d f l o w c o n d i t i o n s are d e p i c t e d f o r a Geysers w e l l . The
c e m e n t i n g c o n d i t i o n s a r e l o w e r t h a n g e n e r a l l y assumed b y
operators. V e r i f i c a t i o n o f t h e GEOTEMP p r o g r a m i s n o t
c o m p l e t e , b u t t h e t e m p e r a t u r e d i f f e r e n c e shown c o u l d b e
s i g n i f i c a n t a n d n e e d s t o b e more c a r e f u l l y e x a m i n e d .

10
W h i l e f a i l u r e s i n cemented s t r i n g s s u c h as c o m p r e s s i o n
a n d / o r t e n s i o n f a i l u r e s and c o n n e c t i o n f a i l u r e s a r e o f c o n c e r n ,
o p e r a t o r s have expressed g r e a t e r concern over c a s i n g buck1 i n g
i n p a r t i a l l y cemented s t r i n g s (Pye, 1980; Kumataka, 1981,
Snyder, 1979). As r e g a r d s p a r t i a l l y c e m e n t e d s t r i n g s , w o r k i n
t h e a r c t i c o i l f i e l d s h a s shown t h a t t h e cement a n d l o r
f o r m a t i o n s u p p o r t needed t o a v o i d b u c k l i n g f r o m s u b s i d e n c e i s
q u i t e s m a l l ( W i l s o n e t al., 1980). ( B o t h s u b s ' i d e n c e and
thermal stress loads are s t r a i n c o n t r o l l e d . ) , Because l i t t l e
l a t e r a l s u p p o r t i s necessary, b u c k l i n g i s l i m i t e d t o areas
where f o r m a t i o n c o n d i t i o n s cause e n l a r g e d h o l e s t o f o r m w i t h
s u b s e q u e n t v o i d s i n t h e cement s h e a t h s u c h t h a t a c o m p l e t e l y
unsupported s e c t i o n occurs ( F i g u r e 2).
Casing i n s t a b i l i t y f a i l u r e s from a thermal l o a d i n
p a r t i a l l y c e m e n t e d s t r i n g s can b e d i v i d e d i n t o f o u r
categories. The f a i l u r e t y p e i s d e p e n d e n t on t h e u n s u p p o r t e d
c a s i n g l e n g t h and i n t e r n a l - e x t e r n a l pressure i n t e r a c t i o n
( F i g u r e 4). The c a t e g o r i e s a r e :
%

.Local p l a s t i c deformation,

~ E u l e rb u c k 1 i n g ,
C o n s t r a i n e d E u l e r b u c k l i n g f o l l o w e d by plas.tic deformation
o r c o l l a p s e due t o o v a l a t i o n ,
' .
*He1 i c a l b u c k l i n g .

I t i s i m p o r t a n t t o emphasize t h e d i f f e r e n c e between
s t a n d a r d c o l u m n b u c k l i n g u n d e r an a p p l i e d . l o a d a
b u c k l i n g f r o m t h e r m a l f a r c e s where s u p p o r t o f - a f o l l o w e r a x i a l
load i s not required. Rather than c a t a s t r o p h i c f a i l u v e from a
. 5

c r i t i c a l t e m p e r a t u r e change, t h e c a s i n g s l o w l y d e f o r m s
e l a s t i c a l l y i n t o t h e d e f o r m e d shape f o r l a r g e + u n s u p p o r t e d
lengths. Thus c o l u m n " b e n d i n g " i s a more a p p r o p r i a t e
d e s c r i p t i o n o f t h e phenomenon. The p i p e s t r i n g i n s t a b i l i t y
m a n i f e s t s i t s e l f as a l a t e r a l d e f l e c t i o n .

11
7 I
LONG
SHORT UNSUPPORTED
UNSUPPORTED LENGTH

a) LOCAL, PLASTIC DEFORMATION

b) EULER BUCKLING

H
c) EULER BUCKLING WITH
SUBSEQUENT WALL CONTACT d) HELICAL BUCKLING
(PLASTIC DEFORMATION OR
COLLAPSE DUE TO OVALATION
POSSIBLE)

Figure 4 . Postulated Buckling F a i l u r e Modes: a ) Local,


P l a s t i c Deformation, b ) Euler Buckling,
c ) Euler Buckling with Subsequent Wall Contact,
a n d d ) H e l i c a l Buckling.

12
. c

The r e s u l t i n g d e f o r m a t i o n may n o t impede o p e r a t i o n s i f t h e


deformation i s slight. The l a r g e s t t h e r m a l s t r e s s e s a r e
introduced during shut-in a f t e r t h e w e l l i s completed, thus the
d a n g e r o f e x c e s s i v e p i p e wear d u r i n g d r i l l i n g h a s p a s s e d .
However, e v e n s l i g h t b e n d i n g a t c o n n e c t i o n s can r e s u l t i n j o i n t
f a f l u r e because s t a n d a r d American P e t r o l e u m I n s t i t u t e ( A P I )
j o i n t s a r e n o t designed t o w i t h s t a n d bending stresses.
F i g u r e 5 q u a l i t a t i v e l y i n d i c a t e s where v a r i o u s buck1 i n g
modes o c c u r . It i s important t o note t h a t internal-external
p r e s s u r e i n t e r a c t i o n has been i g n o r e d . Only unsupported l e n g t h
a n d t e m p e r a t u r e was c o n s i d e r e d .
For s h o r t unsupported l e n g t h s o n l y l o c a l i z e d p l a s t i c
d e f o r m a t i o n a n d / o r c o l l a p s e would be expected. A t longer
unsupported lengths, Euler b u c k l i n g would occur. With
c o n t i n u e d t e m p e r a t u r e i n c r e a s e , t h e c a s i n g c o u l d d e f l e c t enough
t o contact the d r i l l hole sides. P l a s t i c deformation or pipe
c o l l a p s e f r o m t h e weakening e f f e c t s o f c r o s s - s e c t i o n o v a l a t i o n
could follow.
H e l i c a l b u c k l i n g occurs i n l o n g unsupported lengths. In
the o i l well industry, t h e c o r k s c r e w i n g i s due p r i m a r i l y t o
excessive, destabilizing, i n t e r n a l p r e s s u r e s ( L u b i n s k i e t a1 .,
1962). F r e q u e n t l y , t h e d e f o r m a t i o n i s n o t s e v e r e enough t o
c a u s e p e r m a n e n t d e f o r m a t i o n ( T e x t e r , 1955).. Because l o n g
u n s u p p o r t e d l e n g t h s a r e much l e s s l i k e l y and t h e u l t i m a t e
f a i l u r e mechanism i s s i m i l a r t o t h a t e n c o u n t e r e d w i t h s i n g l e
order Euler buckling, t h i s region i s o f less interest.
Two b a s i c s u b j e c t a r e a s need t o b e i n v e s t i g a t e d c o n c e r n i n g
t h e r m a l b u c k l i n g and l o c a l i z e d p l a s t i c d e f o r m a t i o n o f
geothermal casing. First, analysis of the Euler buckling
r e g i m e assuming b u i l t - i n ends and s u b s e q u e n t e l a s t i c - p l a s t i c
b e n d i n g needs t o be examined. Analysis o f nested casing
b e h a v i o r when c o n s t r a i n e d b y cement a n d / o r f o r m a t i o n s c o u l d
a l s o be i n v e s t i g a t e d more t h o r o u g h l y . Second, analysis of
I l o c a l i z e d p l a s t i c d e f o r m a t i o n s s u c h as s y m m e t r i c a l b u c k l i n g and
w r i n k l i n g i n s t a b i l i t i e s needs t o b e e x a m i n e d . Small s c a l e

13
QUALITATIVE DESCRIPTION OF
VARIOUS BUCKLING MODES
1
I-
<I FAILURE ZONE

FAILURE WITH WALL CONTACT

FAILURE WITHOUT
BUCKLING ZONE WALL CONTACT

HELICAL
I- BUCKLING ZONE

NO ADVERSE DEFORMATION

UNSUPPORTED LENGTH, L

F i g u r e 5. Q u a l i t a t i v e P l o t o f T e m p e r a t u r e Change V e r s u s
U n s u p p o r t e d L e n g t h D e p i c t i n g Buck1 i n g R e g i o n s .

14
laboratory t e s t s of thermally-induced buckling should a l s o be
conducted t o enhance the understanding o f the phenomenon.
This report q u a n t i t a t i v e l y d e f i n e s t h e Euler buckling
regime f o r a c a s i n g with f i x e d ends with a n d without subsequent
h o l e wall c o n t a c t .

15 ::
ANALY S IS

-4 - -
T h e o r --
e t i c a l Model
6

-----
ASsumptions. The down h o l e e f f e c t s o f i m p r o p e r c e m e n t i n g
may be m a n i f e s t e d i n many ways. However, w i t h o u t d e t a i l e d
f i e l d o r l a b o r a t o r y d a t a on g e o t h e r m a l c a s i n g b e h a v i o r o r
casing failures, t h e r e i s l i t t l e need t o s h a r p l y f o c u s on one
s u b j e c t area. T h e r e f o r e a s i m p l e a n a l y t i c and n u m e r i c a l model
i s p r e s e n t e d i n o r d e r t o g a i n i n s i g h t i n t o t h e problem. The
a n a l y s i s assumed:

, 1) t h e c a s i n g was i n i t i a l l y v e r t i c a l ( b o d y f o r c e s
i g n o r e d ) and c e m e n t i n g above and b e l o w t h e u n s u p p o r t e d
casing provided fixed-end conditions,

2) c o m p l i c a t i o n s f r o m c o u p l i n g s s u c h as c h a n g e s i n moment
o f i n e r t i a ( I ) a n d weakness i n b e n d i n g w e r e
un i m p o r t a n t ,

3) c a s i n g s t r e s s e s r e m a i n e d i n t h e e l a s t i c r e g i o n and t h e
m o d u l u s o f e l a s t i c i t y ( E ) was i n d e p e n d e n t of
t e m p e r a t u r e a n d e q u a l t o 2 9 x l o 6 p s i (200 GPa),

4) t h e l i n e a r t h e r m a l e x p a n s i o n c o e f f i c i e n t ( a ) was
c o n s t a n t a n d e q u a l t o 6.5 x 10-6'F ( 1 . 2 x lO-5'C),

5) c o m p l i c a t i o n s due t o c a s i n g n e s t i n g w e r e n e g l i g i b l e ,

6) t h e i n t e r n a l and e x t e r n a l t i t b u l a r p r e s s u r e s w e r e e q u a l ,

7) c r o s s - s e c t i o n a l shape c h a n g e s ( o v a l a t i o n ) due t o
l a t e r a l and b e n d i n g f o r c e s w e r e u n i m p o r t a n t .

A s s u m p t i o n s 5, 6, and 7 w e r e j u s t i f i e d b y t h e f o l l o w i n g
facts: F i r s t , casing nesting i s r a r e l y considered i n actual
design applications. Second, c a s i n g o v a l a t i o n problems a t t h e
w a l l c o n t a c t were t h o u g h t m i n o r i f s t r e s s e s remained below
yield. The n u c l e a r r e a c t o r i n d u s t r y h a s been a d d r e s s i n g t h i s

17
p r o b l e m t o some e x t e n t . F i n a l l y f o r low pressure, h o t water,
o r steam r e s e r v o i r s , the casing i n t e r n a l pressure i s l i k e l y t o
be l e s s than e x t e r n a l f o r m a t i o n pressures; hence n e g l e c t i n g
internal-external p r e s s u r e i n t e r a c t i o n was f e l t j u s t i f i e d *
( L u b i n s k i e t a1 ., 1962; H a m m e r l i n d l , 1978; J e n k i n s and Snyder,
1979).
These a s s u m p t i o n s p e r m i t t e d t h e a p p l i c a t i o n o f E u l e r beam
theory. The o u t l i n e o f t h e e q u a t i o n d e v e l o p m e n t i s p r e s e n t e d
i n the following section. More d e t a i l e d d e r i v a t i o n s a r e
p r e s e n t e d i n A p p e n d i x B.

C r i t i c a l Temperature. A f r e e body d i a g r a m f o r a deformed


beam i s shown i n F i g u r e 6. The d i f f e r e n t i a l e q u a t i o n t h a t
d e s c r i b e s t h e beam i s as f o l l o w s : (Terms a r e d e f i n e d i n
F i g u r e 6 and i n A p p e n d i x A ) .

M = MR - Py + V X = EIy"

There a r e f o u r boundary c o n d i t i o n s :

x = o , y = o
x = 0, y' = 0
x = R , y = e
x = R, y ' = 0

The f i r s t t w o b o u n d a r y c o n d i t i o n s e s t a b l i s h t h e e q u a t i o n :

where

* As a c h e c k on t h i s a s s u m p t i o n , one can compare t h e m a g n i t u d e


o f the thermal a x i a l load w i t h t h e load calculated from t h e
i n t e r n a l - e x t e r n a l pressure d i f f e r e n c e times t h e pipe
c r o s s - s e c t i o n a l area. The l a t t e r l o a d s h o u l d be much s m a l l e r
i n comparison t o t h e thermal load.

18
DEFINITION OF TERMS
HOLE WALL
~

4 ENDS

a)

F i g u r e 6. D e f i n i t i o n of Terms: a ) L i n e S k e t c h and b ) F u l l
Body D i a g r a m .

19
The f o u r t h b o u n d a r y c o n d i t i o n e s t a b l i s h e s a r e l a t i o n s h i p
V, and P ( o r K ) .
b e t w e e n MR, There a r e t h r e e s p e c i a l cases
as seen f r o m t h e f o l l o w i n g e q u a t i o n :

MR V
y' = p (K s i n KR) - (1 - cos K R ) (3)

The t h r e e c a s e s a r e :

2) 1 - COS KR = 0 and sin KR = 0

3) M = 0 a..d 1 - cos K R = 0
R

Case 1 i s t h e s i t u a t i o n b e f o r e w a l l c o n t a c t ( y < e ) . The


c a s i n g t a k e s t h e shape o f a c o s i n e f u n c t i o n :

MR
y = p (1 - COS K X ) (4)

where

K = 2n/L

The c r i t i c a l l o a d (Per) i s t h e r m a l l y i n d u c e d and t h u s


e q u a l t o AEaAT. The r e s u l t i n g e x p r e s s i o n f o r t h e c r i t i c a l
t e m p e r a t u r e change AT^,) which i n i t i a t e s b u c k l i n g i s :

2
AT^^ =
4n 1
-2 (5)
L Aa

F i g u r e 7 p l o t s equation (5). The u n s u p p o r t e d l e n g t h ( L )


i s n o r m a l i z e d b y t h e o u t s i d e c a s i n g d i a m e t e r (D). Alternately
o n e can u s e t h e r a d i u s o f g y r a t i o n ( r ) ( N e l s o n , 1975).
9
1300 - \ 13 3/8 tNCH 54.5ppf -
\ rn 9 5/8 INCH 40.0PPf
c1200 ACTUAL \
~EFORMATION
A 9 5/8 INCH 36.OPPf -
100 BEHAVIOR \ -
- -
%ooo
g 900-
- OFAPPROXIMATE LIMIT
EULER BUCKING -
FORMULATION
z -
2 800-
700- -
W
2 600- -
2 500-
400-
1580 CASING
E 300-
200 -
100 -
I I I I I I I
0 I I

Figure 7 . Locus Delineating Euler Buckling Region: P l o t o f


Temperature Change ( A T ) Versus Normal i t e d
!
Unsupported Length ( L / D ) .
!

21
T h r e e t y p i c a l c a s i n g s w e r e examined: 9-5/8 i n c h 36 p p f , 9 - 5 / 8
i n c h 40 p p f , and 1 3 - 3 / 8 i n c h 54.5 p p f ( 2 4 4 mm 54 kg/m, 244 mm
6 0 kg/m, and 340 mm 8 0 k g l m ) . L i t t l e d i f f e r e n c e between t h e
casings exists. The moment o f i n e r t i a ( I ) d e c r e a s e s s l i g h t l y
f o r t h e 9-5/8 i n c h 40 p p f ( 2 4 4 mm 60 k g / m ) p i p e b e c a u s e t h e
o u t s i d e diameter remains constant. This explains the s l i g h t
decrease i n AT^^ f o r t h i s supposedly s t r o n g e r pipe. It i s
i m p o r t a n t t o n o t e from e q u a t i o n ( 5 ) t h a t l a r g e r diameter p i p e
w i l l increase t h e c r i t i c a l b u c k l i n g temperature whether or n o t
the pipe strength increases.
The r a n g e o f a p p l i c a b i l i t y o f e q u a t i o n ( 5 ) c a n be e s t i m a t e d
b y n o t i n g t h a t A I S C ( 1 9 8 0 ) recommends t h e s l e n d e r n e s s r a t i o
( K L / r ) r e m a i n above r ( 2 E / a )ll2. T h i s c r i t e r i o n was
9 Y
e s t a b l i s h e d b e c a u s e c o l u m n f a i l u r e modes s u c h as l o c a l i z e d
p l a s t i c d e f o r m a t i o n o r k i n k i n g became i m p o r t a n t f o r s m a l l e r
values. The above c r i t e r i o n e s t a b l i s h e s a minimum l e n g t h o f
22 f t ( 6 . 8 m ) o r 27.5 D f o r E u l e r b u c k l i n g o f N-80 9 - 5 / 8 i n c h
40 p p f ( 2 4 4 mm 6 0 k g l m ) c a s i n g .
Maximum s t r e s s b e f o r e w a l l c o n t a c t . Figure 7 indicates
when E u l e r b u c k l i n g w i l l i n i t i a t e . Whether t h e b u c k l i n g
r e s u l t s i n p l a s t i c d e f o r m a t i o n s must be examined f r o m t h e
stress standpoint. The t o t a l s t r e s s (at) a f t e r bending a t a
maximum f i b e r i s e q u a l t o t h e a x i a l s t r e s s (a,) plus the
maximum b e n d i n g s t r e s s ( a b ) m a x ( o v a l a t i o n s t r e s s e s
neglected ) :

‘t = lT a + (‘b)max

where

u = Pcr/A = E ~ A T= c~ o n~s t a n t
a

( ‘b )max = M Rr o /I

The end moment r e a c t i o n ( I d R ) i n t h e expression f o r (ab)max


i s f o u n d f r o m t h e c o n d i t i o n e s t a b l i s h e d b y t h e f i x e d ends; the

22
t h e r m a l d i s p l a c e m e n t ( s ( T ) ) m u s t e q u a l t h e sum o f t h e a x i a l
load displacement ( s ( P ) ) and t h e c a s i n g d e f l e c t i o n d i s p l a c e m e n t
( s ( y ) ) ( B o l e y and Weiner, 1960):

The d i s p l a c e m e n t s a r e e x p r e s s e d as:

6 ( P ) = PcrL/AE = constant
(11)

a(y) = (yl)' dx (Timoshenko, 1961) (12)

=($) 2
L

Once b u c k l i n g has o c c u r r e d t h e t h e r m a l l y i n d u c e d l e n g t h change


s ( T ) i s e n t i r e l y absorbed b y t h e column d e f l e c t i o n t e r m s(y);
hence, s ( P ) r e m a i n s c o n s t a n t . Consequently u a remains a t t h e
c r i t i c a l b u c k l i n g s t r e s s as n o t e d above. I n s e r t i n g the
d i s p l a c e m e n t e x p r e s s i o n s i n t o e q u a t i o n ( 9 ) a n d s o l v i n g f o r MR
r e s u l t s i n (AT > AT^,):

MR =
lr
[a(AT - AT^^)] 1 / 2 (14)

A s s e m b l i n g t h e e x p r e s s i o n s f o r u a and ( a b ) m a x and
inserting i n t o (6) yields:

at = EaATcr
f
4Lr0
1 + --51--T-' [ a ( AT-AT,,
~ ( r o ri) +
) 3 I2 1 ( 15)

23
E q u a t i o n ( 1 5 ) i s p l o t t e d f o r 13-3/8 i n c h 54.5 p p f ( 3 4 0 mm
80 k g / m ) c a s i n g w i t h L / D = 50, 100, 200 i n F i g u r e 8. The u p p e r
r a n g e o f a p p l i c a b i l i t y f o r f i g u r e 8 i s when t h e s t e e l r e a c h e s
i t s y i e l d p o i n t ( 8 0 k s i ( 5 5 0 MPa) f o r N-80 c a s i n g ) o r t h e
c a s i n g d e f l e c t s enough t o c o n t a c t t h e h o l e s i d e s . The l a t t e r
c o n d i t i o n i s addressed below. F i g u r e 9 p l o t s maximum
d e f l e c t i o n ( y m a x ) v e r s u s t e m p e r a t u r e change ( A T ) and e n a b l e s
one t o p r e d i c t when w a l l c o n t a c t w o u l d o c c u r .
--- --------------
Maximum stress after w a l l c o n t----
act. Case 2 o f t h e b o u n d a r y
c o n d i t i o n s l e a d s t o t h e r e s u l t t h a t M R = -Mb ( F i g u r e 6).
The d e f o r m e d c a s i n g shape i s n o t c o m p a t i b l e w i t h t h e s e end
moments. Hence c a s e 3, a concentrated shear l o a d ( V ) acting a t
the p o i n t o f contact, was u s e d t o m a t h e m a t i c a l l y d e s c r i b e t h e
c a s i n g a t w a l l contact.* The shape o f t h e c a s i n g b e t w e e n
points and " b t l i n F i g u r e 6 i s :

V
Y = p ( X - Z i i ; s i n 2Kx)

N o t e t h a t t h e e n d moment ( M R ) i s r e p l a c e d w i t h t h e s h e a r
force (V). U n t i l wall contact, t h e c o l u m n shape i s d e s c r i b e d
b y a cosine f u n c t i o n (equation 2). An i n s t a n t a n e o u s change i n
c a s i n g shape i s r e q u i r e d . An i m p o r t a n t c o n s e q u e n c e i s t h a t
s t r e s s v a l u e s a r e n o t c o m p a t i b l e when w a l l c o n t a c t o c c u r s u s i n g
t h e t w o d i f f e r e n t shapes. E q u a t i o n s ( 4 ) and ( 1 6 ) a l o n g w i t h
computer r e s u l t s t o be d i s c u s s e d l a t e r a r e p l o t t e d i n F i g u r e
loa.
A s o l u t i o n t o the predicament (subject t o confirmation by
n u m e r i c a l a n a l y s i s ) was t o assume t h e c o l u m n shape a f t e r
c o n t a c t was t h e same as b e f o r e . The o n l y d i f f e r e n c e was t h a t
i t was " s p l i t . " T h i s a s s u m p t i o n r e q u i r e d i m a g i n a r y end moments

. i T X m o s h E o ( 1 9 5 9 ) d i s c u s s e s t h e c a s e o f a f i x e d e n d beam
u n i f o r m l y l o a d e d w i t h f o u n d a t i o n c o n t a c t b u t n o r e f e r e n c e was
f o u n d d i s c u s s i n g a x i a l l y - l o a d e d members w i t h w a l l c o n t a c t .

24
F
c

GEOTHERMAL WELL CASING


EULER BUCKLING
MAXIMUM STRESS
I I I I 1
1

TEMPERATURE CHANGE, AT ( O R

Figure 8 . Maximum S t r e s s ( a ) Versus Temperature Change ( A T )


f o r 13-318 inch 5 4 . 5 ppf C a s i n g Assuming
Unsupported Lengths ( L / D ) o f 50, 1 0 0 , a n d 2 0 0 .

25
GEOTHERMAL WELL CASING
EULER BUCKLING
MAXIMUM DEFLECTION
I I I

13 3/8 INCH S4.Sppf CASING


UNSUPPORTED LENGTH
A uD=60(58ff)
0 V D = l O O (111 ft)
L/D=200 (223 ft)

OO 100 200 300 400

F i g u r e 9. Maximum D e f l e c t i o n V e r s u s T e m p e r a t u r e Change ( A T )
f o r 1 3 - 3 / 8 i n c h 54.5 p p f C a s i n g Assuming
U n s u p p o r t e d L e n g t h s ( L / D ) o f 50, 100, a n d 200.

26
COMPARISON OF DEFORMED
CASING SHAPES
AT AT EQUAL 80 OF*
10
l a W 6 I C H Mdppf CA6lG
0. UNSUPPORTEO L€NGTn.UD=lOO
HOLE QAP. 010=060 (6.60 NCMS)

6
w 7
6-

-
---
0

___
NARCRESULTS
y,=(lIZ) -
(1 corn Ka), K=Wl
yr=(o/U (a 41121o.ln 2x11) ,

gz 6 - ,g=-
0 6-
- a)
5
g
t:
n
3.
4-
fCP
2-
Af *?aO F WAS AT NECESSARY FOR
WALL CONTACT ~ P R E D I C MBY MARC) -
1- j=,/5°
O- 200 400 600 800
LENGTH (INCHES)

COMPARISON OF DEFORMED
CASING SHAPES
10, I

YARC RESULTS
0 AT=lOOeF
A AT = 200.F
~ ~ = a o o * ~
ANALYTIC RESULTS (AT=SOO*F)

b)

LENGTH (INCHES)

COMPARISON OF DEFORMED
CASING SHAPES
10,
1 15 W 6 INCH 64.5 ppf CASING
UNSUPPORTED LENGTH. U D = 100
HOLE QAP. o/O=O.SO (6.60 INCHES)
1

YARC RESULT
~ ~ = a o o * ~
ANALYTIC RESULT AT AT= S O O T

-.
LENGTH (INCHES)

F i g u r e 10. D e f o r m e d C a s i n g Shapes w i t h W a l l C o n s t r a i n t
P r e d i c t e d by MARC and T h e o r e t i c a l M o d e l s a t
a ) A T = 80°F, b ) M A R C r e s u l t s a t A T o 300°F,
a n d c ) A n a l y t i c R e s u l t s a t A T = 30OoF.

27
(MR) e x i s t e d equal t o Pe/2. The m a t h e m a t i c a l model was
s i m i l a r t o t h a t used p r i o r t o t h e w a l l c o n t a c t w i t h t h e
e x c e p t i o n o f a v a r i a b l e column l e n g t h ( 2 ) .
Figure 6 depicts t h e v a r i a b l e length (2). It i s the length
between t h e f i x e d end and t h e p o i n t o f w a l l c o n t a c t . The
l e n g t h ( 2 ) s h o r t e n s as t h e c a s i n g segment a g a i n s t t h e w a l l
l e n g t h e n s due t o i n c r e a s e d d e f o r m a t i o n . An e x p r e s s i o n f o r
was f o u n d f r o m t h e c o n d i t i o n t h a t t h e - t h e r m a l d i s p l a c e m e n t
(6(T)) e q u a l e d t h e sum o f t h e a x i a l l o a d d i s p l a c e m e n t ( s ( P ) )
and t h e beam d e f l e c t i o n d i s p l a c e m e n t ( a ( y ) ) . . U s i n g t h e same
d i s p l a c e m e n t e x p r e s s i o n s as b e f o r e ( e q u a t i o n s ( l o ) , (ll),
and
(12)) resulted in:

R = {(,e)2 A + A2 + 256 L 2 12 I A a A T I 1 / 2 ) /16LAaAT (17)

The t o t a l s t r e s s ( a b ) a t a maximum f i b e r i n t h e c a s i n g
e q u a l s t h e a x i a l s t r e s s ( u a ) p l u s t h e maximum b e n d i n g s t r e s s
( “b )ma x ( e q u a t i o n 6 ) where:

ua = EaATcr (7)

= M r /I
(“b)max R o

and

MR = P e / 2 = T
2E I e / = 22

The e x p r e s s i o n f o r t h e maximum s t r e s s i s t h u s :

2 2
at = EaATcr + 1 Eero/2R (19)

F i g u r e l l a p l o t s equation (19) f o r a 13-3/8 i n c h 54.5 ppf


( 3 4 0 mm 8 0 k g / m ) c a s i n g 1 0 0 d i a m e t e r s l o n g . Wall c o n t a c t

28
ANALYTIC MODEL OF
EULER BUCKLING WITH SUBSEQUENT
WALL CONTACT
I I

-
loo isa/8INCH s 4 . s p p f CASING
UNSUPPORTED LENGTH, L/D = 100
90 - HOLE GAP, */D
0 0.25 (5.34 INCH)
Q 80- 0 OIO (6.69 INCH)
A 0.71 (10.03 INCH)
m 1.00 0
(13.58 INCH)
0
0
- a)

&'.
i

I
i 400

TEMPERATURE CHANGE, AT (OF)

MARC FE ANALYSIS USING


THIN WALLED BEAM ELEMENT
I I
I I

100 13 518 INCH S4.SPPf CASING

-- 90 -
UNSUPPORTED LENGTH, LID =lo0
HOLE GAP, */D
0 0.26 (3.34 INCH)

- b)
cn 5 0 -

F i g u r e 11.

,-
29
g e n e r a l l y lowers t h e stress i f t h e distance t o the hole wall
(e/D) i s l e s s t h a n 0.50 and t e m p e r a t u r e c h a n g e s ( A T ) a r e w i t h i n
t h e n o r m a l 200-3OO'F (95-15O'C) range.

--
Numerical Model k
i
c
The a n a l y s i s o f c a s i n g b u c k l i n g i s d i f f i c u l t f o r a s t a t i c I
1
f i n i t e e l e m e n t code t o h a n d l e . I n addition, t h e numerical
model f o r m u l a t i o n r e q u i r e s a s l i d i n g i n t e r f a c e c a p a b i l i t y t o 1
1
simulate wall contact. The n u m e r i c a l model d e v e l o p e d used t h e i
I
t h i n - w a l l e d beam e l emen t ( E u l e r t h e o r y ) w i t h c i r c u l a r
cross-section and t h e f r i c t i o n gap e l e m e n t f r o m t h e MARC f i n i t e
element program (1979). As a c h e c k , a n o t h e r model was a l s o r u n
u s i n g a s t a n d a r d beam-column e l e m e n t w i t h an i d e n t i c a l
moment-of-inertia area r a t i o ( I / A ) . The r e s u l t i n g s t r e s s e s
were p r a c t i c a l l y i d e n t i c a l u n t i l n e a r t h e y i e l d p o i n t .
A s s u m---
ptions. The n u m e r i c a l model l i m i t a t i o n s a r e s i m i l a r
t o t h o s e o f t h e a n a l y t i c model. C o m p l i c a t i o n s due t o c a s i n g
n e s t i n g and c r o s s - s e c t i o n a l shape changes ( o v a l a t i o n ) due t o
l a t e r a l and b e n d i n g f o r c e s w e r e n o t i n c l u d e d . Casing
i n s t a b i l i t y from internal-external p r e s s u r e i n t e r a c t i o n was
neglected, F i n a l l y , o n l y 13-3/8 i n c h 54.5 p p f ( 3 4 0 mm 8 0 k g l m )
c a s i n g 100 d i a m e t e r s l o n g was e x a m i n e d . High temperature
changes were a n t i c i p a t e d n e a r t h e s u r f a c e i f w e l l shutdown
o c c u r r e d and t h u s l a r g e d i a m e t e r p i p e was t h o u g h t a p p r o p r i a t e .
The u n s u p p o r t e d l e n g t h s e l e c t e d was a r b i t r a r y . For t h i s
i n i t i a l investigation, i n e l a s t i c a n a l y s i s above t h e y i e l d p o i n t
was o m i t t e d ( 8 0 k s i ( 5 5 2 MPa) f o r N-80 c a s i n g ) .
D i s c u .-s s i o--
n. The n u m e r i c a l model b u c k l e d (became
numerically unstable) a t A T e~
q u a~l t o 58°F ( 1 4 ° C ) . This
v a l u e compares p o o r l y w i t h t h e a n a l y t i c a l l y c o m p u t e d 72°F (22'C)
c r i t i c a l t e m p e r a t u r e change AT^,). However, A T i s a s t r o n g
function o f the eccentricity i n i t i a l l y introduced i n the casing
model.
I t was n o t p o s s i b l e t o p l o t t h e e n t i r e s t r e s s p a t h i n one
run. The c a s i n g w o u l d n e v e r r e g a i n s t a b i l i t y a f t e r b u c k l i n g

30
even though t h e l o a d i n g was t e m p e r a t u r e ( s t r a i n ) c o n t r o l l e d ;
hence i t was n e c e s s a r y t o e s t a b l i s h the c a s i n g d e f o r m a t i o n a t
wall c o n t a c t and then proceed w i t h t h e c a l c u l a t i o n s . Force
e q u i l i b r i u m o c c u r r e d a t A T equal t o 7 8 ° F ( 2 6 ° C ) which i n d i c a t e d
w a l l con t a c t .
Snyder (1979) c l a i m e d thermal b u c k l i n g i n an unsupported
h o l e i s n o t s t r a i n c o n t r o l l e d . F u r t h e r m o r e , he h y p o t h e s i z e d
sudden h o r i z o n t a l movement c o u l d c a u s e c r a c k i n g o f
work-hardened, h i g h g r a d e s t e e l . A t f i r s t g l a n c e , t h e
i n s t a b i l i t y p r o b l e m w i t h MARC (1979) a p p e a r s t o s u p p o r t t h e
sudden horizontal displacement viewpoint.
However, t h e r a t e o f t e m p e r a t u r e i n c r e a s e w o u l d have t o b e
v e r y h i g h ( h i g h s t r a i n r a t e ) f o r t h e above h y p o t h e s e s t o be
t r u e . T h e a n a l y t i c s o l u t i o n (Figure 8 ) suggests l a r g e
h o r i z o n t a l movement i s n o t p o s s i b l e unless c a s i n g s t r e s s h a s
i n c r e a s e d well beyond AT^^ b e f o r e b u c k l i n g . T h e d i f f i c u l t i e s
w i t h t h e MARC model may have been d u e t o t h e a r t i f i c i a l
t e m p e r a t u r e i n c r e a s e r a t e , b u t t h e l a r g e computer time r e q u i r e d
t o r u n t h e model p r e c l u d e d t h e use o f s m a l l e r r a t e s .
I t i s worth m e n t j o n i n g t h a t i n t h e C e r r o P r i e t o geothermal
f i e l d , Baja, C a l i f o r n i a , t h e i n i t i a l t e m p e r a t u r e r i s e t o
p r o d u c t i o n t e m p e r a t u r e s is c a r e f u l l y monitored t o ensure s t r a i n
c o n t r o l . T h e p r o c e d u r e r e q u i r e s 30-60 days ( S n y d e r , 1979).
T h i s r a t e w o u l d b e impractical if many temperature c y c l e s were
required.
As i p d i c a t e d e a r l i e r , t h e s p l i t - c o s i n e b e l l approximation
( 4 ) , t h e t h e o r e t i c a l curve ( 1 6 ) , and t h e MARC d i s p l a c e m e n t
v a l u e s f p r t h e deformed c a s i n g s h a p e a t t h e time of wall
c o n t a c t w i t h a h o l e gap ( e / D ) equal t o 0.50 a r e compared i n
F i g u r e 10. F i g u r e 10b p l o t s t h e MARC deformed s h a p e s f o r
t e m p e r a t u r e changes ( A T ) o f 100, 200, and 300°F ( 3 8 , 93, and
149°C) and a l s o e q u a t i o n ( 1 6 ) a t A T = 30OoF. A t AT e q u a l t o
300"F, t h e d i f f e r e n c e i n s h a p e between e q u a t i o n ( 1 6 ) a n d MARC
i s g r e a t and w o u l d presumably get worse a t h i g h e r t e m p e r a t u r e
changes .
31
For the numerical calculations, the casing contact length
w i t h t h e w a l l was q u i t e s m a l l . A t A T = 300°F and e / D = 0.75,
MARC p r e d i c t e d a c o n t a c t l e n g t h o f 1 0 p e r c e n t o f t h e t o t a l
l e n g t h u s i n g a t o l e r a n c e o f 0.05 i n c h e s (1.27 mm). This
compares w i t h 47 p e r c e n t f r o m a n a l y t i c c a l c u l a t i o n s .
-. .
F i g u r e 1Oc shows t w o shape p r e d i c t i o n s a t A T e q u a l t o 300°F
(149°C) developed f r o m e q u a t i o n ( 4 ) and ( 1 6 ) u s i n g t h e f r e e ,
u n s u p p o r t e d l e n g t h ( R ) d e t e r m i n e d f r o m MARC r a t h e r t h a n
analytically. The r a i s e d - c o s i n e e q u a t i o n ( 4 ) c o i n c i d e d w i t h
t h e MARC d a t a when t h e n u m e r i c a l v a l u e o f R was used. Equation
( 1 6 ) p r e d i c t e d s l i g h t l y more c u r v a t u r e .
I f t h e n u m e r i c a l l y d e t e r m i n e d R i s used i n t h e e x p r e s s i o n
f o r s t r e s s ( a b ) ( e q u a t i o n 19), a v a l u e o f 64 k s i ( 4 4 1 MPa) i s
p r e d i c t e d when e/D = 0.50 and A T = 300°F ( 1 4 9 ° C ) . The maximum
s t r e s s c a l c u l a t e d n u m e r i c a l l y was 72.5 k s i ( 5 0 0 MPa)
(Figure l l b ) . Thus, t h e t h e o r e t i c a l e q u a t i o n s p r o v i d e a good
shape a n d s t r e s s v a l u e p r e d i c t i o n i f t h e l e n g t h ( R ) i s known.
I n m a k i n g c o m p a r i s o n s b e t w e e n e q u a t i o n ( 4 ) and ( 1 6 ) , r e c a l l
t h a t equation (4) d i c t a t e s ut occurs a t t h e w a l l contact w h i l e
equation (16) d i c t a t e s ut occurs a t the quarter p o i n t o f t h e
free length. The MARC model showed a t g r a d u a l l y s h i f t i n g f r o m
t h e w a l l c o n t a c t p o i n t a t A T e q u a l t o 78°F ( 2 6 ° C ) t o t h e
q u a r t e r p o i n t a t 300°F ( 1 4 9 ° C ) when e/D e q u a l s t o 0.50. The
s h i f t o f ut t o the quarter p o i n t occurred w i t h smaller
c h a n g e s i n A T as e d e c r e a s e d i n m a g n i t u d e .
Figure l l b plots at v e r s u s AT f o r MARC v a l u e s . The
analytic calculations from Figure l l a are p l o t t e d f o r
comparison. The a n a l y t i c a n d n u m e r i c a l s o l u t i o n s compare
f a v o r a b l y when t h e w a l l d i s t a n c e ( e / D ) i s 0.50. A t a h o l e gap
s i z e o f 0.25, t h e a n a l y t i c s o l u t i o n shows a d i p b e l o w t h e EaAT
stress line. T h i s i s u n r e a l i s t i c and i n d e e d t h e n u m e r i c a l
s o l u t i o n does n o t c r o s s t h e EaAT l o w e r l i m i t . The n u m e r i c a l
r e s u l t s i n d i c a t e t e m p e r a t u r e changes u p t o 310°F (154°C) c o u l d
b e t o l e r a t e d f o r e/D = 0.75.

32
Addition o f &onstant Stress

It i s important t o note t h e numerical r e s u l t s p a r a l l e l t h e


EaAT l i n e i n d i c a t i n g t h e a d d i t i o n o f a c o n s t a n t s t r e s s t o t h e
E a A T s t r e s s w o u l d model t h e maximum c a s i n g s t r e s s r e a s o n a b l y
well. A s s u m i n g t h e s t r e s s change (AU) i s a l i n e a r function of
t h e h o l e gap ( e ) , a l e a s t s q u a r e s f i t r e s u l t s i n ( r 2 = 0.78)
( i n c h e s and p s i ) :

AU = ae + b

a = 1960; b = 2060 (20)


u = EaAT + Au

T h e M A R C a n a l y s i s and c o n s t a n t s t r e s s change a s s u m p t i o n a r e
compared i n F i g u r e l l c . Note t h a t t h e s i m p l i f i c a t i o n i s v a l i d
as l o n g as t h e c a s i n g c o n t a c t l e n g t h r e m a i n s s m a l l and t h e h o l e
gap ( e ) i s s m a l l .

----
Analysis Summary-

I n summary, t h r e e p r e d i c t i v e s t r e s s methods were examined:


numerical, empirical, and t h e o r e t i c a l . The n u m e r i c a l
f o r m u l a t i o n f o r m o d e l i n g t h e c a s i n g a f t e r w a l l c o n t a c t was
c o n s t r u c t e d u s i n g M A R C beam e l e m e n t s . The e m p i r i c a l m e t h o d
c o n s i s t e d of a d d i n g a s t r e s s w h i c h was a f u n c t i o n o f t h e h o l e
gap d i s t a n c e ( e ) t o t h e t h e r m a l l y i n d u c e d E a A T s t r e s s . The
equation f i t the numerical r e s u l t s reasonably well f o r small e
values. The t h e o r e t i c a l model made u s e o f s i m p l e beam t h e o r y .
B u c k l i n g w i t h o u t w a l l c o n t a c t was e a s i l y e x a m i n e d
theoretically. However, t h e c a s i n g shape a f t e r w a l l c o n t a c t as
d e r i v e d s t r i c t l y 3 r o m E u l e r beam t h e o r y was n o t c o m p a t i b l e w i t h
t h e i n i t i a l b u c k l i n g phase; h e n c e t h e shape and s t r e s s
p r e d i c t i o n s were o n l y i n f a i r agreement w i t h t h e n u m e r i c a l
results. The t h e o r e t i c a l f o r m u l a t i o n ( 1 6 and 1 9 ) p r o v i d e d a
good shape a n d s t r e s s v a l u e p r e d i c t i o n i f t h e n u m e r i c a l l y
d e t e r m i n e d w a l l c o n t a c t l e n g t h ( R ) was used.

33
A d e s c r i p t i o n o f t h e d e f o r m e d c a s i n g as a s p l i t c o s i n e b e l l
( e q u a t i o n 4 w i t h MR = P e / 2 ) was c o n t r a s t e d w i t h t h e n u m e r i c a l
results. T h e s p l i t - c o s i n e f o r m u l a p r o v i d e d a good
a p p r o x i m a t i o n o f t h e d e f o r m e d shape. The s h a p e d e s c r i p t i o n was
e x c e l l e n t if t h e n u m e r i c a l l y d e t e r m i n e d w a l l c o n t a c t l e n g t h was
used. The e x p r e s s i o n f o r t h e maximum c a s i n g s t r e s s was
i d e n t i c a l t o t h a t derived i n the theoretical formulation. Only
the expression f o r the length differed.

34
RESULT IMPLICATIONS

T h e r m a l l y-
---- I n d u c e d E u l e r Buck1 i n g
---1-_1_

L o o k i n g a t F i g u r e 8, N-80 1 3 - 3 / 8 i n c h 54.5 p p f ( 3 4 0 mm 80
kglm) casing w i t h a y i e l d stress (U ) o f a b o u t 75 k s i
Y
( 5 1 7 MPa) a t 500°F ( 2 6 0 ° C ) * and 1 0 0 d i a m e t e r u n s u p p o r t e d l e n g t h
w o u l d s l i g h t l y e x c e e d y i e l d c o n d i t i o n s i f a 300°F ( 1 5 0 ° C )
t e m p e r a t u r e e x c u r s i o n f r o m cement c o n s t r a i n e d c o n d i t i o n s o f
100-200°F (40-95°C) occurred. These c o n d i t i o n s r o u g h l y
correspond t o t y p i c a l i n t e r m e d i a t e c a s i n g i n geothermal w e l l s
(Figure 1). The i n t r o d u c t i o n o f a s m a l l t e n s i l e s t r e s s w o u l d
e a s i l y reduce t h e s t r e s s t o below y i e l d . Consequently, simple I

E u l e r b u c k l i n g s h o u l d n o t c a u s e a s e r i o u s p r o b l e m i f AT i s l e s s
t h a n 275°F ( 1 3 5 ° C ) f o r u n s u p p o r t e d l e n g t h s ( L / D ) above 100.
Note, however, t h a t t h e r e was n o a l l o w a n c e f o r a d e s i g n
factor. Application o f either direct tension or internal
p r e s s u r e d u r i n g t h e c e m e n t i n g p r o c e s s w o u l d e s t a b l i s h an a x i a l
t e n s i l e l o a d a l t h o u g h t h e m i c r o a n n u l u s b e t w e e n t h e c a s i n g and
cement w o u l d b e e n l a r g e d u s i n g i n t e r n a l p r e s s u r e . Operators
have a v o i d e d t h e r m a l w e l l c a s i n g f a i l u r e s i n p a r t i a l l y cemented
s t e a m i n j e c t i o n w e l l s b y u s i n g N-80 o r P-110 g r a d e c a s i n g
( H o l l i d a y , 1969). T h i s tends t o c o n f i r m t h e low p r o b a b i l i t y o f
p r o b l e m s w i t h N-80 c a s i n g .
The u s e o f l a r g e r d i a m e t e r p i p e w o u l d i n c r e a s e t h e c r i t i c a l
buckling temperature b u t n o t s i g n i f i c a n t l y . This i s

* One i s s a f e i n a s s u m i n g n o s i g n i f i c a n t r e d u c t i o n i n u l i i m a t e
c a s i n g s t r e n g t h o c c u r s f o r t e m p e r a t u r e r i s e s b e l o w 660 F
( 3 5 0 ° C ) , b u t t h e y i e l d s t r e n g t h d e f i n i t e l y d e c r e a s e s w i t h an
increase i n temperature. M a n u f a c t u r e r s g e n e r - a l l y do n o t make
t e n s i l e t e s t s a t e l e v a t e d t e m p e r a t u r e s and t h u s s t a t i s t i c a l l y
r e l i a b l e information i s lacking. K a r l s s o n (1978) suggests
t h e u s e o f D I N St. 45.8. The maximum p o s s i b l e r e d u c t i o n i n
y i e l d s t r e n g t h f r o m t h i s f o r m u l a f o r t h e above c o n d i t i o n s i s
19 p e r c e n t . The a b o v e r e d u c t i o n o f 6 p e r c e n t c o r r e s p o n d s t o
t h e minimum o b t a i n e d f r o m s e v e r a l p r i v a t e t e s t s .

35
d e m o n s t r a t e d b y F i g u r e 7 w h e r e commonly u s e d c a s i n g d i a m e t e r s
p l o t on t o p o f each o t h e r . I n addition, the behavior after
b u c k l i n g m i g h t b e i m p a i r e d b e c a u s e t h e minimum u n s u p p o r t e d
l e n g t h f o r Euler b u c k l i n g t o occur would increase.
I t has been t a c i t l y assumed t h a t s t r e s s e s a b o v e y i e l d
constituted failure. This i s a reasonable f a i l u r e c r i t e r i o n
b e c a u s e p e r m a n e n t d e f o r m a t i o n c o u l d h i n d e r r e m e d i a l w o r k on t h e
well. P l a s t i c d e f o r m a t i o n was p e r m i t t e d a t P r u d h o e Bay
(Goodman, 1 9 7 8 ) w h e r e p e r m a f r o s t thaw p r o d u c e d s t r a i n
c o n t r o l l e d compressive f o r c e s , but the usually successful
c e m e n t j o b p r e c l u d e d t h e b u c k l i n g f a i l u r e mode.
The c a s i n g l o a d s a l o n g t h e w a l l c o n t a c t a r e i m p o r t a n t as
concerns c a s i n g c o l l a p s e . The t h e o r e t i c a l a r g u m e n t ( e q u a t i o n
1 6 ) d i c t a t e s an end r e a c t i o n ( V ) a t t h e w a l l s e p a r a t i o n p o i n t .
The e n d r e a c t i o n i n c r e a s e s w i t h h o l e gap s i z e . A t AT = 300°F
and e / D = 0.75, an end r e a c t i o n o f 1 1 9 0 0 l b ( 5 2 . 9 k N ) was
calculated numerically. U s i n g t h i s v a l u e as a p o i n t l o a d on a
cylinder, one c a l c u l a t e s v a l u e s b e t w e e n 51.9 and 77.2 ksi
(358-532 MPa). The mean i s s l i g h t l y b e l o w t h e 7 5 k s i ( 5 1 7 MPa)
y i e l d point. But t h e c a s i n g has d e f i n i t e l y r e a c h e d y i e l d a t
t h e quarter p o i n t ( x / R = 1/4). T h e r e f o r e , y i e l d i s more l i k e l y
t o occur a t the free-length quarter p o i n t f i r s t r a t h e r than a t
the wall contact.
A g a i n r e f e r r i n g t o F i g u r e 8, t h e importance o f b u c k l i n g
changes d r a m a t i c a l l y f o r weaker K-55 casing. The c a s i n g w o u l d
n o r m a l l y y i e l d a t A T = 295°F ( 1 4 5 ° C ) w i t h f u l l l a t e r a l s u p p o r t
assuming u = 55 k s i ( 3 8 0 MPa), b u t s i m p l e E u l e r b u c k l i n g
Y
w o u l d p r o d u c e s t r e s s e s above y i e l d w i t h o n l y a 155°F ( 7 0 ° C )
t e m p e r a t u r e change. I f a n o r m a l 230-3OO'F (95-15O'C)
temperature excursion occurred, t h e K-55 c a s i n g would y i e l d
when b u c k l i n g o c c u r r e d . L a t e r a l s u p p o r t would be a n e c e s s i t y .
( T h e c a s i n g m i g h t , y i e l d even w i t h f u l l l a t e r a l s u p p o r t . ) The
a n a l y s i s has i g n o r e d t h e s t r e n g t h e n i n g o f c a s i n g n e s t i n g w i t h
c o m p l e t e cement j o b s . This s i t u a t i o n might warrant examination.
From F i g u r e l l b i t can b e g e n e r a l l y s t a t e d t h a t w a l l c o n t a c t
a f t e r b u c k l i n g lowered c a s i n g s t r e s s e s i n comparison t o s i m p l e

36
buckling. The n u m e r i c a l r e s u l t s i n d i c a t e d 13-318 i n c h 54.5 ppf
( 3 4 0 mm 8 0 k g l m ) N-80 c a s i n g w i t h u n s u p p o r t e d l e n g t h s ( L / D )
a b o v e 100 w i t h gaps ( e / D ) b e l o w 0.75 should n o t experience
d i f f i c u l t i e s i f temperature excursions are w i t h i n t h e normal
200-300°F (95-150°C) range. These r e s u l t s a r e s u k p o r t e d b y t h e
f i e l d evidence t h a t production tubing, which i s c l o s e l y
confined, s e l d o m p e r m a n e n t l y d e f o r m s when b u c k l e d ( T e x t e r ,
1955) .
L o s t c i r c u l a t i o n zones c o u l d p o t e n t i a l l y i n v o l v e e n l a r g e d
i h o l e s e x c e e d i n g e / D > 0.75. The t r e n d o f t h e maximum s t r e s s
(ut) i n F i g u r e l l b suggest t h a t l i t t l e d e t r i m e n t would occur
I a t w a l l contact with g r e a t l y enlarged holes. The c a s i n g w o u l d
a l r e a d y b e n e a r y i e l d f o r t h e t e m p e r a t u r e change ( A T ) n e c e s s a r y
f o r t h e l a r g e h o r i z o n t a l displacements.

----
J o i n t Behavior

F o r N-80 c a s i n g , a r e l a t i v e l y h i g h a l l o w a b l e AT was p o s s i b l e
before the casing steel yielded. The w o r s t c a s e o c c u r r e d d u r i n g
w e l l s h u t - i n r e q u i r e d because o f a i r p o l l u t i o n standards. If
no e q u i p m e n t m u s t p a s s t h r o u g h t h e c a s i n g d u r i n g t h i s p e r i o d ,
the tubular material should perform s a t i s f a c t o r i l y . However,
I
A P I j o i n t s a r e n o t d e s i g n e d t o w i t h s t a n d b e n d i n g s t r e s s e s and
w i l l f r a c t u r e n e a r t h e l a s t engaged t h r e a d (Greenip, 1978).
B u t t r e s s t h r e a d c o n n e c t i o n s match t h e p i p e body t e n s i l e
s t r e n g t h and a r e c a p a b l e o f w i t h s t a n d i n g b e t w e e n 2.3 and 3.4
p e r c e n t s t r a i n ( d e p e n d i n g on w h e t h e r i n c o m p r e s s i o n o r t e n s i o n )
( W o o l e y e t al., 1977), b u t t h e y a r e s t i l l weak i n b e n d i n g .
Consequently, j o i n t b e h a v i o r under l o a d i n g c o u l d p o s s i b l y be
t h e l a r g e s t f a c t o r i n c a s i n g f a i l u r e s from b u c k l i n g . Behavior
o f shoulder-type j o i n t s under b e n d i n g s h o u l d be examined t o see
i f adequate improvements a r e o b t a i n e d . A 100 p e r c e n t j o i n t
s u c h as t h e e a s i l y a n a l y z e d , f a b r i c a t e d , and a s s e m b l e d t a p e
j o i n t d e v e l o p e d a t S a n d i a may b e u s e f u l . ( H u e r t a and B l a c k ,
1976; R e c h a r d e t a l . , 1982)

.-----

3 7,'
38
SUMMARY AND CONCLUSIONS

L i t t l e i n f o r m a t i o n i s a v a i l a b l e on g e o t h e r m a l w e l l c a s i n g
behavior or failures; t h u s e f f o r t s s h o u l d b e made t o o b t a i n
d e t a i l e d d e s c r i p t i o n o f f i e l d b e h a v i o r and t h e c r i t e r i a on
w h i c h f a i l u r e i s based. Operators have expressed concern over
c a s i n g i n s t a b i l i t y as a p o s s i b l e f a i l u r e mechanism. If a
c a s i n g s t r i n g i s p l a c e d i n a x i a l compression f r o m t h e r m a l
e l o n g a t i o n and i f t h e r e a r e s i z a b l e s e c t i o n s w h e r e n o l a t e r a l
s u p p o r t i s p r o v i d e d due t o i n a d e q u a t e cement o r w a s h o u t zones,
t h e s t r i n g can l a t e r a l l y d e f l e c t ( b u c k l e ) .
T h i s r e p o r t p r o v i d e s p r e l i m i n a r y c a l c u l a t i o n s on t h e
b u c k l i n g phenomenon. I t can g e n e r a l l y b e s t a t e d t h a t t h e r m a l l y
i n d u c e d b u c k l i n g i n N-80 c a s i n g w o u l d n o t b e s e r i o u s i f m i n o r
a d j u s t m e n t s t o i n c r e a s e c a s i n g s t a b i l i t y w e r e made s u c h as
applying a tension preload o r additional i n t e r n a l pressure
w h i l e cementing. However, t h e s i t u a t i o n i s f a r w o r s e f o r t h e
w e a k e r K-55 c a s i n g . F u l l l a t e r a l support would be a necessity.
The e f f e c t o f w a l l c o n t a c t was f o u n d t o b e b e n e f i c i a l f o r
c l o s e l y c o n f i n e d p i p e s t r i n g s and o f n o g r e a t d e t r i m e n t when
h o l e gaps w e r e l a r g e p r o v i d e d p i p e o v a l a t i o n was u n i m p o r t a n t .
T h e weakness o f a l l A m e r i c a n P e t r o l e u m I n s t i t u t e ( A P I ) screw
j o i n t s i n b e n d i n g appears t o be t h e s t r u c t u r a l l i m i t a t i o n .
The a b o v e c o n c l u s i o n s a r e b a s e d on t h e a s s u m p t i o n t h a t
s t r e s s e s above y i e l d c o n s t i t u t e d f a i l u r e . I t was a l s o assumed
t h e t h e r m a l e x p a n s i o n was s l o w enough t o p r o d u c e s t r a i n
c o n t r o l l e d l o a d s and t h a t t h e c a s i n g s t r i n g c o u l d b e c o n s i d e r e d
continuous. I n t e r n a l p r e s s u r e i n s t a b i l i t y was i g n o r e d . The
t e m p e r a t u r e v a r i a t i o n c o n s i d e r e d was b e t w e e n c e m e n t i n g
c o n d i t i o n s o f 100-2OO'F (40-95°C) and s h u t - i n conditions o f
425-450°F (220-230°C)
Another regime o f thermal b u c k l i n g w h i c h needs t o b e
i n v e s t i g a t e d i s s y m m e t r i c a l b u c k l i n g and w r i n k l i n g i n s t a b i l i t i e s

39
i n short, unsupported c a s i n g lengths. Furthermore, i t would be
b e n e f i c i a l i f l a b o r a t o r y e x p e r i m e n t s were conducted t o : 1)
o b s e r v e t h e a b r u p t n e s s and e x t e n t o f h o r i z o n t a l d i s p l a c e m e n t a t
buckling, 2) evaluate stress reduction i n the casing f o l l o w i n g
w a l l c o n t a c t , 3 ) e v a l u a t e weakening e f f e c t s o f p i p e ovalness,
and 4 ) d e t e r m i n e t h e l i k e l i h o o d o f o t h e r f a i l u r e modes.

40
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SPE 7594, O c t o b e r 1-3.

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E n g i n e e r i n g C o n f e r e n c e , T u l s a , OK, S e p t e m b e r 21-25.

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A n a l y t i c a l I n v e s t i g a t i o n o f an I n t e r l o c k i n g Tape J o i n t , "
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New M e x i c o , O c t o b e r .

11. J e n k i n s , C. J., a n d R. E. S n y d e r , 1979, " G e o t h e r m a l W e l l


Casing Design: Basic Design Considerations," Report t o
Sandia N a t i o n a l L a b o r a t o r i e s b y Completion Technology
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Temperature Geothermal Wells," Geothermal Resources
C o u n c i l , T r a n s a c t i o n s , V o l . 2, pp. 355-358.

41
13. Kumataka, M. K., 1981, l e t t e r t o James R. K e l s e y , Sandia
N a t i o n a l L a b o r a t o r i e s , f r o m A m i n o i l USA, J u l y 28.

14. L u b i n s k i , A., W. J. A l t h o u s e , J. L. Logan, 1962, " H e l i c a l


B u c k l i n g o f T u b i n g S e a l i n g i n P a c k e r s , " J. o f P e t r o l e u m
T e c h n o l o g y , pp. 655-670.

15. M A R C G e n e r a l P u r p o s e F i n i t e E l e m e n t Program, 1979, MARC


A n a l y s i s R e s e a r c h Corp., P a l o A l t o , C a l i f o r n i a 94306.

16. N e l s o n , C. G:, 1975, " P r o g r a m i s D e s i g n e d t o A n a l y z e


C a s i n g B u c k l i n g i n T h e r m a l R e c o v e r y , " The O i l and Gas
J o u r n a l , December 8, pp. 79-82.

17. M i t c h e l l , R. F., 1982, "Advanced W e l l B o r e T e m p e r a t u r e


S i m u l a t o r , GEOTEMPE, I'SAND82-7003, S a n d i a N a t i o n a l
L a b o r a t o r i e s , A l b u q u e r q u e , New M e x i c o .

18. Pye, S., 1980, l e t t e r t o S. G. Varnado, S a n d i a N a t i o n a l


L a b o r a t o r i e s , f r o m U n i o n O i l , March 15.

19. Rechard, R. P., 3 . T. B l a c k and S. D. Meyer, 1982,


" G u i d e l i n e s f o r D e s i g n i n g Tape J o i n t s , " SAND82-2416,
S a n d i a N a t i o n a l L a b o r a t o r i e s , A l b u q u e r q u e , New M e x i c o

20. Snyder, R. E., 1979, " G e o t h e r m a l W e l l C a s i n g D e s i g n : A


S t u d y o f F a i l u r e Modes and C e m e n t i n g L i m i t a t i o n s , " R e p o r t
t o Sandia N a t i o n a l L a b o r a t o r i e s by Completion Technology
Company, May.

21. T e x t e r , H. G., 1955, "Why O i l - W e l l T u b i n g and C a s i n g


Fail... b y Wear, E r o s i o n , B u c k l i n g , T o r s i o n and
C o r r o s i o n , " The O i l and Gas J o u r n a l , A u g u s t 29, pp. 85-99.

22. Timoshenko, S., 1959, S t r e n g t h o f M a t e r i a l s , D. Van


N o s t r a n d Co., I n c . , P r i n c e t o n , New J e r s e y .

23. Timoshenko, S., J. M. Gere, 1961, T ------


heory o f E l a s t i c
S t a b i l i t y , M c G r a w - H i l l Book Co. I n c . , New Y o r k .

24. W i l s o n , W. H., T. K. P e r k i n s , and J. H. S t r i e g l e r , 1980,


" C a s i n g B u c k l i n g S t u d i e s Lower Cementing Costs," W o r l d
O i l , September, pp. 63-67.

25. Wooley,.G. R., S. A. C h r i s t m a n , J. G. C r o s e , 1977, "Strain


L i m i t D e s i g n o f 1 3 - 3 / 8 i n c h N-80 B u t t r e s s C a s i n g , " 3. o f
P e t r o l e u m T e c h n o l o g y , pp. 355-359.

26. Wooley, G. R., 1980, " W e l l - B o r e and S o i l T h e r m a l


S i m u l a t i o n f o r G e o t h e r m a l We1 1 : C o m p a r i s o n o f GEOTEMP
P r e d i c t i o n s t o F i e l d D a t a and E v a l u a t i o n o f F l o w
V a r i a b l e s , " SAND79-7116, S a n d i a N a t i o n a l L a b o r a t o r i e s ,
A l b u q u e r q u e , New M e x i c o , March.

42
APPENDIX A

Nomencl a t u r e

A - casing cross-sectional area (L*)

D - outside casing diameter (L)

I E - modulus o f e l a s t i c i t y ( M / t L )

e - gap b e t w e e n c a s i n g and d r i l l h o l e ( L )

I - moment o f i n e r t i a ( ~ 4 )

L - t o t a l unsupported l e n g t h ( L )
R - u n s u p p o r t e d l e n g t h between f i x e d end and
point o f contact with wall (L)

Mb, MR - moment a t p o i n t b and r e a c t i o n moment ( M / t )

P, PCrr Pe - a x i a l l o a d , a x i a l l o a d when E u l e r b u c k l i n g
i n i t i a t e d , and r e a c t i o n l o a d ( M / t L )

ri, r o - i n s i d e and o u t s i d e c a s i n g r a d i u s ( L )

- radius of gyration (L)

v, VR - shear f o r c e a p p l i e d a t w a l l c o n t a c t and
r e a c t i o n shear f o r c e ( M l t L ) .
,
Y S Ymax - c a s i n g d e f l e c t i o n and maximum c a s i n g
deflection (L)

Y', Y" - f i r s t and s e c o n d d e r i v a t i v e s , respectively

AT, A T c r - t e m p e r a t u r e change and t e m p e r a t u r e change


when E u l e r b u c k l i n g i n i t i a t e d ( T )

a - l i n e a r c o e f f i c i e n t o f thermal
expansion (T-1

dP), dT) - a x i a l l o a d and t h e r m a l l o a d d i s p l a c e m e n t s

&l(Y), 6 d Y ) - d e f l e c t i o n d i s p l a c e m e n t s b e f o r e and a f t e r
wall contact (L)

43
u a s (Qblmax - a x i a l s t r e s s a n d maximum bending
s t r e s s (MltL)
Q w / s Qw/o - t o t a l casing s t r e s s w i t h a n d without w a l l
contact (MltL)
Qt - t o t a l c a s i n g s t r e s s (MltL)

OY
- yield stress ( M / t L )

44
APPENDIX B
Derivation o f Equations

Appendix B p r e s e n t s i n g r e a t e r d e t a i l t h e d e r i v a t i o n s o f
pertinent equations i n the text. The c o n c e p t s a r e q u i t e
simple, b u t t h e a l g e b r a can b e t e d i o u s . The c a s i n g shape
d e s c r i p t i o n and t h e e x p r e s s i o n f o r maximum s t r e s s b e f o r e w a l l
contact are derived f i r s t . The c a s i n g s h a p e a n d s t r e s s
equations a f t e r wall contact follow. For c l a r i t y , additional
e q u a t i o n s and f i g u r e s w e r e added t o t h o s e p r e s e n t e d i n t h e
text. T h e y a r e p r e f i x e d w i t h t h e l e t t e r IIB."

-- -
D i f f e r e n t i a1 E q u a t i o n

From t h e f r e e b o d y d i a g r a m i n F i g u r e 6b, the following


e q u i l i b r i u m c r i t e r i a m u s t b e met:

I f a s e c t i o n t h r o u g h t h e beam i s t a k e n b e f o r e p o i n t b
(Figure B-la) then the f o l l o w i n g equation results:

45
FREE BODY DIAGRAMS OF WELL CASING

HOLE WALL

F i g u r e B-1. S u p p l e m e n t a r y F r e e Body D i a g r a m s
By a s s u m i n g ( y ' ) ' i s s m a l l compared t o yi' i n t h e m a t h e m a t i c a l
expression f o r curvature, E u l e r beam t h e o r y e x p r e s s e s t h e
moment M as:

M = EIy"

2
T h i s e q u a t i o n a p p l i e s assuming: 1) (y') 2 ) Hook's
i s small,
l a w a p p l i e s , 3) E i s t h e same f o r t e n s i o n and c o m p r e s s i o n ,
4 ) a p l a n e s e c t i o n r e m a i n s p l a n e a f t e r bending, and 5 )
l o n g i t u d i n a l f i b e r l e n g t h s do n o t change. Substituting f o r M

The s o l u t i o n o f t h e d i f f e r e n t i a l e q u a t i o n i s

where

K2 = P/EI

From F i g u r e 6 a i t i s e v i d e n t t h e f i x e d - e n d b o u n d a r y c o n d i t i o n s
a t p o i n t a are:

x = o , y = o

x = 0, y ' = 0

Consequently:

- MR V
-
Y = T (1-cos KX) + (x sin KX)

47
--
Cr5tical temperature.
---a_---- Before w a l l c o n t a c t , t h e shear f o r c e
(V) i s zero. C o n s e q u e n t l y t h e c a s i n g t a k e s t h e shape o f a
raised cosine function:

*R
y = -p ( 1 - COS Kx) (4)

T h e d e f l e c t i o n and s l o p e a t p o i n t c i s a l s o s p e c i f i e d a n d
e s t a b l i s h e s two a d d i t i o n a l boundary c o n d i t i o n s :

x = L = 22, y = 0

x = L = 22,y' = o
B o t h b o u n d a r y c o n d i t i o n s e s t a b l i s h a f u r t h e r r e s t r i c t i o n on K :

K = 2~m/L, m = 0, 1, 2 ,...
E q u a t i n g t h e two e x p r e s s i o n s f o r K and l e t t i n g m = 1 r e s u l t s i n :

2 2
P = 4r E I / L

For a thermally induced load:

Pcr = AEaAT (6-4)

S u b s t i t u t i n g f o r t h e l o a d P and s o l v i n g f o r A T :

2
A T = 4n I
K
-----
Maximum S ---
tress. The t o t a l s t r e s s ( u t ) a f t e r t h e c a s i n g has
buckled equals (neglecting oval a t ion stresses) :

Qt-
- 0
a +

The e x p r e s s i o n o f u a i s :

48
ua = PcrIA = EabTcr = constant (7)

F o r a l o n g , s l e n d e r c a s i n g i t i s r e a s o n a b l e t o assume a b = Mc/I
w h i l e s t r e s s e s remain below y i e l d . From e q u a t i o n ( 6 - 2 ) where
v = 0:

= MR C O S K X (using 4)

The maximum b e n d i n g s t r e s s o c c u r s a t t h e end p o i n t s


when:

(‘b)max = MRrolI

The r e s t r a i n i n g moment a f t e r b u c k l i n g ( M R ) i s found b y t h e


p r o c e d u r e o u t l i n e d by Boley and Weiner ( 1 9 6 0 ) . The t h e r m a l l y
induced l e n g t h change ( s ( T ) ) must equal t h e sum of t h e a x i a l
l o a d d e f o r m a t i o n ( s ( P ) ) and t h e c a s i n g d e f l e c t i o n ( s ( y ) )
( F i g u r e B-2a) :

T h e e x p r e s s i o n s f o r t h e thermal and a x i a l d i s p l a c e m e n t s a r e

s(T) = aATL (10)

6(P) = PcrL/AE = constant (11 1

T h e d e f l e c t i o n d i s p l a c e m e n t i s e q u i v a l e n t t o (where ds i s
measured a l o n g t h e c a s i n g ) :

q(y) = /oL(ds-dx)

49
U s i n g a T a y l o r e x p a n s i o n o f t h e i n t e g r a n d and n e g l e c t i n g h i g h e r
order terms r e s u l t s i n :

but

-MRK
y’ = s i n Kx

hence

Substituting (lo), ( l l ) , and ( 1 3 ) i n t o ( 9 ) and s o l v i n g f o r M:

A s a r g u e d i n t h e r e p o r t , o n c e b u c k l i n g has o c c u r r e d , s(T) i s
e n t i r e l y absorbed by s(y); hence s ( P ) r e m a i n s c o n s t a n t .
Consequently u a remains a t t h e c r i t i c a l b u c k l i n g s t r e s s .
S u b s t i t u t i n g (6-4) i n t o (9-5) yields:

I n s e r t i n g e q u a t i o n ( 1 4 ) i n t o ( 8 ) and e v a l u a t i n g I f o r a p i p e
yields:

(Ob)max = AEaATcr[a(~T - AT,^)] 1 ’ 2 4 L r 0 / n ( r o2 + r 7i ) (6-6)

S u b s t i t u t i n g (9-6) and ( 7 ) i n t o ( 6 ) r e s u l t s i n :

50
DISPLACEMENT RELATIONSHIPS

a)

6(T) = 6(P) + 262(P) 262(Y)

.-
= 6(P) + 262(Y)

b)
.
F i g u r e 6-2. Thermal, A x i a l , and Beam D e f l e c t i o n D i s p l a c e m e n t
Relationships.

51
~
.

---
After Wall € o n t a c t

-
Casingshape. A f t e r w a l l c o n t a c t o c c u r s t h e f i x e d end
b o u n d a r y c o n d i t i o n s a t p o i n t "an1 s t i l l h o l d and t h u s e q u a t i o n
(2) i s applicable. Two new b o u n d a r y c o n d i t i o n s a t t h e p o i n t o f
w a l l c o n t a c t are:

x = R , y = e

x = R, y' = 0

The f o u r t h b o u n d a r y c o n d i t i o n e s t a b l i s h e s :

where

K' = P/ER

The p l a u s i b i l i t y o f a c o n c e n t r a t e d s h e a r l o a d ( V ) as
opposed t o a d i s t r i b u t e d l o a d a t t h e w a l l c o n t a c t i s argued i n
C r a n d a l l and Dah1 ( 1 9 5 9 ) . The a r g u m e n t i s b a s e d on t h e
a s s u m p t i o n t h a t t h e beam-column i s straight a t the surface
contact. This s i t u a t i o n precludes the p o s s i b i l i t y o f a
moment Mb.
E q u a t i o n ( 3 ) e s t a b l i s h e s a r e l a t i o n s h i p b e t w e e n MR, V and
P ( o r K ) b u t s e v e r a l cases a r e e v i d e n t . F i r s t whenever s i n K R
and l - c o s K R equal zero the equation holds. However, when t h i s
c a s e i s i n s e r t e d i n t o t h e s t a t i c moment r e l a t i o n i t i s f o u n d
MR = -Mb. T h i s f a c t i s n o t c o m p a t i b l e w i t h t h e deformed
c a s i n g shape a f t e r w a l l c o n t a c t ( F i g u r e 8 b ) .
A n o t h e r p o s s i b i l i t y i s w h e r e MR and l - c o s KR equal zero.
( A f t e r wall contact, t h e shear f o r c e ( V ) i s nonzero i n
equation ( 3 ) . ) Because Mb i s assumed t o e q u a l z e r o i t i s
p o s s i b l e t o show M R = 0 a l s o .

52
The p l a u s i b i l i t y o f t h i s f a c t c a n b e seen b y e x a m i n i n g t h e
f r e e body diagram i n F i g u r e B-lc. Figure B-lc i s simply the
m i r r o r image o f F i g u r e B - l b w h i c h was u s e d t o o b t a i n e q u a t i o n
(8-2). O n l y t h e moment MR i s m i s s i n g . Another h e u r i s t i c
argument i s f o u n d b y assuming F i g u r e s B - l b and B - l c are d i v i d e d
a t t h e change i n c u r v a t u r e . A t the point o f counterflexure,
M = 0. A sum o f moments i n F i g u r e B - l c r e s u l t s i n Pe = V R .
A p p l y i n g t h i s r e l a t i o n s h i p t o t h e moment r e l a t i o n s h i p o f
equation (B-1) w h e r e M = 0 r e s u l t s i n M R = 0. Therefore, if
a s t r a i g h t section e x i s t s i n the casing a t the wall contact,
b o t h e n d moments a r e r e p l a c e d w i t h c o n c e n t r a t e d s h e a r f o r c e s
(V).
From t h e c o n d i t i o n MR = 0 a n d 1-cos K ' x = 0 i n equation
( 3 ) , t h e shape o f t h e c a s i n g b e t w e e n p o i n t s ''a" and ''b" i s :

where

K ' = 2n/R

A t t h e moment o f c o n t a c t R = L / 2 o r K ' = 4rlL. Use o f t h e t h i r d


b o u n d a r y c o n d i t i o n r e s u l t s i n Pe = V R .
I n o r d e r t o make c o m p a r i s o n s b e t w e e n e q u a t i o n ( 4 ) a n d ( 8 - 7 )
i t i s d e s i r a b l e t o d e f i n e K = 2 r l L i n which case equation (6-7)
becomes :

V
Y = p ( X - z s i n 2Kx) (16)
.
i

Up u n t i l - w a l l c o n t a c t , t h e c a s i n g s h a p e was d e s c r i b e d b y
the cosine expression (4). A f t e r contact, equation (16)
r e q u i r e s an i n s t a n t a n e o u s c h a n g e i n c a s i n g shape. The
predicament r e s u l t s f r o m t h e assumption o f a s t r a i g h t s e c t i o n
a t the i n s t a n t o f contact. T h e r e i s a c t u a l l y a t r a n s i t i o n zone
w h e r e b o t h a moment and a s h e a r f o r c e e x i s t , but the

53
r

s i g n i f i c a n c e o f t h e c a s i n g moment s h o u l d g r a d u a l l y d e c r e a s e
a f t e r wall contact.*
Because o f t h e e x i s t e n c e o f a t r a n s i t i o n z o n e w h e r e b o t h a
moment and a s h e a r ( o r more r e a l i s t i c a l l y , a distributed force)
e x i s t simultaneously, a more d e t a i l e d a n a l y t i c s o l u t i o n i s
required. However, an a l t e r n a t i v e i s t o d e s c r i b e t h e c a s i n g
shape as a " s p l i t c o s i n e b e l l " i n t h e t r a n s i t i o n zone. The
split-cosine f o r m u l a t i o n i s developed i n a subsequent s e c t i o n .
V a r i a b -l e----
L e n --
g t h f-k--) . The v a r i a b l e l e n g t h ( R ) i s shown i n
Figures B-la and B-2b. I t i s t h e l e n g t h between t h e f i x e d end
and t h e p o i n t o f w a l l c o n t a c t . The l e n g t h ( a ) s h o r t e n s as t h e
c a s i n g segment a g a i n s t t h e w a l l l e n g t h e n s due t o i n c r e a s e d
deformation. An e x p r e s s i o n f o r t h e v a r i a b l e l e n g t h ( 2 )
p e r t a i n i n g t o equation (16) i s found from the c o n d i t i o n t h a t
t h e t h e r m a l d i s p l a c e m e n t ( a ( T ) ) e q u a l s t h e sum o f t h e a x i a l
l o a d d i s p l a c e m e n t ( a ( P ) ) and t w i c e t h e c a s i n g d e f l e c t i o n
(6*(y)) ( F i g u r e B-2b):

The e x p r e s s i o n s f o r d i s p l a c e m e n t s a r e e q u a t i o n s ( l o ) , (ll), and


( 1 2 ) as b e f o r e . Substituting equation (16) i n t o equation (12)
r e s u l t s in:

*gimportance o f t h e moment c o u l d i n c r e a s e a g a i n i f enough


t h e r m a l e l o n g a t i o n o c c u r r e d such t h a t t h e c a s i n g began t o
buckle i n the region o f wall contact. (With a t h i n - w a l l e d .
p i p e i t i s more l i k e l y t h a t p l a s t i c d e f o r m a t i o n s u c h as
k i n k i n g o r c o l l a p s e would o c c u r b e f o r e assuming a h i g h e r
b u c k l i n g mode.) T h e b u c k l i n g phenomenon i s e a s i l y v i s u a l i z e d
i f a f l e x i b l e bar or note card i s buckled against a s o l i d
surface.

54
f
c

It i s important t o note the difference i n the casing


d e f l e c t i o n b e t w e e n e q u a t i o n s ( 1 3 ) and (B-9). By c o m b i n i n g
e q u a t i o n s ( 1 3 ) a n d (B-5) i t i s e a s i l y shown:

al(y) = aL(AT - AT^^) (B-10)

The e x p r e s s i o n f o r c a s i n g d e f l e c t i o n a f t e r w a l l c o n t a c t i s
g i v e n b y (B-9) b u t V = eP/R; hence:

3 e2
9(Y) = (B-11)

A t t h e instance o f wall contact, e = ymax = 2MR/P.


E x p r e s s i n g MR b y ( B - 5 ) and s u b s t i t u t i n g i n t o (B-11) yields:

2
6,(y) = aL(AT - AT^^) 6/r (B-12)

E q u a t i o n s (B-10) a n d (B-12)
2
d i f f e r by t h e f a c t o r 6 1 ~ .
A r e l a t i o n s h i p f o r the v a r i a b l e length i s found by
substituting (lo), (ll),
and (B-11) i n t o (B-8) which y i e l d s :

(B-13)

-but

2 2
= 471 E I / L (8-1 5)
'cr

. S u b s t i t u t i n g t h i s e x p r e s s i o n i n t o (8-13), e v a l u a t i n g I and A,
and s o l v i n g f o r R ( A T > AT^^ 1:

R1 = 7 e 2 L / [ aATt
2
- r 2 ( r i +r: )] (B-14)
n
I t can b e shown !tl = ( 1 2 / r L ) L a t t h e i n s t a n t o f c o n t a c t r a t h e r
t h a n 1 / 2 L.

55
I n t h e above f o r m u l a t i o n , i t was assumed t h e d i s p l a c e m e n t
f r o m t h e a x i a l l o a d remained c o n s t a n t ( P = Pcr). However, a
new c r i t i c a l b u c k l i n g l o a d e x i s t s f o r t h e s h o r t c a s i n g o f
l e n g t h ( a ) w h i c h i s 4 t i m e s as g r e a t .

2
4r E 17
P = ''
4
F r i c t i o n a l o n g t h e w a l l c o u l d p r o v i d e a mechanism f o r t h i s new
t h r e s h o l d t o be reached. A l s o i f t h e c a s i n g was t o assume a
h i g h e r b u c k l i n g mode, l a r g e r a x i a l loads than the c r i t i c a l load
a s s o c i a t e d w i t h t h e f i r s t b u c k l i n g mode seemed p o s s i b l e .
Consequently, an e x p r e s s i o n f o r R was d e r i v e d w h i c h p e r m i t t e d
an i n c r e a s e i n t h e a x i a l l o a d ( P ) , A quadratic expression
results:

5 = (3e + [9e4 + ~ A T2Lr 2 ( d o2 + d i2) ] 1 ' 2 } /4aATL (B-16)

T h e l o a d P was e x p r e s s e d as r 2 E I / R 2 . This i s the i n i t i a l


v a l u e o f t h e l o a d P. The t h r e s h o l d f o r t h e l o a d P w o u l d b e
2 2
4r E I I R . The t w o e x p r e s s i o n s f o r R , e q u a t i o n s (B-14) a n d
(B-15) a r e compared i n T a b l e B - I . From t h e d i s c r e p a n c i e s i n
T a b l e B-1, i t i s e v i d e n t t h a t t h e l e n g t h ( 2 ) i s a l i k e l y source
o f e r r o r i n t h e a n a l y t i c a l e x p r e s s i o n f o r t h e maximum s t r e s s
d e r i v e d below. (Good a g r e e m e n t e x i s t s b e t w e e n (B-16) and (17)
and w i l l b e d i s c u s s e d i n a s u b s e q u e n t s e c t i o n . ) The
a p p r o x i m a t i o n f o r beam d e f l e c t i o n d i s p l a c e m e n t ( s ( y ) ) was
e x a m i n e d as a p o s s i b l e s o u r c e o f e r r o r i n t h e t h e o r e t i c a l
d e t e r m i n a t i o n o f R. The s e c o n d t e r m i n t h e T a y l o r e x p a n s i o n o f
s ( y ) was i n c o r p o r a t e d b u t i t s i n f l u e n c e was i n s i g n i f i c a n t as
o r i g i n a l l y assumed.
Maximum
- ---
s t r e s s a f t e r wall c o n t a c t . - I _ The t o t a l s t r e s s ( u t )
a f t e r t h e c a s i n g h a s b u c k l e d and c o n t a c t e d t h e w a l l i s
e x p r e s s e d b y t h e sum o f u a and ( e q u a t i o n 5). The
express i o n f o r (ab)max i s a g a i n M c / I . The v a l u e f o r M i s

56
Table B-I. Comparison o f A n a l y t i c R e s u l t s
f o r 13-318 i n c h 54.5 D D f N-80 C a s i n q
w i t h an 'Unsupportede L e n g t h o f l O O D -
(ATCr = 71.7 F =: 22'C)

temp hole unsupported l e n g t h


c h an a e d is D 1 a c e me n t qap
- . cons€ant P var. F- S P l l t maximum s t r e s s
AT
n c r
-
Yma x
D D
e -
2a1
L
2R3
-
L
-
awl 0
=Y
pwl
OY

1.5 0.978
...250
500
..03 71 98 .828
-870 .-.825
860
.300
0411
750 .714 0944 920 .486
.978 1.215 1.044 1. 000 .519 0745

2.0 1.370 ..500


250 ..162
040 -718 -716
.743
.344
-709
.750
. ..364 .750
-805 .786
.854
,602
.660
1 000
1.370
649
1.214
.888
1.073 .
1 000 -659 ,659

4.0 2.380 ..750


500 .054
.120
.520
.547
-517
.538 .
-839
1 094
1. 000
1.500
-214
.048
.587
-713
-571
-671
1.268
.
1 362
2.380 1.214 1.131 1.000 1.466 1.021
f o u n d f r o m e q u a t i o n (B-2) w h e r e MR = 0. Expressing y by
e q u a t i o n ( 1 1 ) and s u b s t i t u t i n g i n t o ( 8 - 2 ) results in:

M = K' s i n K'X

The maximum moment w i l l o c c u r a t t h e q u a r t e r p o i n t s : X/R = 1/4


o r X / R = 3/4. ( T h i s d i f f e r s f r o m t h e c o s i n e e q u a t i o n ( 4 ) where
t h e maximum b e n d i n g s t r e s s o c c u r s a t x = L / 2 . ) Thus:

( 'b) max = V r o / K ' I

but

K' = 2n/R = ( P / E I ) 1 / 2

h en ce

) = n E e r o / 2 R2
'b(max

Therefore

ut = EaATCr + rEero/2R2

where i s d e s c r i b e d b y e q u a t i o n 8-14 o r B-16. The u s e o f t h e


n u m e r i c a l l y determined R i n equation (19) d i d improve t h e
correspondence w i t h t h e numerical r e s u l t s .
I t s h o u l d b e n o t e d t h a t an i n c o n s i s t e n c y e x i s t s i n t h e
above d e r i v a t i o n . The a x i a l l o a d ( P ) i n c r e a s e s b e y o n d P c r in
t h e e x p r e s s i o n o f R (B-16) w h i l e t h e a x i a l s t r e s s c a n n o t exceed
Pcr/A i n equation (19). Replacing AT^^
w i t h AT i n (19)
results i n the t o t a l stress (at) i n c r e a s i n g much f a s t e r w i t h
i n c r e a s i n g AT. The r e s u l t i n g v a l u e s do n o t c o r r e s p o n d w i t h t h e
n u m e r i c a l r e s u l t s and t h u s e q u a t i o n ( 1 9 ) was n o t a l t e r e d .

58
.

found from e q u a t i o n (6-2) w h e r e MR = 0. Expressing y by


e q u a t i o n ( 1 1 ) and s u b s t i t u t i n g i n t o ( 6 - 2 ) r e s u l t s in:

M = {,sin K X

The maximum moment w i 1 o c c u r a t t h e q u a r t e r p o i n t s : X/& = 1/4


o r X / R = 3/4. ( T h i s d i f f e r s f r o m t h e c o s i n e e q u a t i o n ( 4 ) where
t h e maximum b e n d i n g s t r e s s o c c u r s a t x = L / 2 . ) Thus:

.. = Vro/KII
(Ob ) ma x

but

V = Pe/R

K' = 2 r / R = (P/EI) 1/2

hence

2
= rEero/2

Therefore

u t = EaAT,, + r E e r 0 / 2 R2
(19)

w h e r e ! t i s d e s c r i b e d b y e q u a t i o n 6-14 o r 6-16. The u s e o f t h e


n u m e r i c a l l y determined R i n equation (19) d i d improve t h e
correspondence w i t h t h e numerical r e s u l t s .
I t , s h o u l d b e n o t e d t h a t an i n c o n s i s t e n c y e x i s t s i n t h e
above d e r i v a t i o n . The a x i a l l o a d ( P ) i n c r e a s e s b e y o n d Pcr in
the expression o f R ( 6 - 1 6 ) w h i l e t h e a x i a l s t r e s s cannot exceed
Pcr/A i n equation (19). Replacing AT^^
w i t h AT i n (19)
r e s u l t s i n t h e t o t a l s t r e s s ( u t ) i n c r e a s i n g much f a s t e r w i t h
i n c r e a s i n g AT. The r e s u l t i n g v a l u e s do n o t c o r r e s p o n d w i t h t h e
n u m e r i c a l r e s u l t s and t h u s e q u a t i o n ( 1 9 ) was n o t a l t e r e d .

59
1
1

SD 1 it-Cos in e F o r mu 1 a t ion

F i g u r e 10a d e m o n s t r a t e s t h e t w o a n a l y t i c a l e x p r e s s i o n s ( 3 )
and ( 1 6 ) do n o t a g r e e i n shape when c o n t a c t o c c u r s . There i s a
t r a n s i t i o n p e r i o d f r o m e q u a t i o n ( 3 ) and ( 1 6 ) . Rather than
r e s o r t t o a more c o m p l i c a t e d m a t h e m a t i c a l d e s c r i p t i o n o f t h e
casing during the transition, t h e c a s i n g shape was d e s c r i b e d as
a split-cosine bell. One m u s t assume t h e end moments c o n t i n u e
t o act a f t e r wall contact. Summing moments a b o u t an end o f t h e
f r e e body diagram y i e l d s :

MR = P e / 2 (B-17)

The f o l l o w i n g shape d e s c r i p t i o n r e s u l t s when t h e end moment


expression i s substituted i n t o (3):

y = 7
e (1- COS Kx) (B-18)

An i d e n t i c a l e x p r e s s i o n pops o u t f r o m e q u a t i o n ( 2 ) i f V i s s e t
e q u a l t o z e r o and t h e b o u n d a r y c o n d i t i o n s a p p l i c a b l e a f t e r w a l l
con t a c t a r e a p p l i e d .
Lenqth d e s c r i p t i o n R 3 . The d e r i v a t i o n f o r t h e
description of length (a3) follows the steps outlined i n the
previous section. E q u a t i o n (B-8) describes the thermal
displacement ( s ( T ) ) . E q u a t i o n (8-13) d e s c r i b e s t h e beam
d i s p l a c e m e n t ( ~ ( y ) ) . The a x i a l d i s p l a c e m e n t t e r m c o r r e s p o n d s
t o (11) except t h a t t h e a x i a l load i s allowed t o increase
beyond Pcr. I t f o l l o w s t h a t R 3 i s r e p r e s e n t e d by:

2 P
R3 = ( n e ) /(8LoAT - m) (6-19)

2
I f the expression f o r the load P = 7 EI/R2 i s substituted i n
(6-18) and t h e r e s u l t i n g q u a d r a t i c i s s o l v e d f o r R 3 , then:

1/2
= ((ne) A'+ [ ( x ~ ) ~ A +' 256L 2 n 2 I A a A T ] )/16LAtr~T
R3

60
.
i

V a l u e s of k3 f o r v a r i o u s t e m p e r a t u r e changes ( A T ) and h o l e
gaps a r e t a b u l a t e d i n T a b l e B - I . The a g r e e m e n t b e t w e e n ( 1 7 )
a n d (B-19) i s v e r y good.
Maximum s t r e s s .
----_II
The t o t a l maximum s t r e s s ( u t ) is
e x p r e s s e d b y e q u a t i o n s (6), ( 7 ) , and ( 8 ) e x c e p t t h a t MR i s
e q u i v a l e n t t o P e / 2 (B-17). An e x p r e s s i o n i d e n t i c a l t o ( 1 9 )
results.

61-62
.
. .
Distribution:
TID-4500-R66-UC-66~ (507) Gene P o l k
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Tom A n d e r s o n 6 4 0 0 Uptown B l v d . NE, 365W
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Security Division U. S. D e p a r t m e n t o f E n e r g y ( 4 )
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T u l s a , OK 74155 D. C l e m e n t s
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D. A l l e n

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9700 E. H. B e c k n e r
9730 W. D. W e a r t
9740 R. K. T r a e g e r
9741 J. R. K e l s e y ( 1 0 )
9741 6. C. Caskey ( 5 )
9743 H. C. H a r d e e
9746 B. Granoff
9747 P. J. Hommert
9750 V. L. Dugan
9760 R. W. L y n c h
9770 G. E. B r a n d v o l d
8214 M. A. Pound

64
0 V . S . GOVERNMENT PRINTING OFFICE: 1983-0-676-027/525

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