CTES, L.

C
9870 Pozos Lane
Conroe, Texas 77303
phone: (936) 521-2200
fax: (936) 521-2275
www.ctes.com

Tubing Limits for Burst and Collapse

Subject Matter Authority: Ken Newman

September 25, 2002

Contents Summary

CT Stresses ....................................2 When there is a large pressure differential across the CT wall, especially
Axial Force Definitions...................3 when combined with a large axial force, you run a risk of a CT failure
Axial Stress .....................................4 (burst or collapse). Typically the greatest risk of burst or collapse in a CT
Radial Stress....................................4 job occurs at the wellhead. You can use a mathematical model to determine
Hoop Stress .....................................4
these limits prior to performing a job to make sure that the operation stays
Torque .............................................5
The von Mises Yield Condition ......5
within safe working limits.
The Limits Curve ..........................6
A widely accepted model uses the von Mises combined stress to predict
Maximum Pressure Considerations 7
Diameter Growth Considerations....8
tubing burst and collapse limits. You can also take into account helical
The Limits Curve in Hercules.........9 buckling, maximum expected pressures, diameter growth, and torque.
Applying Safety Factors................10
Nomenclature ..............................11
References ...................................11

Tech Note CTES, L.C. 1

 Tubing Limits for Burst and Collapse

CT Stresses A widely accepted method of predicting tubing failure due to pressure and
tension limits is based on the von Mises stress. If the von Mises stress
exceeds the yield strength of the material, the CT is assumed to fail.

The von Mises stress is a combination of the three principal stresses in CT

and the shear stress caused by torque. The three principal stresses are:

! axial stress (σa)

! radial stress (σr)

! tangential or hoop stress (σh)

FIGURE 1 Three Principal Stresses

Note that these stresses are determined by the geometry of the CT and the
well, as well as three variables:

! internal pressure (Pi)

! external pressure (Po)

! axial force (tension or compression) (Fa)

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 Tubing Limits for Burst and Collapse

Axial Force Definitions Before axial stress can be defined, two types of axial force must be defined.
These are known as the "real force", Fa , and the "effective force", Fe , also
known as the "weight". The real force is the actual axial force in the pipe
wall, as would be measured by a strain gauge. The effective force is the
axial force if the effects of pressure are ignored.

To better understand these forces, consider the following simple example

shown in Figure 2.

A B C
Empty Pipe Add Fluid Add Pressure

FIGURE 2 Axial Force Example

A closed ended piece of pipe is hung from a scale as is shown in case A.

The scale is measuring the weight of the pipe. The real axial force at the top
of the pipe is the same as the weight measured by the scale.

In case B the piece of pipe is full of fluid. The weight is increased by the
weight of the fluid. The real axial force at the top of the pipe is still the
same as the weight measured by the scale.

In case C, pressure is applied to the fluid inside the pipe. The weight
remains the same as in case B. However, the real axial force in the pipe
wall is now increased by the internal pressure multiplied by the cross sec-
tional area. Thus, the weight (also known as the effective force) and the
real force are not the same.

The relationship between real and effective force can be written as:

Fa = Fe + Ai Pi − Ao Po
EQ 1

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 Tubing Limits for Burst and Collapse

Effective force, or weight, is important for two reasons:

! The weight indicator on a CT unit measures the weight, not the real
force, just as the scale in Eq 1above measures the weight.

! When buckling occurs depends upon the effective force. Thus the heli-
cal buckling load is an effective force.

The real force is important because it is the force required to calculate the
axial stress, and thus to determine the CT limits.

Axial Stress The axial stress is caused by the axial force (tension or compression)
applied to the CT. When the CT is in tension, the axial stress is the axial
force divided by the cross-sectional area:

Fa
σa = (tension)
A EQ 2

If the compressive force exceeds the helical buckling load, the CT forms a
helix in the hole. This helix causes an additional axial bending stress in the
CT, which must be added to the axial stress.

Note that in a vertical well the helical buckling load is nearly zero. The CT
buckles into a helix as soon as the effective force becomes compressive
(which is defined as a negative force value). Hercules assumes that the CT
is buckled if the effective force is less than zero.

Fa Fe Rro
σa = + (compressi on / helical buckling)
A 2I EQ 3

This additional axial bending stress also truncates the elliptical shape of the
traditional von Mises limits curve.

Radial Stress According to Lame's equation, the radial stress at a given location in the
CT wall is the stress through the CT wall due to internal and external pres-
sures. The maximum stress always occurs at the inner or the outer surface.
Since yielding occurs first at the inner surface, Hercules uses the radial
stress at the inner surface in its calculations.

σ r = −Pi EQ 4

Hoop Stress According to Lame's equation, the hoop stress at a given location in the CT
wall is the stress around the circumference of the CT due to internal and
external pressures. As with the radial stress, the maximum stress always

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 Tubing Limits for Burst and Collapse

occurs at the inner or the outer surface. Again, because yielding occurs first
at the inner surface, Hercules uses the hoop stress at the inner surface in its
calculations.

σh =
(r i
2
)
+ ro2 Pi − 2ro2Po
ro2 − ri 2
EQ 5

Torque In some situations the CT may also be subject to a torque, T. If the torque is
significant, then torsion of the CT occurs and causes the associated shear
stress, τ, which is given by:

2Tr
τ=
(
π ro4 − ri 4 ) EQ 6

The variable r ranges from ri to ro, with the greatest shear stress occurring
at ro. Although the radial and hoop stresses are calculated for the inner CT
surface, the shear stress is calculated for the outer surface, a more conser-
vative approximation.

The von Mises Yield The von Mises yield condition is commonly used to describe the yielding
Condition of steel under combined states of stress. The initial yield limit is based on
the combination of the three principle stresses (axial stress, radial stress,
and hoop stress) and the shear stress caused by torque.

σ VME =
1
2
{ }
(σ h − σ r )2 + (σ h − σ a )2 + (σ a − σ r )2 + 3τ 2
EQ 7

Note that if there is no torque, the shear stress term drops out of the equa-
tion.

The yield limits for CT are calculated by setting the von Mises stress, σvme
to the yield stress, σy , for the material.

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 Tubing Limits for Burst and Collapse

The Limits Curve There are four forces which determine the combined stress limits in CT.
They are the internal pressure, Pi, external pressure, Po, the real axial force,
Fa, and the torque, T. To simplify the presentation of the limits, the pressure
difference Pi - Po is calculated. A positive differential pressure represents a
"Burst" condition. A negative differential pressure represents a "Collapse"
condition.

One method of drawing the limit curve is to hold the external pressure con-
stant at zero for the top or Burst half of the plot and hold the internal pres-
sure constant at zero for the bottom or Collapse portion of the plot. The von
Mises equation now has only two variables, real axial force and internal
pressure for the Burst portion, and external pressure for the Collapse por-
tion. The Weight can also be calculated using Eq 1. Thus, this curve can be
drawn versus either the real axial force or the effective axial force (which
will be called Weight for the remainder of this document).

FIGURE 3 Single Limit Curves with External Pressure Constant at Zero

The resulting plots of pressure difference versus axial force are elliptical.
In the Weight case, the ellipse is horizontal. In the Real Force case, the
ellipse is inclined somewhat. The left side of the ellipse is truncated, due to
the helical buckling stress. For the Weight case, the helical buckling begins
at the Y axis, when the Weight becomes negative. For the Real Force case,
the onset of buckling occurs at the maximum and minimum pressure differ-
ence points.

Maximum Pressure Drawing the limits curve for a constant external (Burst case) or internal
Considerations (Collapse case) pressure only shows the limits for that pressure. However,
pressures do not stay constant throughout the CT job. To form a limits
curve that addresses a range of pressures, one can create a composite of
multiple limits curves.

First, a limit curve is drawn as in Figure 3, holding the external pressure at

zero for the Burst case and the internal pressure zero for the collapse case.
A second limit curve is drawn holding these same two pressures to their
expected maximum values. The resulting set of limits curves are shown in
Figure 4.

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 Tubing Limits for Burst and Collapse

FIGURE 4 Limit Curve for Zero and Maximum

The inner most (closest to the origin) portion of these 2 curves in the Real
Force plot, shown as a thick black line in Figure 4, is the limit curve pro-
duced by Hercules. Note that this limit curve no longer represents the true
yield limit of the CT. Rather, it represents a conservative combination of
the actual limits.

Note that the curve of the limit versus Weight is exactly the same for 0 and
maximum pressure. Thus absolute pressure does not affect the CT limits
when considered with respect to weight.

Diameter Growth Depending upon the application, CT may have a tendency to increase in
Considerations diameter during its life. This change in geometry changes the stresses, and
thus the limits. In previous versions of Hercules, the user was able to input
a percentage growth factor, and this increased diameter was taken into con-
sideration. However, this caused confusion amongst the users, and often
included diameter growth greater than was really seen in the field. For this
reason the diameter growth parameter has been removed. If there is signifi-
cant diameter growth and associated wall thinning, the user must input the
correct diameter and wall thickness into Hercules.

Applying Safety The limits curve calculated by the von Mises yield condition represents
Factors where the CT would begin to yield. Although combining two limits curves
for 0 and maximum pressure does introduce a small safety margin, more is
desirable.

Hercules uses safety factors to produce a “working limits” curve with a

larger safety margin. It multiplies the limits curve by safety factors to
obtain a working limits curve. There are different safety factors for burst
and for collapse. The safety factor for collapse should be more conserva-
tive to account for ovality. (During its life, CT becomes somewhat oval due
to bending on the reel and over the gooseneck. Increased ovality increases
the likelihood of collapse. However, the von Mises stress does not take
ovality into account.)

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 Tubing Limits for Burst and Collapse

FIGURE 5 Hercules Limit and Working Limit Curves versus Real Axial
Force

FIGURE 6Hercules Limit and Working Limit Curves versus Effective Axial
Force (Weight)

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 Tubing Limits for Burst and Collapse

Nomenclature A = cross sectional area of the CT material

Fe = effective axial force
Fa = axial force on CT (positive for tension, negative for compres-
sion)
I = moment of intertia of CT section
Pi = internal pressure inside the CT
Po = external pressure outside the CT
R = radial clearance between the CT and the hole (hole radius - ro)
ro = radius from the center of the CT section to the outside of the wall
ri = radius from the center of the CT section to the inside of the wall
T = torque
σa = axial stress
σh = hoop or tangential stress
σr = radial stress
σy = yield stress
σvme = von Mises stress
τ = shear stress caused by torque

References 1. Newman, K.: "Coiled Tubing Pressure and Tension Limits," SPE paper
23131, Proceedings from Offshore Europe 91, Aberdeen, September
1991.

2. Newman, K., “Coiled Tubing Forces and Stresses Modelling Improve-

ments”, 2nd ICoTA/SPE European CT Roundtable, October 1995.

3. McSpadden, A., Newman, K., “Modified CT Limits Analysis for Prac-

tical Well Intervention Design”, SPE paper 74828, SPE/ICoTA CT
Conference & Exhibition, April 2002.

CTES

Tech Note CTES, L.C. 9