Full Automated Casing Running: The Next Step Completed in Field Automation

Abstract

Although the drilling industry is slowly moving toward a higher degree of automation, casing running is still left out of this equation. Until now. Due to the more delicate handling that is required to handle casing, the task is often handed over to dedicated casing running service companies. This year, a new rig is build that performs the task of casing running, including making and monitoring the connection, fully automated and 100% hands off: "just press start sequence". To enable full-automated casing running, it is required to have a dedicated handler with high precision handling and measuring systems. To reach the maximum safety level, the goal is set to have no people in the red zone on the floor for any assistance. An integrated (scada) control system needs to combine data as casing length, positioning, amount of turns to spin in and make up torque into one system. It also needs to communicate to the other rig equipment as drawworks and topdrive to enable smooth fully hands off operations. The above is this year integrated in an HM100 mobile rig and will be deployed in the oilfield in Q3 2020 for a mayor operator. The equipment is capable of handling casing up to 13 3/8" in full automated sequences at a speed of ∼ 1300 ft/hr, more then 300% faster then manual operations. At a traditional catwalk machine, casing is pushed over the pipe slide. For this reason the thread needs to stay protected by thread caps, until the pipe is in wellcentre. Here usally 2-3 people are present to guide the casing and apply dope etc. To make sure that no people need to work in the red zone on the floor, it is chosen to develop a pipe handler that lifts the casing from pipe bed to wellcentre in one movement, while keeping the thread clear: a massive safety improvement. The sequence is completed by an automated hand over to the casing running tool on the topdrive. As final step, while making the connection, the integrated torque turn graph system controls and monitors the connection and stores this combined with the length in the auto-tally system. Fast save operations, with data readily available. This is the industry first mobile rig with full automated casing running capabilities, an important step in the ongoing field automation. With a consistent speed of over 30 casings / hour the time per well is reduced significantly, while there is no need to have separate crews and tools available on location. Casing running will now be predictable in time and duration, with real time results immediately available on the OPC-UA server for the client.