SPE/IADC 92627
Running Casing Faster and Safer with Less Cost, Using Existing Rig Crew:
A Case Study
Noureddine Hadj Moussa, SPE, National Drilling Company; John Warren and Ron Roling, Varco
Copyright 2005, SPE/IADC Drilling Conference
This paper was prepared for presentation at the SPE/IADC Drilling Conference held in
Amsterdam, The Netherlands, 23-25 February 2005.
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Abstract
A new safe and cost effective method of running casing has
been employed, using the existing rig crews instead of
specialized casing crews. By using a casing running tool
connected to a top drive system, the drilling crew can run
entire strings of casing more efficiently and for less cost than
with conventional casing crews and equipment.
Introduction:
Conventional casing operations typically involve
specialized crews and equipment that are brought to a rig site
for the sole purpose of running the casing. The casing crews
rig up and operate the equipment, connect each joint of casing
to run in the hole, cement it in place and are demobilized at
the completion of the job. During this operation, the regular
drilling crew plays a secondary role and usually just assists in
the process. Keep in mind that this same drilling crew just
finished drilling the well by connecting sections of drill pipe
and running it in the hole. The concept for the casing running
tool was developed by asking what would it take for the
existing rig crew to run the casing in the hole, just like they
run every other tubular in the hole?
Drill crews have used top drive systems for years to make-up
pipe connections and to efficiently drill wells. Top drives pick
up singles, doubles, or triples of drill pipe, connect them
together, and provide the power necessary to drill the well.
The challenge was to develop a viable method of using top
drives (operated by the existing drilling crew) to make-up and
run casing strings, just as strings of drill pipe have historically
been run. The solution was the casing running tool (CRT).
The casing running tool (CRT) incorporates a simple method
of picking up single joints of casing and stabbing them into the
string; this practically eliminates the necessity for a person to
be located at the casing stabbing board. Because the top drive
provides the torque to make up the connection, additional
casing tongs are not required and fewer personnel are needed
on the rig floor during casing operations. The result has been
shown to be faster and safer casing runs.
The Drilling Rig:
In this case, a fast-moving desert land rig was
commissioned in March of 2004 and was equipped with a top
drive system and casing running tool. The combination of
specifications, equipment, and personnel on this particular rig
made it well suited for the demands of desert drilling.
However, it was vital that the economic benefits of the CRT
were recognized immediately, as many competitive rigs were
drilling alongside this relatively sophisticated rig. The use of
the CRT, as opposed to hiring in an additional casing crew,
was one of the methods used to demonstrate the financial
return capable by utilizing technology instead of conventional
methods.
The rig crew was carefully selected to work on this particular
rig, and completed two weeks of theoretical and practical
training on a specially designed and supplied simulator.
Dedicated specialists from the supplier trained the crews for
operating and maintaining the sophisticated drilling
equipments and systems. In addition, two performance
engineers were assigned to the rig for 60 days after the rig
commissioning to assist the rig crew in equipment trouble-
shooting, and to fine-tune their required training on specific
operations. There was no “trial well” and the rig was put to
work immediately after being accepted from the supplier.
Although this approach was considered risky, (considering the
degree of new technology employed on this rig), the rig crew
quickly adapted to the challenge and successfully completed
the first well. The expectation is that the performance of the
rig and the crew will continue to improve on subsequent wells,
and the success will be measured by their results.
2 NOUREDDINE HADJ MOUSSA, SPE, NATIONAL DRILLING COMPANY; JOHN WARREN & RON ROLING, VARCO
The Equipment:
The rig was introduced with a top drive system and CRT
installed by the rig manufacturer. The use of the CRT during
casing runs, as compared to conventional casing operations,
was intended to result in less manual intervention, a less
cluttered work environment, and a faster and safer operation
overall. When a CRT is used, there is also less casing
equipment to rig up. With conventional casing operations,
powered casing tongs, casing elevators and spiders, and a
dedicated hydraulic power unit are typically required to be
installed just prior to the casing job. This installation involves
the entire casing crew along with much of the rig crew.
However, with a CRT, the amount of equipment to be rigged
up is greatly reduced. In addition, utilizing a CRT practically
eliminates the necessity of having a person located at the
stabbing board, although a person may still be maintained
during the initial casing runs to validate successful connection
of the CRT to the casing joint. Overall, the casing process
involving the CRT greatly reduces the crew’s exposure to
hazardous equipment and operations, thus contributing to a
much safer work environment.
The CRT is connected below the top drive just prior to casing
operations. The tool incorporates a set of slips, similar to the
slips used in conventional elevators and spiders, and the size is
selected based on the size of casing to be run. These slips can
support the weight of the entire casing string (up to 500 tons)
and can transmit the torque required to make up the casing
connections (up to 35,000 ft-lbs @ 2,000 psi). A single-joint
elevator, supported by the CRT, is used to lift joints of casing
to the well center. Each joint of casing is stabbed into the
previous joint at the well center and the CRT/top drive is
lowered until the CRT covers the top of the new joint being
added. At this point, the slips of the CRT are automatically
set on the joint of casing.
With the slips of the CRT set on the joint of casing, the top
drive can now be energized, applying the required torque
through the CRT to the casing connection. Torque backup for
the connection is achieved through the power slips set at the
drill floor from the 1st joint to the end of the complete casing
string. There is no need of any manual back up tong at rig
floor. Since the CRT is powered by the top drive, the torque
applied to the connections can be carefully controlled and
monitored, and makeup torque limits can easily be set,
preventing any torque overshoot. In addition, the top drive
control system can be set to “automatically” make-up the
casing connection to the desired torque and ensure that the
desired torque-turn profile is achieved. The torque vs. turn
measurement is a critical part of ensuring that the connection
is made up properly. If high torque is achieved before the
requisite number of turns, this could be a sign that the
connection is cross-threaded or otherwise damaged. The built-
in torque-turn system monitors this ratio and provides an
alarm to the driller if the system detects an anomaly. If the
applied torque and measured turns falls within the limits
defined by the casing connection manufacturer, the control
SPE/IADC 92627
system provides the driller with a signal indicating that the
casing connection was properly made-up.
The CRT system incorporates a fill-up and circulating tool. At
any point in the casing running process, this tool can engage
inside the casing to supply fluid to the casing. This fill-up
process can be initiated much faster than with conventional
casing operations, resulting in substantial time savings. The
fill-up tool can also supply fluids at pressures up to 5000 psi,
allowing fluid circulation to be used to facilitate the casing
being run into the hole. With the CRT being connected to the
top drive at all times, and with the ability to circulate at
relatively high pressures and flows, the casing string can be
rotated and circulated into the hole whenever required. This
capability greatly increases the chances of getting the casing to
bottom, particularly in difficult formations or deviated hole
sections.
The Well:
A fourth well was drilled in the Rumaitha field, and the
planned WDL (Well Delivery Limit) target for this well was
40 days. The well has been drilled and completed in 31.5 days,
8.5 days faster than originally planned.
The time saving achieved can be attributed to several factors,
one of which is the use of the casing running tool. The CRT
alone is credited with contributing 11 hours of the 204 hours
saved, or 5 % of the total over-achievement.
The Results:
The use of the CRT, powered by the top drive, provided
instantaneous benefits. The equipment required to run casing
with the CRT was completely rigged up in 1.5 hours,
compared to the reported average time of 3 hours to rig up
conventional tongs and equipment (including rig up of the
pick-up machine). Although CRT operations were not
intended to require a person on a stabbing board, drilling
management chose to maintain a person at the stabbing board
level to ensure that the CRT successfully stabbed over the
casing joint and to provide verbal feedback to the driller. This
person at the stabbing board may not be required on future
casing jobs, once familiarity and confidence in the CRT is
established.
The actual casing run time when using the CRT proved to
match or exceed conventional run times. Keep in mind that
this was the first casing run with the CRT and the crew was
not given any specific training on the process. Regardless, a
6,800 ft. string of 13 3/8" casing was installed at an average
rate of 18 joints/hr. As the crew becomes comfortable with
operating the equipment and the possibilities of the CRT are
fully recognized, the running rate is expected to increase on
subsequent wells. It was reported that with some drillers the
running speed of the 9 5/8" casing had momentarily reached
22 joints/hr.
SPE/IADC 92627RUNNING CASING FASTER AND SAFER WITH LESS COST, USING EXISTING RIG CREW: A CASE STUDY 3

This casing run was achieved utilizing a crew of 3 people, as

compared to a conventional casing installation requiring 5 Photo 1
people (including pick-up machine operator). As the casing
was being run, the driller was able to remotely control the fill-
up operation as the casing string was being lowered. The
overall result is that the fill-up operation was much faster than
conventional methods, contributing to a 4 hour time savings
on a 6,800 ft. section. Following casing operations, the rig
down time of the CRT was measured to be 1 hour, compared
to an average 3 hour rig down time for conventional tongs and
related equipment. Again, these time savings were achieved
on the first casing run that this crew made with the CRT, and
are expected to improve further as the crew becomes more
experienced with the equipment.

Conclusions:
The casing running tool proved to save time in the process
of installing a casing string, as compared to conventional
casing methods. In addition, the casing was installed by the
existing drilling crew and no additional casing crew was
required to be present, thus furthering the cost savings. The
casing run was accomplished with less equipment on the drill
floor and fewer people were thus exposed to potentially
hazardous operations.

Acknowledgements:
We would like to thank the National Drilling Company of
Abu Dhabi for providing the supporting information and
allowing us to publish the performance of NDC Rig ND34.
4 NOUREDDINE HADJ MOUSSA, SPE, NATIONAL DRILLING COMPANY; JOHN WARREN & RON ROLING, VARCO SPE/IADC 92627

Casing Running Tool Details

Figure 2

1. Links
Transfers the string load from the CRT
Figure 1 to the Top Drive
2. Air Compensator
Compensates the movement/weight of
the pipe when making-up/breaking-out
casing
3. Springs
Balances out the movement of the
compensator
4. Splined Shaft
Transfers the torque from the Top Drive
to the torque frame
5. Hoist Ring
Part of the torque frame; will transfer
load from the torque frame to the links
6. Catch Plate
Limits the downward movement of the
CRT over the casing
7. Fill-up and Circulating Tool
Allows mud circulation up to 5,000 psi
8. Torque Frame
This part will transfer the load from the
body to the hoist ring
9. Body
Suspends the casing string through the
slips to the torque frame
10. Slips
Slip with insert carrier for running
10-3/4" x 9-5/8" mixed strings
11. Bell Guide
SPE/IADC 92627RUNNING CASING FASTER AND SAFER WITH LESS COST, USING EXISTING RIG CREW: A CASE STUDY 5

Running Casing Faster and Safer with Less Cost, using Existing Rig Crew
Performance Data: required to validate perceived advantages of utilizing a casing running tool

S/N Benefit NDC Comments

1 Safety Cost saving

As per design the CRT is fitted with a guide.

Theoretically the Stabber is not required. However
No person required we found from our experience that we need to have
a at stabbing board the Stabber / Derrickman at stabbing board to No cost saving : Nil
during casing runs assist in centering and directing the casing from
time to time when the joint is leaning too much
outside reach of the guide.

Less Manual For conventional system, the rig floor & stabbing
b Intervention in casing board crew is of 5 persons. For rig equipped with See item (4-a) here below
running process CRT tool we need only a crew of 3 persons.

The rig floor is less congested with people and

Less cluttered work
c equipment, therefore the working environment is No cost saving : Nil
environment
more neat and safe.
In conventional system, we need to rig up power
Less equipment to tong, spider elevator, spider slips, fill up tool and
d rig up for running casing pick up machine . For rig equipped with CRT No cost saving : Nil
casing tool, the only equipment to rig up is the CRT tool
itself.
2 Efficiency Cost saving
In conventional system, we need 3 hrs as Estimated at average of US$
a Faster rig up time
compared to 1.5 hours for the case of CRT tool. 2,875 per running casing job

Due to our limited experience on using CRT tool,

b Faster run time
the best average so far achieved by the crew in
running 13 3/8" casing for example is 18 Cost saving cannot yet be
joints/hour. With conventional system this speed of assessed. We don’t have yet
running 13 3/8" casing is quite usual. We think that enough reliable data.
by time the crews will learn more and will improve
more their efficiency in using CRT.

In conventional system, we need 3 hrs as Estimated at average of US$

c Faster rig down time
compared to one hours for the case of CRT tool. 3,833 per running casing job

The fill up is done in the case of using the CRT tool

d Faster filling time
while running the casing joint. Therefore practically
there is no loss of time due to fill up exercise . We
Estimated at average of US$
think that for a complete job of running 6800 ft of
7,667 per running casing job
13 3/8" casing, the fill up time that can be saved
with CRT tool is about 4 hours as compared to
conventional system .

3 Increase Capabilities Cost saving

6 NOUREDDINE HADJ MOUSSA, SPE, NATIONAL DRILLING COMPANY; JOHN WARREN & RON ROLING, VARCO SPE/IADC 92627

Pulling out of hole a casing string,

reconditioning the hole and
running back is not frequent,
however we can estimate that
such case is happening at an
average of two times per year per
With conventional system we cannot rotate and
rig. Therefore our cost saving is
circulate simultaneously. With the CRT tool we can
computed on the basis of this
do that easily. Due to this capability the running
Rotate and circulate assumption. Based on ND34 day
a casing in difficult formations can be easily done in a
in the hole rate, the yearly cost saving is
smooth manner overcoming being stuck and
estimated to US$ 216,000. Also in
avoiding being pulled out of hole for hole
a year drilling program we run an
reconditioning and running back.
average of 40 casing strings ( all
size included). Thus we can
assume for calculation purpose
that the average saving attributed
to each casing job ( all sizes
included) is about US$ 5400 .
With the CRT tool the RPM and Make Up Torque
More accurate joint are set up and accurately controlled by the VICIS
b No cost saving : Nil
make up system. This accuracy is not available with the
conventional casing running equipment..

4 Economic Value Added Cost saving

No additional casing Rig crew is running the casing. No additional Estimated at average of US$
a
crew required people are required. 9,200 per running casing job

Due to CRT tool feature of rotating casing joint

clockwise and anticlockwise and also due to its high
Less damage to Estimated at average of US$
b accuracy of make up torque and monitoring system,
casing 1,000 per running casing job
there is less chance of casing damage during
running operations.
Due to CRT tool feature of rotating and circulating
up to 5000 psi pressure, the cleaning efficiency is
Get casing to bottom
c tremendously improved and consequently the See item (3-a) here above
more frequently
chances of running the casing to bottom are highly
increased.
Average Total Saving per Running 13 3/8" Casing Job for Rig ND34 -
5 US$
29,975

Being more conservative we can assume that average saving per running casing job for all sizes
included should not be less than US$ 25,000