Automated Connection Integrity Beats Traditional Tubular Running by Delivering Zero Rejected Joints, Efficiency Enhancements, and Personnel Reductions

Abstract

The automated connection integrity system known as Vero employs computer-controlled makeup and autonomous evaluation algorithms to run and pull completion strings. Results from automated and traditional (non-automated) equipment on similar jobs shows the difference.

This paper compares thread inspection reports after running and pulling completion strings using both types of equipment. The automated jobs included three completion runs and pulls; the traditional job included one completion run and pull with the same type and size of tubulars in the same well configuration. Comparing additional data on personnel reduction and operational efficiency, including joints per hour and rig and rig down time, provides insight into overall system efficiency, safety, and well integrity benefits of the automated system over traditional ones.

The thread inspection results from 761 connections after completion pullout show 77% of tubulars passed with the automated system; however, zero passed with traditional equipment. In addition, the automation system reduced rig up and down time by 25% and personnel up to 50% during heat stress periods, which required six instead of 12 people. Over the nine jobs for this customer, Vero helped to make up more than 1,200 connections with zero rejected and laid-down pipes. The precise torque control enables operators to achieve the final torque at liner maximum torque and the allowed higher torque while reaming the liner string to total depth (TD) on drillpipe. With computer control of rotations per minute (RPM) and torque, Vero delivers a 2% variance of final torque, which enables operators to target the higher end of the maximum torque recommended by the original equipment manufacturer (OEM) without exceeding the limit. These higher makeup values enable applying higher torque while reaming the liner string to TD on drillpipe in challenging wellbores.

The Vero system uses computer-controlled processes for automating the makeup, breakout, and evaluation of premium connections. This solution controls the makeup and breakout parameters to reduce thread damage caused by rig-floor conditions while consistently achieving and thoroughly evaluating OEM criteria. Through automation, Vero improves operational performance while enhancing safety risk management and well integrity assurance.