OTC-26726-MS

Improving the Operational Performance and Reliability of Casing and

Tubing With the Use of Dope-Free Connections
Actis Goretta Emiliano and Merliahmad Mustaffa, Tenaris

Copyright 2016, Offshore Technology Conference

This paper was prepared for presentation at the Offshore Technology Conference Asia held in Kuala Lumpur, Malaysia, 22–25 March 2016.

This paper was selected for presentation by an OTC program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
This paper describes how the adoption of Dope-Free connections is simplifying and improving the
operational performance of Casing and Tubing operations and a methodology to analyze the efficiency of
running operations.
Dope-Free connections are tubular connections with a multifunctional dry coating applied to their
threads and seal areas in a controlled industrial environment that eliminates the need for storage and
running thread compounds during the tubulars’ full life. The impact of Dope-Free connection in an
operation can be easily quantified by using readily available data. This is performed by analyzing the
connection make-up charts (torque vs turns) of Dope-Free and standard connections from running
operations.
Most connection problems and failed installations occur at the well site, driven by inexperience
personnel, improper execution, and/or wrong interpretation of the make-ups caused by variability on the
behavior of thread dopes under different environments. Removing the thread compound from the
connection reduces the risk by having a lower possibility of miscommunications, connection damage,
improper procedures, and applying the wrong dope. Although initially driven by environmental issues, the
elimination of storage and running compounds from Casing and Tubing strings brings an array of benefits,
from improved operational performance and HSE to well productivity. Operators experiences, after a
short learning curve, showed great reductions in installation time, reduction on connections re-make ups
and rejects along with improvement on workers’ Health & Safety conditions by eliminating unsafe tasks
and creating cleaner work areas, and minimization of the environmental impact.
The rig time saved due to less remake-ups and rejects of a Dope-Free connections running compared
to standard connections can be easily converted to economic savings. This is especially important for
offshore operations where high daily rate cost rigs are used.

Introduction of Dope-Free connections

The Dope-Free technology is a dry coating applied to casing and tubing connections in a controlled
industrial environment at the mill after the machining of threads and seals. This solution completely
eliminates the traditional use of storage and running compounds on casing and tubing operations.
2 OTC-26726-MS

The coating applied to the connections ensures easy make-up and improved galling resistance by
providing the required tribological properties. Make-up operations are more consistent and reliable,
guaranteeing improved performance. The connections can be subjected to repeated make-ups and
break-outs without re-applying any lubricant in between those operations.
There is no need to remove storage compounds nor applying any running compounds during the pipe
full life. The dry coating is applied to the pin and box connections at the mill and no treatment is required
until the connections are run in the field. Therefore, the connections are rig-ready. Strict processed and
quality control systems ensure the appropriate corrosion resistance and lubrication.
Dope-Free connections are also compatible with their related standard version if running compounds
are applied. This is especially important in case some non Dope-Free accessories needs to be installed in
the same string.

Figure 1—Pictures of Dope-free connections, Dopeless® Technology (top) Standard connections with thread compound, dope
(bottom).

Operational Performance and Reliability of Dope-Free Connections

The elimination of storage and running compounds from tubular strings brings an array of benefits, from
improved operational performance and HSE to well productivity. Some of the most noticeable impacts
rely on improved efficiency during Casing and Tubing preparation and installation, thus reducing the
operation total cost.
A faster preparation of pipes is performed since connections are ready to be delivered to the rig without
the need of connection cleaning. Thread protectors management is also simplified for the same reason.
Less labor is required, no water is used and no waste is generated during this stage.
OTC-26726-MS 3

Elimination of Connections Cleaning in the Rig Floor

Dope-Free connections comes rig ready without any thread compound, so there is no need of connection
cleaning during the connection full life. In some operations, the connection cleaning or final cleaning is
performed on the rig floor prior to running (Fig 2).

Figure 2—Standard connection cleaning at rig floor.

Elimination of Running Compound Application

The reliability of tubular installations is heavily dependent on the quality of connection makeup. In
standard connections, all the quality controls performed during the pipe and connections manufacturing
process relies at the end on a manual application of thread compounds with a brush in the rig (Fig 3).

Figure 3—Thread compound application on standard connections.

Dope-Free connections comes with the proper solid lubrication applied automatically in a controlled
environment in the mill, thus eliminating the low control process of manual dope application.
Elimination of Entrapped Dope Effect on Big Casing Sizes
For some big diameters connections, the effect of entrapped dope requires the application of the torque
twice or holding the torque for several seconds (double bump). It is a normal practice to repeat this process
at the rig when running double or triple stands of pre-ensambled casings from onshore service centers.
Dope-Free connections eliminate this requirement thus reducing running time.
Reduction of Re-Make Ups and Rejects during Running
Since the connection make-up process is more stable, downtime problems introduced by make-up
inconsistencies are significantly reduced. Dope-free connections provide the exact amount of solid
lubrication without the human factor intervention. Typical re-make ups and rejects ratios for Dope- Free
connections are lower than for standard connections with thread compound. This results in a faster
installation of the string with time savings.
4 OTC-26726-MS

Several steps are involved for each rejected or re-made up connection:

For every rejected connection:
● Connection break out
● Pin and Box cleaning (avoided step for dope-free connections)
● Visual inspection
● Pin pipe and Box pipe Pull out and lay down.
● New Pin side pipe pick up
● Running compound application (avoided step for dope-free connections)
● Make up
For every re made-up connection:
● Connection break out
● Pin and Box cleaning (avoided step for dope-free connections)
● Visual inspection
● Running compound application (avoided step for dope-free connections)
● Make up
By representing in a bar chart the time between every two consecutive connections make ups for each
connection of the entire string, the efficiency of that running operation can be analyzed.
If each abnormal time related to non productive time (NPTs) such as power tong issues, mud
circulation, etc, are identified and removed, then the ⬙Net Running time⬙ can be calculated keeping only
the connections related issues.(Fig 4)

Figure 4 —Bar chart showing the running efficiency.

With this representation of the running time efficiency, it is evident that by reducing the amount of
rejects and re make-ups during running, rig time is saved and a faster casing and tubing instalations is
achieved. (Fig 5). Based on field history, Dope-Free connections runnings’s have very low rejects and re
make-ups.
OTC-26726-MS 5

Figure 5—Reduction of rejects and re make ups occurrence and times.

In the same chart, it can be shown that thread compound cleaning and application on the rig floor, and
the elimination of the double bump operation reduce the average running time. (Fig 6). Dope-Free
connections do not require cleaning, thread compound application nor double bump.

Figure 6 —Reduction of average running time.

Methodology

The following section describes the details of a method to quantify and compare the operational
performance of Dope-Free and standard connections running. With the mentioned method, the rig time
saving of casing running operation can be easily converted to economic savings. Often times the lack of
detailed information captured on the rig during the running made this exercise not possible. A new method
to effectively analyze the net running time of casing running based on the information from the torque vs.
turn make up charts is presented here.
In many operations today, connections are being made-up with a power tong connected to a computer
that records the torque vs. turn of a given connection (Fig 7). The information recorded also includes the
charts itself, time of each make-up (MU), and any relevant comments inputted by the running crew. These
make-up recordings provide the necessary data to perform the analysis.
6 OTC-26726-MS

Figure 7—Make up torque vs. turn file cover, Summary table, and MU charts with information.

Once extracting the information from the make up (torque vs. turn) reports to an excel file, then it is
possible to calculate the time spent to run each joint by simply subtracting the time between two
successive make-up, being called the ⬙Total Running Time Per Connection⬙.
For example (Fig 8):

Figure 8 —Information from make up charts and Total Running Time per connection calculation.

Make-up of joint 35 at 1:46:22 AM

Make-up of joint 36 at 1: 55:03 AM ⫽ make-up time 8:41 minutes.
Re make-up of joint 36 at 2:32:38 AM ⫽ re make-up time 37:35 minutes.
OTC-26726-MS 7

The total running time per connection includes the re make ups, rejects and Non Productive Time (NPT)
times.
The next step would be to plot a bar chart showing the total running time for each connection and
identify the abnormal values: operation start up, NPTs and, re make-ups and rejects. By plotting the total
running time per connection in a bar chart it is possible to easily identify the abnormal make-ups times.
Then each datapoints can be classified based on the information provided in the make-up charts’
comments, from the field service reports or other rig info (Fig 9).

Figure 9 —Total Running Time per connection and abnormal time identification.

To obtain the ⬙Net Running Time⬙, it is necessary to remove the operation startup and NPTs. By
removing the operation startup times and all the NPTs it is then obtained the ⬙Net Running Time per
Connection⬙. The make-ups related to the operation startup, where several accessories are installed, are not
considered for the time analysis (Fig 10).

Figure 10 —Start up time table.

Regarding the NPTs, the following methodology could be used to remove the NPTs time but
considering the time spent during the MU of the connection:
– Identify the NPT abnormal time.
– Assume a MU time identical to the previous MU in normal condition.
– The Net NPT time is then obtained by subtracting the total NPT time to the assumed MU time.
8 OTC-26726-MS

This calculation is shown in the example below(Fig 11):

Figure 11—NPT time removal criteria.

Once removed the startup time, and all the NPTs, then it is possible to plot the Net Running Time for
each connection (Fig 12).

Figure 12—Net Running Time per connection chart.

It is worth to note that each re-make up or reject implies extra time compared to the running of a
connection without issues. By reducing the amount of re-make ups and rejects, as it is the case of
connections with Dope-Free connections, less time is consumed during running, achieving faster instal-
lations.
Finally, the instantaneous speed and the average speed could be calculated by extrapolating the MU
time of each connection to the entire running (Fig 13).

Figure 13—Instantaneous and average speed.

OTC-26726-MS 9

For example, if the make-up time of one connection were 8 minutes and 41 seconds (521 seconds), then
the instantaneous speed would be 6.9 joints/hour (3600 sec/521 sec). The average of these instantaneous
speeds is the average running speed of the all operation.

Case Studies
Previous paper by the authors (6) has highlighted case studies from various regions around the world
where Dope-Free technology has shown to improve tubular casing running speed. In the first usage of
Dope-Free technology in Southeast Asia by an operator drilling in offshore Indonesia, an average
improvement in running speed of 16.5% was achieved with the Dope-Free technlogy compared with
standard doped connection for the same operator. In another case cited in the paper, an improvement of
40% was achieved in offshore West Africa where runnings of 13-3/8⬙ T95 semi flush connection with
standard doped connection and Dope-Free technology was compared.
To demonstate the previously mentioned methodology, a recent of case Dope-Free technology will be
analyzed. In 2014, an international oil company installed a 13-5/8⬙ casing string with Dope-Free
technology in deepwater Indonesia. The well was drilled with a semisubmersible rig in water depth of
around 4,500ft. The casing was a string of 13-5/8⬙ 88.2ppf P110 threaded with a Dope-Free premium
threaded and coupled connection. Sixty-six joints were installed as an intermediate casing in the hole
without rejects.
To compare the performance of the Dope-Free with a standard version of the same premium
connection, data from a previous well was obtained. The previous well utilized the same 13-5/8⬙ 88.2ppf
standard version of the premium connection. The same rig was also utilized in the previous well. In
running of the standard connection, the operator installed 79 joints of the connection in a deepwater well.
The make-up recordings were obtained for each running operations. As explained in the previous
section, total running time for each connection of each operation were plotted (Fig 14).

Figure 14 —Total Running Time comparison.

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Next, the running speed of each operation was plotted and compared as shown in the figure below. It
was calculated that the average running speed of the Dope-Free is around 8.26 joints/hour compared to
the standard connection running speed of 7.10 joints/hour. The Dope-Free connection run was 16.33
percent faster than the standard connection running. (Fig 15)

Figure 15—Running speed comparison.

During the Dope-Free connections running, there was zero rejection and one re make-up while the
standard connection running had three rejections and one re make-up processes. Rejection and re-make
up processes affect the casing and tubing running time and in turn the operational cost, since rejected pipes
must laid down and returned to yard in order to having further action (repairing or scrap).

Figure 16 —Rejects and re make-ups comparison.

OTC-26726-MS 11

The connection make-up performance could also be evaluated by analyzing the torques distribution. A
typical torque-turn chart (as shown below) provides valuable information to evaluate the behavior of a
connection make-up. The graph will indicate at least the shoulder and final torque, where both must fall
into a specific torque ranges specified by the connection’s manufacturer. Upon the completion of each
make-up, the computer recorder would automatically determine the shoulder torque based on the sharp
change in the slope of the line (that is evident visually).

Figure 17—A typical torque-turn chart for a shouldered connection.

While the final torque could be easily controlled by setting the power tong to dump torque at a certain
value, the shoulder torque of a make-up is much less controlled. The shoulder torque of a make-up
depends on many factors but one of the most critical variable is the lubrication between the connection’s
pin and the box. The variability of dope type, amount and contamination would significantly affects the
shoulder torque value. As the shoulder torque must fall within a certain range to be considered as
acceptable for any make-up, repeatable and consistent shoulder torque is desired to reduce risk of a
rejected make-up.
As shown in the figure below, the Dope-Free connections’ torque charts show consistent make-up and
shoulder torque values compared to the standard connections’ charts. A consistent distribution of shoulder
torques demonstrates a reliable make-up operation.
12 OTC-26726-MS

Figure 18 —Make-up torques comparison.

Conclusions
The optimization of the running operation is achieved by reducing the rejects and re make ups related to
the connections. It is also achieved by simplifying the operation in the rig floor as result of the cleaning
and dope application elimination. For some connections the need of double bump it is also eliminated.
The improvement in the running efficiency can be translated in monetary saving. This has great impact
in environments with high daily rig costs. The described method allows to calculate the net running time
and the average running speed with the information provided in the make up charts files.

References
1 ⬙First Gas Field Developed Using Exclusively Dope-Free Casing and Tubing Connections - Statoil Snøhvit⬙
SPE/IADC 10585 - Gabriel Carcagno, SPE, Tenaris; Tomás Castiñeiras, SPE, Tenaris; Dag Johan Eiane, Statoil.
2 ⬙25 Cr Super Duplex liner Fitted with a Dope-free Connection in Statoil-Snøhvit Field⬙, IADC World Drilling
Conference, Rome, June 9 –10 2005 - Castiñeiras, T.H., Aivalis, J.G. and Eiane, D.J.:
3 ⬙Newly Developed Dope-Free Coatings Help Improve Running Operations In Remote Protected Areas⬙, Rio Oil &
Gas Expo and Conference 2008, September 15–18, 2008 - Santi, N., Gallo, E.
4 ⬙Dry Dope-free OCTG Connections: A novel Environmentally Friendly, Technology Validated Through Diverse and
Severe Field Conditions⬙, Paper SPE 119642, 2009 - Castiñeiras, T, Núñez, A., Gallo, E., Carcagno, G.
5 ⬙Why Dope-Free connections are improving the Operational Performance and Reliability of Casing and Tubing⬙ -
2015 EAPC&E Kigali-Rwanda - Actis Goretta E., Castiñeiras T., Langrill C., Ahaneku P., Tenaris.
OTC-26726-MS 13

6 ⬙The Use of Dope-Free Tubulars in Offshore Operations: Experiences and Benefits⬙, OTC 24740 - Emiliano Actis
Goretta, Tomas Castiñeiras, Bruno Giacomel and Mustaffa Merliahmad, Tenaris.
7 ⬙Sharing experiences of the use of ⬙Dope-Free⬙ connections⬙ - IPA13-E-145 Tomas Castiñeiras, Emiliano Actis
Goretta and Mustaffa Merlihamad, Tenaris.
8 Dopeless® Technology: Quantifying operational, well productivity and HSE benefits.
9 ⬙Dope-Free Technology Improves Health, Safety and Environment Performance of Casing and Tubing Field
Operations in Vaca Muerta Play, Neuquen Argentina⬙ - SPE-177172-MS - Espinosa C., Tenaris, Braghieri E., YPF,
Actis Goretta E., Codega D., Zalazar G., Tenaris.
10 Dopeless® Technology Case Studies— www.tenaris.com