BPM CRS Operation Manual Completo

Casing Running System (CRS)
Operation Manual
Beijing Petroleum Machinery Co.

March 2014
Foreword
Based on the wellbore structure, casing string needs to be set for each wellbore
interval accordingly. The drilled borehole (especially the open hole) encounters undersizing,
collapsing, cuttings depositing and many other issues frequently, however, during the
conventional rotary rig casing running process, operations like mud circulation, casing
rotation, raising or lowering the casing, cannot be performed simultaneously and will not
adapt to the wellbore very well, thus the casing may not be able to reach the bottom of the
hole. With the development of the drilling industry, casing running equipment and
technology is advancing rapidly. With more and more focus on drilling speed and efficiency,
the application of more advanced top drive casing running system is becoming highly
necessary, and this will surely bring the drilling industry remarkable social and economic
benefit.
The performance and operating time of the top drive Casing Running System (CRS)
depends not only on the design and manufacturing of this product, but also the proper
operation by the operators. We will provide you products with high quality in compliance
with the specification of the quality assurance system of ISO 9001. At the mean time, to
make sure you are operating this equipment properly, please read this operation manual
carefully before you start. The reliability and performance may change as the operation and
service of the equipment goes on, and it relies on the proper operation and quality level of
the maintenance work.
This manual is intended for the operation and maintenance of the CRS manufactured
by the company. It may not serve for special applications, so the operator should make the
right judgement on the selection and applications of the CRS. As the products upgrade, the
actual product may not be exactly the same as the one mentioned in the manual, but this
will not affect the understanding of the structure, performance and operation of the product,
and also the function. If in doubt, please contact us immediately, and we will give you
detailed instructions.
As the drilling technology develops, the customers will have new requirements of the
application. We will improve our products continuously to meet your special requirements.
We value your comments and suggestions. Welcome to contact us by the following
methods.
Address:
Fax:
Phone:
Web site:
E-mail:
No. 41 Zhixin Road,Haidian District, Beijing 100083, China

86-10-6231 1837
86-10-8359 7381/8359 2109Sales
http://www.bpmc.com.cn
[email protected]
[email protected]
Table of Contents
1. Safety Information .......................................................................................................... 1
2. General Information ........................................................................................................ 1
3. Model Description ........................................................................................................... 2
4. Structure and Working Principles ................................................................................... 2
5. Technical Specifications ................................................................................................. 6
6. Hoisting and Storage ...................................................................................................... 7
7. Installation and Testing ................................................................................................... 8
7.1 Installation .............................................................................................................. 8
7.2 Testing .................................................................................................................. 10
8. Application and Operations .......................................................................................... 11
8.1 Preparation before Running Casing ....................................................................... 11
8.2 Casing Running ...................................................................................................... 13
9. Intelligence Aided Equipment ....................................................................................... 16
9.1 Control System and Software ............................................................................... 16
9.2 Video Monitoring System ...................................................................................... 17
10. Maintenance and Repair of the Internal Gripping CRS................................................. 18
10.1 Inspection and Maintenance during the casing running operation ........................ 18
10.2 Routine Inspection and Maintenance ................................................................... 19
10.3 Repair Preparation ............................................................................................... 20
10.4 Disassembly ......................................................................................................... 20
10.5 Assembly .............................................................................................................. 22
11. Maintenance and Repair of the External Gripping CRS ............................................... 27
11.1 Inspection and Maintenance during the casing running operation ........................ 27
11.2 Routine Inspection and Maintenance ................................................................... 28
11.3 Repair Preparation ............................................................................................... 29
11.4 Disassembly ......................................................................................................... 29
11.5 Assembly .............................................................................................................. 31
12. Troubleshooting ............................................................................................................ 35
13. Spare Parts and Corollary Tools ................................................................................... 35

14. Order Notice ................................................................................................................. 35
Appendix ASlips, Cup Packer, Stabbing Guide and Packer Cap Selecting Guide ......... 37
Appendix BSpare Parts List ........................................................................................... 43
Appendix COptional Auxillary System ............................................................................ 45
Appendix DCorollary Tools ............................................................................................. 45
BPM
CRS Operation Manual
XTG SM
1. Safety Information
The top drive Casing Running System (CRS) should be operated by personnel with top
drive experience. Please read this manual and relevant technical documents before the
operation.
Notes, Cautions and Warnings provide user with additional information, and to advise
the user to take specific action to avoid personal injury and damage to the equipment.
Please pay close attention to these advisories.
Note
The note symbol indicates that additional information is provided about

the current topic.
Caution
The caution symbol indicates that potential damage to equipment, or

injury to personnel exists. Follow instructions explicitly.
Warning
The warning symbol indicates a definite risk of equipment damage or

danger to personnel. Failure to follow safe work procedures could
result in serious or fatal injury to personnel, significant
equipment damage, or extended rig non-production time.
2. General Information
Integrating mechanical and hydraulic system, the CRS has emerged recently as a
casing running device based on the top drive drilling system. A series of products have
been developed for different sizes of casings, so they are applicable for running casing with
regular wall thickness. It replaces casing tongs and other casing running equipment which
is widely used in drilling operation. Fully utilizing the advantage of the top drive, CRS
makes automatic connection of the casing string possible, and it provides the ability of
casing rotation and mud circulation, which greatly reduces the chances of stuck casing and
other potential safety hazards, thus improves the efficiency of the casing running operation.
CRS makes sure to set the casing to the expected depth, and minimizes the number of
casing crews that are required, so it is safe and effective.
The successful application of the CRS is a technical advance of the drilling equipment,
and it will boost the automation level of the drilling equipment. The CRS expands the range
of application of the top drive, and has great potential for further promotion and market
outlook.
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3. Model Description
XTG
168
.
Applicable Casing Size (mm): 140,168,244,340 etc.
Product Code: Casing Running System
4. Structure and Working Principles

The CRS is divided into two categories, namely, the internal gripping and external
gripping structure depending upon the casing size. When the diameter of the casing is
140mm (5 1/2 in) or less, external gripping equipment will be used, and when the diameter
is 168mm (6 5/8 in) or greater, internal gripping equipment will be used. Both of the devices
have main structure such as: the connecting thread with the top drive, hydraulic mechanism
to actuate the slips to engaged or disengaged position, slip mechanism to transfer work
load (tensile and torque load), sealing packer for mud circulation and stabbing guide for
casing connection. The internal gripping CRS structure is shown in Figure 1, and the
external gripping CRS structure is shown in Figure 2. In order to achieve a reliable
connection and for the sake of safety, there is anti-rotation mechanism and ect. The
schematic drawing for the top drive and the CRS is shown in Figure 3.
This device is connected with the main shaft of the top drive at the upper end, so the
make-up torque is precisely controlled during the casing running operation. The working
principles are as follows: through the hydraulic supply of the top drive, the upper or lower
chamber of the actuating cylinder is filled up with fluid and when the working pressure is
reached, piston will move up or down to drive the slip mechanism to disengage or engage,
so as to release or grip the casing, transfer torque and hoisting load, accomplish casing
make-up and hoisting or lowering operation. This device employs self-sealing cup packer
mechanism, which enables the mud circulation during casing running operation, so as to
reduce or avoid tragic accident.
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1. Mandrel 2. Cylinder 3. Coupler Ring 4. Retainer Ring

5. Slip Mandrel 6. Slip Die 7. Slip 8. Cup Packer 9. Stabbing Guide
Fig.1 Structure Schematics of the Internal Gripping CRS
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1. Mandrel 2. Cylinder 3. Coupler Ring 4. Slip Housing 5. Links

6. Slip 7. Slip Die 8. Center Pipe 9. Cup Packer 10. Stabbing Guide
Fig.2 Structure Schematics of the External Gripping CRS
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1. Top Drive System 2. Elevator Links

3. Casing Running System 4. Elevator 5 Casing 6. Air Slips
Fig. 3 Top Drive and CRS Working Schematics
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The safety of the casing running operation is extremely important, so the device has
incorporated hydraulic lock design and self-locking slip mandrel structure to ensure the
safety and reliability of the product. Hydraulic lock is realized through the application of
hudraulic valves to keep a stable pressure inside the actuating cylinder in case of
emergency or loss of hydraulic source, thus avoiding any accident that can be caused by
fluctuation of the pressure. The self-locking slip mandrel structure is shown in Figure 3. As
a tapered structure is applied between the mandrel and slips, the slips tend to move
downward along the taper to create a self-locking effect under the weight of the casing
strings, so a self-locking mechanism is present to ensure that there will not be casing
slip-off and thus a safe casing operation.
Fig. 4 Self-locking Mechanism
5. Technical Specifications
Technical speicifications of the CRS are listed in Table 1.
Table 1 Technical Specifications of the CRS
Technical Content
Technical Data
Product Model
XTG140
Gripping Manner
External Gripping
Applicable Casing
Nozzle Diameter
mm
(in)
mm
(in)
XTG168
XTG244
XTG340
Internal Gripping
114~140
(4-1/2~5-1/2)
168~244
(6-5/8~9-5/8)
244~340
(9-5/8~13-3/8)
340~508
(13-3/8~20)
31.75
(1-1/4)
31.75
(1-1/4)
50.8
(2)
76
(3)
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Technical Content
Technical Data
Product Model
XTG140
Gripping Manner
External Gripping
Rated Hoist Load
Rated Torque Load
Nozzle Pressure
Upper Connection
Thread
Hydraulic Supply
Pressure PrPressure
Hydraulic Supply
Flow Rate
System Height
kN
(US ton)
kNm
(ft-lb)
MPa
(psi)
XTG SM
XTG168
XTG244
XTG340
Internal Gripping
4,500
(500
)
50
4,500
(500)
2,250
(250)
2,250
(250)
35
(30,000)
35
(30,000)
(40,000)
65
(50,000)
35
(5,000)
35
(5,000)
35
(5,000)
35
(5,000)
API
4 1/2 IF or 6 5/8 REG BOX
MPa
(psi)
16MPa (rated), 10.5MPa (rated)

2,280psi (rated), 1,500psi (min.)
L/min
40
mm
(in)
2 540
(100)
6. Hoisting and Storage

As the CRS is a hydraulically actuated device, there are strict requirements for safety
and reliability in the field. It is necessary to follow the rules of hoisting, shipping and storage
strictly:
1) Make sure the hoisting device is working properly, the ancillary equipment is in
good condition, and the lifting height satisfies requirement.
2) Based on the recommended hoisting point on the equipment, hoist slowly and
smoothly.
Caution: Do not damage the connection thread, hydraulic ports, surface
strenthening area.
3) Have wood blocks around the equipment during shipping; avoid bumping of the
vehicle to minimize rolling and colliding of the equipment.
4) The products should be kept horizontally in a dry, clean and ventilating storage. If
kept outdoors, a cover is recommended to protect the products from corrosion.
5) Rubber sealing element should be kept in a dry and cool storage place, and should
not be kept more than 18 months.
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6) If the assembly is kept for more than 18 months, seals and perishable medium
should be replaced before operation.
7. Installation and Testing

The installation and testing of the CRS should be performed by certified and
experienced personnel, who has also received training on drilling operation and drilling
safety. Please be aware of the following guidelines:
Wear protection appliances in accordance with the rules (such as gloves, apparel,
safety hat, etc.)
When work high above the ground, please wear a safety belt, and the tools and
components should be tied with safety rope or put in a tool bag to avoid falling off.
7.1 Installation
1) Preparation before Insallation
a) The technical and safety supervisor installation should be assigned, and
meetings should be arranged for technical communication, and technical plan
should be discussed and finalized, making sure that everyone for this job
knows the installation plan and safety measures clearly.
b) It is necessary to check all the equipment and accessories according to the
shipping list, and to make sure they are in place and in good condition, and that
the lubricating product, tools and other accessories are readily available, so as
to avoid work interruption because of insufficient preparation during the
installation process.
2) Installation Procedure
a) Shut down the power and hydraulic supply of the top drive.
b) Remove the regular 120" elevator links of the top drive, determine whether to
remove the torque wrench, hydraulic hoses and saver sub.
Note: Before removal of the hydraulic hoses, prepare suitable containers,
cotton cloth and plugs to avoid spill of hydraulic oil and contaminating the
equipment and surrounding environment.
Warning: Shut off valves in the system and relieve the system pressure slowly
before removing the hydraulic hoses.
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Warning: The hydraulic oil might be hot after operation, so it takes time for it to
cool down to a level for access.
c) Remove the thread protector and other protectors, then apply thread compoud
or grease accordingly.
d) Based on casing size, wall thickness or inner diameter, and refer to Appendix B,
choose the right slip dies, cup packer, stabbing guide and packer cap.
e) Lift the CRS toghther with shipping frame to rig floor, adjust the shipping frame
to fit with the rotary table. Remove the lifting sub, align the mandrel of the CRS
with the main shaft of the top drive, and thread on through the top drive shaft
rotation. Remove the shipping frame and make up the connection between the
CRS and top drive through torque wrench.
1 Hoist CRS with Shipping
2Adjust the Shipping Frame
Frame to Rig Floor
3Align the Connection Thread
to Fit with Rotary Table
4Make up the Connection
of the CRS and Top Drive

Fig.5 Installation of the CRS
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through Torque Wrench
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XTG SM
f) Have the CRS connected to the top drive through anti-rotation bracket (the
anti-rotation bracket may vary based on different top drive design).
Hanger
Anti-rotation
Bracket
1Anti-rotation Bracket
2Installation
Fig. 6 CRS Anti-rotation Bracket and Installation

g) Connect hydraulic hoses between the power supply and CRS actuating
cylinder through proper fittings.
h) Adjust the CRS upper inlet pressure to 16MPa (2,280 psi) or no less than
10.5MPa (1,500 psi).
i) Install the proper elevator links and casing elevator.
7.2 Testing
1) Inspect the installation and connections, and make sure they are correct before
testing.
2) Perform functional test in accordance with the testing procedures of the top drive
operation manual, making sure the top drive works properly.
3) Raise and lower the CRS along the top drive guide rail (travel distance should be
no less than the length of the casing) and turn the rotating head around to make
sure the CRS and the hydraulic hoses do not have any interference anywhere.
4) Open the hydraulic supply, pressure up the upper and lower chamber of the
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actuating cylinder, and monitor whether the pressure is normal and the slips can
perform disengaged and engaged function.
5) Rotate the main shaft of the top drive for a 3~5 minutes with 0 50 rpm
continuously, and see if the CRS works properly.
8. Application and Operations

8.1 Preparation before Running Casing
Because of the process of the casing job and all the hazards that will be confronted
with, it is important to be able to run the casing continuously. So it is essential to be fully
prepared for the following aspects:
1) Casing preparation, such as making a record of the quantity, specification, size,
and labeling the casing.
2) Surface equipment preparation, such as examining the derrick, crown block, top
drive, braking system, transmission system, pneumatic system, hoisting system,
circulation system, weight indicator, pump pressure indicator, blowout preventer
equipment, electrical equipment and electric circuit, so as to make sure that the
surface equipment works properly. Casing running equipment and the tools should
be in place, and spare parts should be ready.
3) Thread protecter for casing running operation preparation, as the stabbing guide
and cup packers will be inserted to the inner casing, it is hard to avoid damage to
the casing thread or the cup packers. Therefore, it is strongly recommended to
prepare thread protector for the female casing thread. If there is no such casing
protector, the regular thread protector can be converted: the thread protector
should be hollow, and the ID should be about the same as the casing, and the
thread are recommended to be trimmed down to 3~4 turns to relieve the labor
intensity. Fig. 7 shows a protecter of the female casing thread.
4) If coupless casing needs to be run with external gripping XTG140 model, casing
lifting sub should be prepared. The ID of the sub should be about the same as the
casing, and the OD should be no more than the value recommended in Table 2.
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1. Protector of the Female Casing Thread 2. Casing Couping

Fig. 7 Protector of the Famale Casing Thread
Table 2 Recommended OD of the Casing Lifting Sub
Max. AllowableLifting Sub OD
Casing OD (in)
mm (in)
4 1/2
135 (5.31)
146 (5.75)
5 1/2
159 (6.26)
5) When using external gripping XTG140 model, a mark should be made around the
OD of casing about 790mm (31") away from the female thread end for the
observation of stabbing depth during casing running operation. It is recommended
to use white painting spray for marking.
Note: Marking is extremely important for the casing running operation.
6) Elevator links preparation, normally 180" elevator links are configured for CRS.
Please user or drilling contractor prepare the proper elevator links for this
application.
7) Wellbore preparation, such as flushing the wellbore based on the design and
drifting.
8) Before casing running, rig manager/drilling supervisor should organize a meeting
for engineering personnel to communicate with the casing crews for technical
details, also make sure the job is clearly assigned, and safety precaution, work
standard and project schedule is clear.
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8.2 Casing Running

(1) Casing Job Precautions
a) Take care of the connection thread on the casing, prevent damage or dirt which
could lead to bad connection.
b) Operate smoothly, control the speed when lowering, apply the assited braking
in time. Any abrupt raising, lowering and braking is prohibited.
c) It is prohibited to throw casing protectors from the drill floor to the ground to
avoid injuries. Casing protectors should be collected and send back to the
ground with air winch.
d) Casing should be centralized before making the connection. Turn the casing
slowly at the beginning, and if there is any sign that the casing cannot be made
up, break out the connection, examine or rework the thread, and then stab the
casing, make up the connection and lower the casing into the wellbore.
e) During make-up, if the casing vibrates too much, the make-up speed should be
slowed down. If the problem still exists, then it might be caused by disalignment
of the axis of the thread and the casing, and this is an indication of quality issue,
therefore the casing should not be run into the wellbore.
f) When lowering the casing, avoid impact load which could lead to casing body,
coupler shoulder and thread damage.
g) When lowering the casing, perform the mud fill-up timely according to the
casing program.
h) When lowering the casing, minimize the inactive time, and move the casing up
and down.
i) When lowering the casing, if stuck casing or other complex situation happens,
take advantage of the top drive, for example, rotate the casing, raise or lower
the casing, circulate the mud and etc. Avoid the situation getting worse, and
ensure a smooth casing running job.
j) There should be assigned personnel to watch and record the drilling mud return,
record the changes of the suspending load, and if there is abnormal situation,
take measures accordingly.
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(2) Casing Running Procedure:

a) Field personnel should roll the casing to the catwalk, tie the rope sling to the
casing firmly 1.5m (5 ft) away from the female thread, have the thread protector
on and have it hung from the air hoist, tie down the rope sling.
b) Bring casing to the catwalk, stop the movement when the female thread portion
reach the rig floor for over 2m (6.6 ft) (or put the casing in the mouse hole), the
casing operator remove the casing thread protector and rope sling.
c) Operate the elevator link to forward position so that the elevator is close to the
casing coupler, then have the casing held in the elevator under the assistance
of a rig floor crew, and lock up the elevator.
Fig.8 Have the Casing Held in Elevator

d) Hoist the top drive and the casing, operate elevator link to backward position.
When it returns to the center of the wellbore approximately, operate the
elevator link to neutral position and tilt cylinders will be in unload mode.
Fig.9 Hoist the Casing and Prepare for Connection

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e) Hoist the casing to return it to a center position. Remove the thread protector,
apply casing grease and thread sealant evenly.
f) Tighten up the casing guide shoes with the hydraulic tongs.
g) Driller releases the brake, and the first casing will be set. Repeat the previous
steps to hoist the second casing to a point where its male thread is 0.2m (8")
higher than the female thread of the previous casing segment.
h) Rig crews remove the thread protector, and the driller releases the brake. Stab
carefully to avoid cross threading. Avoid dust or dirt falling into the thread, and
take care of the metal sealing area.
i) Have the stabbing guide and cup packer insert into the casing, lower the CRS
slowly till the retainer ring is about 50mm (2") above the casing coupling (with
the assistance of the video monitoring system), stop stabbing. For XTG140
model, lower the CRS slowly when the equipment approaches the mark
painted on the casing, and stop stabbing when the hook load changes by
watching the weight indicator. Now the slips are placed at right position for
gripping. Operate the "Engage" button to actuate the CRS slips to grip the
casing, and then make up the connection to the specified torque by the top
drive.
Warning: For external gripping model XTG140, the CRS must be lowered to the
right position for gripping the casing, otherwise the casing coupling OD might
be gripped and this would result in damage of the casing and the CRS.
j) After the makeup operation, hoist the casing slowly for about 0.2m (8 ") before
braking, wait till the slips of the rotary table release, then apply the brake slowly
and lower the casing. When the elevator is about 2m (7 ft) above the rotary
table, slow down and make the stop when the elevator is about 0.5m (1.5 ft)
above the rotary table. Apply slips to grip the casing.
k) Remove protector of the female casing thread. Repeat the previous steps to set
all the casings into the wellbore.
Warning: Before the slips grip the casing while running the casing in hole, do
not disengage the casing elevator.
(3) Disassembly of the CRS
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a) After the completion of the casing job, disconnect all the piping connections,
fasteners, accessories from the top drive.
Note: Before disassembling the hydraulic hoses, prepare suitable containers,
cotton cloth and oil plugs to avoid the hydraulic oil spill and contaminating the
equipment and surrounding environment.
Warning: Shut off the valves in the system and relieve the system pressure
slowly before disassembling the hydraulic line. Make sure there is no trapped
pressure in the system.
Warning: The hydraulic oil might be hot after operation, so it takes some time
for it to cool down to a level for access.
b) Before disassembly, please mark the assembly positions of the connections for
a correct re-assembly work.
c) After disassembly, please inventory the parts and clean up for repair work or reuse.
Note: After the disassembly, restore the top drive saver sub, retaining
equipment, backup tong, hydraulic hoses and pressure relief valve to the
original condition, making sure a safe application of the top drive next time.
9. Intelligence Aided Equipment

In order to promote the CRS casing job automation and intelligentization, and to ensure
job security and efficiency, devices like travel switch, and video monitoring system have
been integrated into the system design.
9.1 Control System and Software
When the rig is equipped with BPM top drive, the CRS can use the hydraulic line from
the backup wrench of the top drive, and the makeup and breakout torque can be controlled
by the PLC-VFD precision control of the top drive.
Ex-proof laptop computer installed with CRS casing running operation software is an
option provided in Appendix C. The software contains database of casing specs API 5CT,
and when the casing size is selected, the optimal makeup torque is set automatically.
During operation, the torque/turns curve will show up in real time and can be played back.
Data sheet with torque/turns curve can be generated when the operation is completed. The
software interface shows in Fig.10.
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Fig.10 CRS Operation Software Interface

9.2 Video Monitoring System
In order to monitor the CRS insertion into the casing, and to ensure the operation
precision, the CRS is equipped with an optional video
monitoring system: a video camera which is infrared
and explosion-proof is installed on the derrick, a
monitor and a controller are installed in the drillers
console to achieve point to point video monitoring
(refer to Fig.11).
The installation height of the video camera should
be about the same as the length of a casing stand
above the drill floor. The video camera focus on the
casing coupling that is hoisted, so the casing hoisting,
Fig.11 Video Monitoring System
CRS lowering and stabbing into the casing, slips engaging, casing rotation, casing string
lowering, circulation and the working conditions of the slips and the abrasion of the cup
packer are all under monitoring.
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10. Maintenance and Repair of the Internal Gripping CRS

A safe and reliable CRS determines whether the casing job will be successful or not
and the benefit. So to ensure a properly working CRS during the casing job, there is
relatively high requirements for the quality level of the routine maintenance and repair work.
Notes: The CRS maintenance should be done in accordance with the requirements, it
will increase the service life of the system and is very important for operation safety.
Warning: The repair quality of the CRS is related to safety and reliability of this product,
so the maintenance personnel must be trained and has valid certification for repair work
from the equipment manufacturer, and written approval needs to be obtained for the repair
work environment. It is strictly prohibited to disassemble the hydraulically actuating section
for maintenance and replace the relevant parts for any company or individual without the
authority and permission from the manufacturer.
10.1
Inspection and Maintenance during the casing running operation
1) Inspection Items:
a) Check if the slips are in good condition.
b) Check if the cup packer is in good condition.
c) Check the locations where grease is needed.
2) Maintenance Items:
a) Check the condition of the slips every 1000m (3000 ft) of casing run. If there is
slipping during the makeup, check if the slip teeth are plugged by mud or other
foreign matters and the slips should be disassembled from the CRS and
cleaned thoroughly. If the slipping are caused by severe wear of the slips, then
it is time to replace them. Refer to section 10.5 for guidelines.
b) Check the condition of the cup packers every 1000m (3000 ft) of casing run, if
the cup packer is worn out and can not bear the circulation pressure, it is time
to replace the cup packer. Refer to section 10.5 for guidelines.
c) There are bearings inside the actuating cylinder and the coupler ring, and they
needs to be lubricated for every 1000m (3000 ft) casing run. The lubrication is
done with grease gun and the lubrication point are shown as in Figure 12.
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1. Anti-Rotation Bracket 2. Actuating Cylinder 3. Coupler Ring 4. Grease line 5. Grease Gun
Fig.12 Lubrication Scheme of the CRS
10.2
Routine Inspection and Maintenance
a) Check if the engage/disengage of the slips is normal.
b) Check if there is any leakage of the hydraulic fluid.
c) Check if there is any loose fasteners or damage of the fasteners.
d) Check the abrasion condition of the seals.
e) Check if there is abnormal condition of the surface-treated locations.
f)
Check the locations where grease is needed.
a) Remove the oil contamination and foreign matters timely, avoid plugging the
pressure balance orifice on the actuating cylinder.
b) Ensure the fastners are tightened and locked. Replace the damaged parts in time.
Warning: Prevent the fastners from loosening up and hurting someone.
c) There are bearings inside the actuating cylinder and slip coupler, so pump
bearing grease through the grease nipple and gaps regularly.
d) If there is excessive wear(flat teeth) or flake of large area, then it needs
replacement.
e) Watch the pressure gauge closely each time setting the casing, if the pressure
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is not stable, then it should be disassembled and repaired. In principle, all the
seals and backup rings need to be replaced for each disassembly and repair.
Warning: Avoid the hydraulic fluid leaking, as it might cause injury and slipping
of slips.
Note: After each completion of the casing job by the CRS, inspect each
component carefully; make sure the hydraulic cylinder is working properly and
leak free, and the slips are in good condition. If necessary, disassemble and
repair the equipment to ensure a safe operation.
10.3
Repair Preparation
1) Disassembly and assembly frame, and proper tools (including special tools, pipe
tongs, chain tongs, steel wire rope, and etc.).
2) All the lubricants (lithium based grease, L-HM32 anti-friction hydraulic oil, bearing
grease).
3) Documents associated with the equipment (including the Operation Manual, Seals
Checklist and etc.).
4) Spare parts (including seals, backup rings and etc.).
10.4 Disassembly
CautionDuring disassembly, it is prohibited to nip the sealing surface and the outer
surface of the thin wall sleeve. There is Y680 bonding agent applied on the connecting
thread between the shaft and slip mandrel (normally, it is not necessary to unthread the
connection between the mandrel and slip mandrel), so before breakout, the thread portion
should be heated to around 250 (170) evenly to break the bond between the parts,
then unthread the connection.
1) Mount the CRS mandrel on the bench clamp of the disassembly breakout machine,
prepare a container for oil collection, use allen key to remove two hexagon plugs, and drain
the hydraulic oil out of the two chambers.
2) Remove two hex. socket set screws on the stabbing guide with allen key, and then
remove the stabbing guide.
3) Remove three hex. socket set screws on the outer sleeve of the retainer ring with
allen key, then remove the outer sleeve, the leaf spring, retainer ring, inner sleeve.
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4) Remove three socket head cap screws on the outer sleeve of the slip coupler with
allen key, and than remove the sleeve, and the split coupler.
5) Remove the bearing housing, thrust ball bearing, slips, thrust ball bearing, and
spacer sequentially.
6) Remove four socket head cap screws on the die blocks, rotate each die block as
Fig. 13 shows till the wedge on the die block fully appears, remove the die blocks. The slip
dies can be removed easily.
Wedge on the Die Block
Slip Die
Die Block
Fig.13 Disassembly of the Die Blocks and Slip Dies
Caution: The slips may drop out after the constraints have been removed, so take
caution and do not get hurt.
WarningThe hydraulic cylinder will be disassembled, and unauthorized personnel
should not take on this job, otherwise the relevant personnel should be responsible for any
severe consequence that may follow.
7) Remove the locking wire on the hex head bolt.
8) Remove the hex. head bolts and lock washers that are between the upper, lower
cylinder head and the actuating cylinder, and then remove the upper and lower
cylinder head.
9) Use the hoisting strap to remove the actuating cylinder and the piston together
horizontally. Make sure the alignment of the actuating cylinder and mandrel.
10) Tie the hoisting strap to the lower end of the piston, then take the cylinder and
piston apart.
11) Remove the backup ring, lock nut, tapered bearing, spacer, and tapered roller
bearing sequentially from the mandrel.
12) Use the spline sleeve tool to remove the slip mandrel from the top drive shaft.
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13) Remove the o-rings, backup rings, wiper rings and wear band from each
component.
14) Flush all the components with cleaning equipment. Inspect all the components
visually for any severe wear or damage. Examine the mandrel, slip mandrel,
actuating cylinder, piston, slips and other important components nondestructively,
and determine whether they need replacements accordingly.
15) All the sealings need to be replaced after each disassembly and repair.
10.5 Assembly
Caution: During assembly, it is prohibited to nip the sealing surface and the outer
surface of the thin wall sleeve. It is also prohibited to use sharp tool for the assembly of
seals. It is recommended to use soft rubber/plastic tools.
1) Remove the components that were rejected after examination, and replace with
new parts. Prepare for a set of backup seals and greasing tools.
Note: Please refer to the instructions in the package for installation location.
2) Actuating System Assembly
a) Mount the mandrel on the bench clamp of the disassembly and assembly frame,
Use the spline sleeve to engage the slip mandrel and mandrel following the
instructions of Table 2.
b) Heat the inner ring of the roller bearing and install it onto the mandrel (pay
attention to the direction), and then install the spacer, and likewise, install the
other inner ring of the bearing, then install the outer rings of the bearings from
each side.
c) Thread the clamping nut onto the mandrel, and tighten the thread with the
groove outside, make sure the bearing has been pressed tight, and then install
the lock washer. Apply bearing grease around the bearing.
d) Install the wear band, O-ring and backup ring at the right place, and apply
calcium based grease at the groove.
e) Install the wear band inside the pistonTurcon Roto-glyd ring and Turcon
VariSeal, then apply lithium based grease at the groove.
Caution: Ensure each part is clean, and it is prohibited to heat the seals with hot
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water.
f)
Push the piston assembly slowly into the actuating cylinder, pay attention to the
seals and wear band, make sure it is clean inside the cylinder, the orifices, and
there are no foreign matters in the orifices and injection ports.
g) Mount the mandrel on the bench clamp of the disassembly and assembly frame,
hoist the actuating cylinder and piston assembly slowly and push the assembly
from the right side of the slip mandrel till the face of the actuating cylinder inner
bore aligns with the face of tapered roller bearing.
h) Install the backup ring, o-ring, backup ring, o-ring, wear band, wiper ring at the
corresponding locations, apply lithium based grease at the groove.
i)
Push the lower housing assembly onto the mandrel from the right side, pay
attention to the seals, make sure to align the thread holes of the lower housing
and the actuating cylinder.
j)
Slide the spring washer onto the hex head bolt, thread the bolts into the tapped
holes in a diametrically staggered pattern following the instructions of Table 3.
k) Fix the outer housing, and try to rotate the mandrel to make sure the mandrel
can rotate smoothly and easily.
l)
Measure and remachine the upper housing to adjust the axial clearance of the
bearing.
m) Install the wiper ring in the upper housing, and push the upper housing
assembly from the left side of the mandrel. Make sure to align the tapped holes
of the upper housing and the actuating cylinder. Apply Loctite 510 at the
interface between the upper housing and the actuating cylinder.
n) Fit the spring washer onto the hex head bolt, thread the bolts into the tapped
o) Install the direct injection grease nipple at the corresponding location, and
make sure the orifice is clean and clear.
3) Slips Assembly
a) Measure and remachine the spacer to adjust the axial clearance of the thrust
ball bearing.
b) Fix the mandrel, mount the assembly on the bench clamp of the disassembly
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and assembly frame, support in the middle if necessary. Install the spacer,
thrust ball bearing from the right side of the slip mandrel (pay attention to the
direction), and then install the slips sequentially into the spline grooves, and
hold them together with iron wire. Install the other thrust ball bearing (pay
attention to the direction, and apply enough lithium based grease), then install
the bearing housing to hold the bearing and slips.
c) Adjust the spacing between the piston and the bearing housing, connect the
piston and the coupler ring with the split type coupler. Slide the sleeve onto the
coupler and fasten with hex. socket set screws following the instructions of
Table 2.
d) Slide the inner sleeve of the retainer ring onto the slips from the right side,
install the four-pieces retainer ring onto the slip mandrel, and install four leaf
springs at the corresponding locations of the retainer ring, then push the inner
sleeve to the right so it touches the retainer ring and make sure the leaf spring
is compressed. Slide the outer sleeve on from the right side, tighten the hex.
socket set screws between the inner sleeve and the outer sleeve in accordance
with the requirements of Table 2.
4) Guideline for Slips, Cup Packer, Stabbing Guide and Packer Cap Selection,
Assembly and Disassembly
a) Based on the specification of the casing (OD and Wall Thickness) and refer to
Appendix A, pick the right slips, cup packer, stabbing guide and seal cap for the
application. The first step is to know the specification of the casing (OD and
Wall Thickness), for example, if 6 5/8" casing with wall thickness of 8.94mm
( WT/FT 24.00lb/ft) will be set, then refer to Appendix A, Slip 9556910146 is
selected, then Cup Packer 24-28# is the one to pickand the stabbing guide
9556905158 follows, and then Seal Cap 9556906628. Pick these parts in the
right order.
b) Apply a thin layer of lithium based grease on the Stabbing Guide. Fig. 14 shows
how the Stabbing Guide and Cup Packer fit together.
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1.Stabbing Guide
2.Cup Packer
XTG SM
3.Seal Cap
4.O-ring
5.Set Screws 6.O-ring 7.Slip Mandrel

Fig. 14 Cup Packer, Seal Cap and Stabbing Guide
c) Refer to Fig.15, install the Seal Cap with O-ring at the end of the Slip Mandrel.
Place the O-ring at the left end of the Stabbing Guide, have the Stabbing Guide
with Cup Packer installed threaded to the Slip Mandrel. The Seal Cap with
O-ring installed now abuts against the Cup Packer.
1.Stabbing Guide 2.O-ring 3.Cup Packer 4.O-ring (not included in some models)
5.Seal Cap and Snap Ring 6.Slip Mandrel 7.Set Screws
Fig. 15 Illustration for Assembly of the Stabbing Guide and Cup Packer
d) Have the Set Screws threaded to the Slip Mandrel and so the dog point sets
into the groove in the Stabbing Guide for anti-loosening. Place the snap ring in
position.
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e) For disassembly, reverse the procedures above.
5) Assembly Completion
a) Plug the tapped holes on the actuating cylinder with blanking plugs, tighten the
plugs manually.
b) Keep the hex head bolts from getting loose by using the steel wire to hold the
bolts circumferentially.
c) Inject bearing grease for the tapered roller bearing with grease gun till the
chamber is full. The assembly is complete now.
Notes: All the thread connections are to be tightened with grease and to the specified
torque values according to Table 2.
Table 3 CRS Thread Makeup Torque and Grease
XTG168/XTG244/XTG340
Model
Torque
Thread
Additive
kNm (ft lb)
Mandrel Thread
62 (50,000)
Loctite 680
Bolt Thread
0.33 (250)
Loctite 243
Screw Thread
Manually Tighten
MoS2 Grease
Other Thread
Manually Tighten
MoS2 Grease
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11. Maintenance and Repair of the External Gripping CRS

A safe and reliable CRS determines whether the casing job will be successful or not
and the benefit. So to ensure a properly working CRS during the casing job, there is
relatively high requirements for the quality level of the routine maintenance and repair work.
Notes: The CRS maintenance should be done in accordance with the requirements, it
will increase the service life of the system and is very important for operation safety.
Warning: The repair quality of the CRS is related to safety and reliability of this product,
so the maintenance personnel must be trained and has valid certification for repair work
from the equipment manufacturer, and written approval needs to be obtained for the repair
work environment. It is strictly prohibited to disassemble the hydraulically actuating section
for maintenance and replace the relevant parts for any company or individual without the
authority and permission from the manufacturer.
11.1
Inspection and Maintenance during the casing running operation
a) Check if the slips are in good condition.
b) Check if the cup packer is in good condition.
c) Check the locations where grease is needed.
a) Check the condition of the slips every 1000m (3000 ft) of casing run. If there is
slipping during the makeup, check if the slip teeth are plugged by mud or other
foreign matters and the slips should be disassembled from the CRS and
cleaned thoroughly. If the slipping are caused by severe wear of the slips, then
it is time to replace them. Refer to section 11.5 for guidelines.
b) Check the condition of the cup packers every 1000m (3000 ft) of casing run, if
the cup packer is worn out and can not bear the circulation pressure, it is time
to replace the cup packer. Refer to section 11.5 for guidelines.
c) There are bearings inside the actuating cylinder and the coupler ring, and they
needs to be lubricated for every 1000m (3000 ft) casing run. The lubrication is
done with grease gun and the lubrication point are shown as in Figure 16.
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1. Anti-Rotation Bracket 2. Actuating Cylinder 3. Grease line 4. Grease Gun

Fig. 16 Lubrication Scheme of the CRS
11.2
Routine Inspection and Maintenance
a) Check if the engage/disengage of the slips is normal.
b) Check if there is any leakage of the hydraulic fluid.
c) Check if there is any loose fasteners or damage of the fasteners.
d) Check the abrasion condition of the seals.
e) Check if there is abnormal condition of the surface-treated locations.
f)
Check the locations where grease is needed.
f)
Remove the oil contamination and foreign matters timely, avoid plugging the
pressure balance orifice on the actuating cylinder.
g) Ensure the fastners are tightened and locked. Replace the damaged parts in time.
Warning: Prevent the fastners from loosening up and hurting someone.
h) There are bearings inside the actuating cylinder and slip coupler, so pump
bearing grease through the grease nipple and gaps regularly.
i)
If there is excessive wear(flat teeth) or flake of large area, then it needs

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replacement.
j)
Watch the pressure gauge closely each time setting the casing, if the pressure
is not stable, then it should be disassembled and repaired. In principle, all the
seals and backup rings need to be replaced for each disassembly and repair.
Warning: Avoid the hydraulic fluid leaking, as it might cause injury and slipping
of slips.
Note: After each completion of the casing job by the CRS, inspect each
component carefully; make sure the hydraulic cylinder is working properly and
leak free, and the slips are in good condition. If necessary, disassemble and
repair the equipment to ensure a safe operation.
11.3
Repair Preparation
1) Disassembly and assembly frame, and proper tools (including special tools, pipe
tongs, chain tongs, steel wire rope, and etc.).
2) All the lubricants (lithium based grease, L-HM32 anti-friction hydraulic oil, bearing
grease).
3) Documents associated with the equipment (including the Operation Manual, Seals
Checklist and etc.).
4) Spare parts (including seals, backup rings and etc.).
11.4 Disassembly
CautionDuring disassembly, it is prohibited to nip the sealing surface and the outer
surface of the thin wall sleeve. There is Y680 bonding agent applied on the connecting
thread between the shaft and slip mandrel (normally, it is not necessary to unthread the
connection between the mandrel and slip mandrel), so before breakout, the thread portion
should be heated to around 250 (170) evenly to break the bond between the parts,
then unthread the connection.
1) Mount the CRS mandrel on the bench clamp of the torque master, prepare a
container for oil collection, use allen key to remove two hexagon plugs, and drain
the hydraulic oil out of the two chambers.
2) Remove two hex. socket set screws on the stabbing guide with allen key, and then
remove the stabbing guide.
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3) Remove the pin between the links and the coupler ring, and then remove the links
together with the slips from the slip housing.
4) Remove the pin between the links and the slips with a wrench.
5) Remove the hex. head bolt from the slips, and then remove the pin holder and the
pin, and then remove the slip dies from the slips.
6) Remove five socket head cap screws on the outer sleeve of the slip coupler with
allen key, and then push the outer sleeve away from the actuating cylinder onto the slip
housing. Remove the split coupler.
WarningAvoid the split coupler falling off and cause injury.
7) It is the thrust ball bearing inside the coupler ring. Remove two socket head cap
screws on the busing of the thrust ball bearing. Remove the bushing and the balls of the
bearing.
8) Break out the thread coupling between the mandrel and slip housing using the
torque master.
9) Remove the outer sleeve of the coupler and outer ring of the bearing.
WarningThe hydraulic cylinder will be disassembled, and unauthorized personnel
should not take on this job, otherwise the relevant personnel should be responsible for any
severe consequence that may follow.
10) Remove the locking wire on the hex head bolt.
11) Remove the hex. head bolts and lock washers that are between the upper, lower
cylinder head and the actuating cylinder, and then remove the upper and lower
cylinder head.
12) Use the hoisting strap to remove the actuating cylinder and the piston together
horizontally. Make sure the alignment of the actuating cylinder and mandrel.
13) Tie the hoisting strap to the lower end of the piston, then take the cylinder and
piston apart.
14) Remove the backup ring, lock nut, tapered bearing, spacer, and roller bearing
sequentially from the mandrel.
15) Remove the o-rings, backup rings, wiper rings and wear band from each
component.
16) Flush all the components with cleaning equipment. Inspect all the components
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visually for any severe wear or damage. Examine the mandrel, slip mandrel,
actuating cylinder, piston, slips and other important components nondestructively,
and determine whether they need replacements accordingly.
17) All the sealings need to be replaced after each disassembly and repair.
11.5 Assembly
Caution: During assembly, it is prohibited to nip the sealing surface and the outer
surface of the thin wall sleeve. It is also prohibited to use sharp tool for the assembly of
seals. It is recommended to use soft rubber/plastic tools.
1) Remove the components that were rejected after examination, and replace with new
parts. Prepare for a set of backup seals and greasing tools.
Note: Please refer to the instructions in the package for installation location.
2) Actuating System Assembly
a) Place the mandrel on the ground with the bulk end facing down, heat the inner ring
of the roller bearing and install it onto the mandrel (pay attention to the direction),
and then install the spacer, and likewise, install the other inner ring of the bearing.
b) Thread the clamping nut onto the mandrel, and tighten the LH thread with the
groove outside, make sure the bearing has been pressed tight, and then install the
lock washer. Apply bearing grease around the bearing.
c) Install the wear band, o-ring and backup ring at the right place, and apply lithium
based grease at the groove.
d) Install the wear band inside the pistonRoto-glyd ring and rotary seals, then apply
lithium based grease at the groove.
Caution: Ensure each part is clean, and it is prohibited to heat the seals with hot
water.
e) Push the piston assembly slowly into the actuating cylinder, pay attention to the
seals and wear band, make sure it is clean inside the cylinder, the orifices, and
there are no foreign matters in the orifices and injection ports.
f)
Place the mandrel on the bench clamp of the torque master, then install the outer
rings of the bearings from each side. Hoist the actuating cylinder and piston
assembly slowly and push the assembly from the bulk side of the mandrel till the
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face of the actuating cylinder inner bore aligns with the face of roller bearing.
g) Install the backup ring, o-ring, backup ring, o-ring, wear band, wiper ring at the
corresponding locations, apply lithium based grease at the groove.
h) Push the lower cylinder head into the cylinder bore. Pay attention to the seals,
make sure to align the thread holes of the lower cylinder head and the cylinder.
i)
Slide the spring washer onto the hex head bolt, thread the bolts into the tapped
j)
Fix the cylinder, and try to rotate the mandrel to make sure the mandrel can rotate
smoothly and easily.
k) Measure and remachine the upper cylinder head to adjust the axial clearance of the
bearing.
l)
Install the wiper ring in the upper cylinder head, and push the upper cylinder head
into the bore of mandrel. Make sure to align the tapped holes of the upper housing
and the actuating cylinder. Apply Loctite 510 at the interface between the upper
housing and the actuating cylinder.
m) Fit the spring washer onto the hex head bolt, thread the bolts into the tapped holes
in a diametrically staggered pattern following the instructions of Table 4.
n) Install the direct injection grease nipple at the corresponding location, and make
sure the orifice is clean and clear.
3) Slips Assembly
a) Place the actuating assembly on the bench clamp of the torque master. Push the
outer ring of the ball bearing to the piston and fill the space in between the outer
ring and the piston with bearing balls, and then secure the bushing of the outer ring
in place with two cap screws.
b) Place the outer sleeve of the coupler ring onto the slip housing.
c) Use the spline sleeve to engage the slip housing and the mandrel following the
instructions of Table 4.
d) Fit the split ring of the coupler to the outer ring of the bearing, and then push the
outer sleeve onto the split ring, secure the outer sleeve in place with five hex.
socket set screws.
e) Slide the slip die into the slip along the keyway, insert the pin between the slip die
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and the slip, and then install the pin holder, fasten the hex. head bolt.
f)
Slide the slip assembly together with the link into the slip housing along the keyway,
insert the pin between the link and the coupler, and then fasten the hex. head nut to
secure the pin.
g) Install O-ring on the center pipe at the runout groove of the male thread end, and
make up the thread between the center pipe and slip housing with the center pipe
torque sleeve.
4) Guideline for Slips, Cup Packer, Stabbing Guide and Packer Cap Selection, Assembly
and Disassembly
a) Based on the specification of the casing (OD and Wall Thickness) and refer to
Appendix A, pick the right slips, cup packer, stabbing guide and seal cap for the
application. The first step is to know the specification of the casing (OD and Wall
Thickness), for example, if 6 5/8" casing with wall thickness of 8.94mm will be set,
then refer to Appendix A, Slip 9556910146 is selected, then Cup Packer 24-28# is
the one to pickand the stabbing guide 9556905158 follows, and then Seal Cap
9556906628. Pick these parts in the right order.
b) Apply a thin layer of lithium based grease on the Stabbing Guide. Fig.17 shows
how the Stabbing Guide and Cup Packer fit together.
1.Stabbing Guide 2.Cup Packer 3.Seal Cap 4.O-ring

5.Set Screws 6.O-ring 7.Center Pipe
Fig. 17 Cup Packer and Stabbing Guide
c) Refer to Figure 18, install the Seal Cap with O-ring at the end of the Center Pipe.
Place the O-ring at the left end of the Stabbing Guide, have the Stabbing Guide
with Cup Packer installed threaded to the Center Pipe. The Seal Cap with O-ring
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installed now abuts against the Cup Packer.
1.Stabbing Guide 2.O-ring 3.Cup Packer 4.O-ring

5.Seal Cap 6.Set Screws 7.Center Pipe
Fig. 18 Illustration for Assembly of the Stabbing Guide and Cup Packer
d) Have the Set Screws threaded to the Center Pipe and so the dog point sets into the
groove in the Stabbing Guide for anti-loosening.
e) For disassembly, reverse the procedures above.
5) Assembly Completion
a) Plug the tapped holes on the actuating cylinder with blanking plugs, tighten the
plugs manually.
b) Keep the hex head bolts from getting loose by using the steel wire to hold the bolts
circumferentially.
c) Inject bearing grease for the roller bearing with grease gun till the chamber is full.
The assembly is complete now.
Notes: All the thread connections are to be tightened with grease and to the specified
torque values according to Table 4.
Table 4 CRS Thread Makeup Torque and Grease
XTG140
Model
Torque
Thread
Additive
kNm (ft lb)
Mandrel Thread
62 (50,000)
MoS2 Grease
Bolt Thread
0.33 (250)
Loctite 243
Screw Thread
Manually Tighten
MoS2 Grease
Other Thread
Manually Tighten
MoS2 Grease
Page 34 of 45
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12. Troubleshooting
Problems that might be encountered during the operation and the solutions:
Issue 1The slips cannot engage the casing to transfer torque or hoist load
Solution:
a) Check the hydraulic power supply to see if there is enough pressure 10.5 MPa ~16
MPa (1500 psi~2280 psi)the slips will not be able to engage the casing if there is
not enough pressure. Please increase the hydraulic supply pressure.
b) If the hydraulic supply pressure has reached the maximum working pressure 16MPa
(2280 psi), then it might be caused by stucked components which transfer the
power, or leaked seal, or severe wear of the slip teeth, please replace the slip dies
in time. Or please send the CRS to designated service point.
Issue 2: Mud circulation or casing pressure test cannot be performed normally:
Solutions:
a) Compare the cup packer in application with the one specified Appendix A and see if
the cup packer fits the application. If it does not fit, please replace the packer.
b) If the cup packer fits the casing, then it might be caused by severe wear. Please
replace the cup packer in time.
13. Spare Parts and Corollary Tools

Generally, after the operation of the CRS, all the seals should be replaced during each
repair. Check the mandrel, cylinder, actuating cylinder, slip mandrel and the slips and other
parts that are under loads, and parts under abrasion, and replace the damaged parts.
Please refer to the spare parts list and special tools list (See Appendix B).
14. Order Notice

The reliability, service life and performance of the CRS are not only based on the
manufacturing quality, but also on the right operation and repair. To make sure the products
and components you need can be delivered to you correctly and timely, please pay
attention to the following aspects:
1) Please write down the product model clearly, so if the model that the customer has
ordered is revised, then the newest model will be provided and there will be no additional
notice.
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2) If there are special requirements for the products, please specify the details while
ordering. If there is no instruction, the standard products will be provided.
3) If the components are ordered, then please specify part name, order number and
quantity.
Page 36 of 45
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Appendix ASlips, Cup Packer, Stabbing Guide and Packer Cap Selecting Guide
Guide for selection of XTG140 components

Casing Specifaction
Wall
thick
Selecting CRS Components (Part No.)
WT/FT
OD
lb/ft
mm
4-1/2
9.50
114.30
5.21
103.88
4-1/2
10.50
114.30
5.69
4-1/2
11.60
114.30
4-1/2
13.50
4-1/2
Labels
ID
Drift
dia.
Slips
Cup Packer (BPM)
Stabbing Guide
100.70
9554500114
4A (5303940570)
9554501114
102.92
99.74
9554500114
4A (5303940570)
9554501114
6.35
101.60
98.42
9554500114
4A (5303940570)
9554501114
114.30
7.37
99.56
96.38
9554500114
4B (5303940580)
9554501114
15.10
114.30
8.56
97.18
94.00
9554500114
4B (5303940580)
9554501114
11.50
127.00
5.59
115.82
112.64
9554500127
5A (5303940370)
9554501127
13.00
127.00
6.43
114.14
110.96
9554500127
5A (5303940370)
9554501127
15.00
127.00
7.52
111.96
108.78
9554500127
5A (5303940370)
9554501127
18.00
127.00
9.19
108.61
105.44
9554500127
5B (5303940560)
9554501127
21.40
127.00
11.10
104.80
101.62
9554500127
5B (5303940560)
9554501127
23.20
127.00
12.14
102.72
99.54
9554500127
4A (5303940570)
9554501114
24.10
127.00
12.70
101.60
98.42
9554500127
4A (5303940570)
9554501114
mm
mm
mm
Page 37 of 45
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Casing Specifaction
Wall
thick
Selecting CRS Components (Part No.)
WT/FT
OD
lb/ft
mm
5-1/2
14.00
139.70
6.20
127.30
5-1/2
15.50
139.70
6.98
5-1/2
17.00
139.70
5-1/2
20.00
5-1/2
Labels
ID
Drift
dia.
Slips
Cup Packer (BPM)
Stabbing Guide
124.12
9554500140
54A(5303940540)
9554501140
125.74
122.56
9554500140
54A(5303940540)
9554501140
7.72
124.26
121.08
9554500140
54A(5303940540)
9554501140
139.70
9.17
121.36
118.18
9554500140
54B(5303940550)
9554501140
23.00
139.70
10.54
118.62
115.44
9554500140
54B(5303940550)
9554501140
5-1/2
26.80
139.70
12.70
114.30
111.12
9554500140
5A (5303940370)
9554501127
5-1/2
29.70
139.70
14.27
111.16
107.98
9554500140
5A (5303940370)
9554501127
5-1/2
32.60
139.70
15.88
107.94
104.76
9554500140
5B (5303940560)
9554501127
5-1/2
35.30
139.70
17.45
104.80
101.62
9554500140
5B (5303940560)
9554501127
5-1/2
38.00
139.70
19.05
101.60
98.42
9554500140
4A (5303940570)
9554501114
5-1/2
40.50
139.70
20.62
98.46
95.28
9554500140
4B (5303940580)
9554501114
5-1/2
43.10
139.70
22.22
95.25
92.08
9554500140
4B (5303940580)
9554501114
mm
mm
mm
Page 38 of 45
BPM
XTG SM

Casing Specifaction
Labels
WT/FT
lb/ft
Selecting CRS Components
OD
Wall
thick
ID
Drift
dia.
Slip
Cup Packer(BPM)
Stabbing
Guide
Packer Cap
6-5/8
20.00
168.28
7.32
153.64
150.46
9556910146
5303940220 (7B)
9556901158
9556902158
6-5/8
24.00
168.28
8.94
150.40
147.22
9556910146
5303940220 (7B)
9556901158
9556902158
17.00
177.80
5.87
166.06
162.88
9556910158
5303940210 (7A)
9556901158
9556902158
20.00
177.80
6.91
163.98
160.80
9556910158
5303940210 (7A)
9556901158
9556902158
23.00
177.80
8.05
161.70
158.75
9556910158
5303940210 (7A)
9556901158
9556902158
23.00
177.80
8.05
161.70
158.52
9556910158
5303940210 (7A)
9556901158
9556902158
26.00
177.80
9.19
159.42
156.24
9556910158
5303940210 (7A)
9556901158
9556902158
29.00
177.80
10.36
157.08
153.90
9556910146
5303940220 (7B)
9556901158
9556902158
32.00
177.80
11.51
154.78
152.40
9556910146
5303940220 (7B)
9556901158
9556902158
32.00
177.80
11.51
154.78
151.60
9556910146
5303940220 (7B)
9556901158
9556902158
35.00
177.80
12.65
152.50
149.32
9556910146
5303940220 (7B)
9556901158
9556902158
38.00
177.80
13.72
150.36
147.18
9556910146
5303940220 (7B)
9556901158
9556902158
7-5/8
24.00
193.68
7.62
178.44
175.26
9556910178
5303940430 (75A)
9556901178
9556902178
7-5/8
26.40
193.68
8.33
177.02
173.84
9556910178
5303940430 (75A)
9556901178
9556902178
7-5/8
29.70
193.68
9.52
174.64
171.46
9556910178
5303940430 (75A)
9556901178
9556902178
7-5/8
33.70
193.68
10.92
171.84
168.66
9556910158
5303940440 (75B)
9556901178
9556902178
7-5/8
39.00
193.68
12.7
168.28
165.10
9556910158
5303940440 (75B)
9556901178
9556902178
7-5/8
42.80
193.68
14.27
165.14
161.96
9556910158
5303940210 (7A)
9556901158
9556902158
7-5/8
45.30
193.68
15.11
163.46
160.28
9556910158
5303940210 (7A)
9556901158
9556902158
7-5/8
47.10
193.68
15.88
161.92
158.74
9556910158
5303940210 (7A)
9556901158
9556902158
7-5/8
51.20
193.68
17.45
158.78
155.60
9556910158
5303940450 (75C)
9556901158
9556902158
7-5/8
55.30
193.68
19.05
155.58
152.40
9556910146
5303940450 (75C)
9556901158
9556902158
Page 39 of 45
BPM
XTG SM

Casing Specification
Labels
WT/FT
lb/ft
OD
Wall
thick
ID
Drift
dia.
Slip
Cup Packer(BPM)
Stabbing Guide
Packer Cap
7-3/4
46.10
196.85
15.11
166.63
165.10
9556910158
5303940440 (75B)
9556901178
9556902178
7-3/4
46.10
196.85
15.11
166.63
163.45
9556910158
5303940440 (75B)
9556901178
9556902178
8-5/8
24.00
219.08
6.71
205.66
202.48
9556910198
5303940400 (9D)
9556901198
9556902198
8-5/8
28.00
219.08
7.72
203.64
200.46
9556910198
5303940400 (9D)
9556901198
9556902198
8-5/8
32.00
219.08
8.94
201.20
198.02
9556910188
5303940410 (8A)
9556901188
9556902188
8-5/8
36.00
219.08
10.16
198.76
195.58
9556910188
5303940410 (8A)
9556901188
9556902188
8-5/8
40.00
219.08
11.43
196.22
193.04
9556910188
5303940410 (8A)
9556901188
9556902188
8-5/8
44.00
219.08
12.70
193.68
190.50
9556910188
5303940420 (8B)
9556901188
9556902188
8-5/8
49.00
219.08
14.15
190.78
187.60
9556910188
5303940420 (8B)
9556901188
9556902188
9-5/8
32.30
244.48
7.92
228.64
224.66
9556910215
5303940240 (9A)
9556901215
9556902215
9-5/8
36.00
244.48
8.94
226.60
222.63
9556910215
5303940240 (9A)
9556901215
9556902215
9-5/8
40.00
244.48
10.03
224.40
222.25
9556910215
5303940240 (9A)
9556901215
9556902215
9-5/8
40.00
244.48
10.03
224.40
220.45
9556910215
5303940240 (9A)
9556901215
9556902215
9-5/8
43.50
244.48
11.05
222.38
218.41
9556910215
5303940250 (9B)
9556901215
9556902215
9-5/8
47.00
244.48
11.99
220.50
216.54
9556910215
5303940250 (9B)
9556901215
9556902215
9-5/8
53.50
244.48
13.84
216.80
215.90
9556910198
5303940250 (9B)
9556901215
9556902215
9-5/8
53.50
244.48
13.84
216.80
212.83
9556910198
5303940250 (9B)
9556901215
9556902215
9-5/8
58.40
244.48
15.11
214.25
212.72
9556910198
5303940390 (9C)
9556901198
9556902198
9-5/8
58.40
244.48
15.11
214.25
210.29
9556910198
5303940390 (9C)
9556901198
9556902198
9-5/8
59.40
244.48
15.47
213.50
209.58
9556910198
5303940390 (9C)
9556901198
9556902198
9-5/8
64.90
244.48
17.07
210.30
206.38
9556910198
5303940390 (9C)
9556901198
9556902198
9-5/8
70.30
244.48
18.64
207.20
203.23
9556910198
5303940400 (9D)
9556901198
9556902198
9-5/8
75.60
244.48
20.24
204.00
200.02
9556910198
5303940400 (9D)
9556901198
9556902198
Page 40 of 45
BPM
XTG SM

Wall
thick
WT/FT
OD
lb/ft
mm
9-5/8
32.30
244.48
7.92
228.60
9-5/8
36.00
244.48
8.94
9-5/8
40.00
244.48
9-5/8
40.00
9-5/8
Drift
dia.
Slips
Cup Packer
(Global)
Stabbing Guide
Seal Cap
224.66
9559510222
5303940240 (9A)
9559512210
9559500025
226.60
222.63
9559510210
5303940240 (9A)
9559512210
9559500025
10.03
224.40
220.45
9559510210
5303940240 (9A)
9559512210
9559500025
244.48
10.03
224.40
222.25
9559510210
5303940240 (9A)
9559512210
9559500025
43.50
244.48
11.05
222.38
218.41
9559510210
5303940250 (9B)
9559512210
9559500025
9-5/8
47.00
244.48
11.99
220.50
216.54
9559510210
5303940250 (9B)
9559512210
9559500025
9-5/8
53.50
244.48
13.84
216.80
212.83
9559510210
5303940250 (9B)
9559512210
9559500025
9-5/8
53.50
244.48
13.84
216.80
215.90
9559510210
5303940250 (9B)
9559512210
9559500025
9-5/8
58.40
244.48
15.11
214.25
212.72
9559510210
5303940390 (9C)
9559512210
9559500025
9-5/8
58.40
244.48
15.11
214.25
210.29
9559510210
5303940390 (9C)
9559512210
9559500025
10-3/4
32.75
273.05
8.89
255.30
251.31
9559510245
5303940320 (10A)
9559512235
9559513235
10-3/4
45.50
273.05
10.16
252.70
248.77
9559510245
5303940320 (10A)
9559512235
9559513235
10-3/4
45.50
273.05
10.16
252.70
250.82
9559510245
5303940320 (10A)
9559512235
9559513235
10-3/4
51.00
273.05
11.43
250.20
246.23
9559510235
5303940320 (10A)
9559512235
9559513235
10-3/4
55.50
273.05
12.57
247.90
243.94
9559510235
5303940330 (10B)
9559512235
9559513235
10-3/4
55.50
273.05
12.57
247.90
244.48
9559510235
5303940330 (10B)
9559512235
9559513235
10-3/4
60.70
273.05
13.84
245.40
241.40
9559510235
5303940330 (10B)
9559512235
9559513235
10-3/4
65.70
273.05
15.11
242.80
238.86
9559510235
5303940330 (10B)
9559512235
9559513235
Labels
mm
ID
mm
mm
Page 41 of 45
BPM
XTG SM

Wall
thick
WT/FT
OD
lb/ft
mm
11-3/4
42.00
298.45
8.46
281.50
11-3/4
42.00
298.45
8.46
11-3/4
47.00
298.45
11-3/4
54.00
11-3/4
Drift
dia.
Slips
Cup Packer
(Global)
Stabbing Guide
Seal Cap
277.50
9559510270
5303940340 (11A)
9559512260
9559513260
281.50
279.40
9559510270
5303940340 (11A)
9559512260
9559513260
9.53
279.40
275.44
9559510270
5303940340 (11A)
9559512260
9559513260
298.45
11.05
276.40
272.39
9559510260
5303940340 (11A)
9559512260
9559513260
60.00
298.45
12.42
273.60
269.65
9559510260
5303940350 (11B)
9559512260
9559513260
11-3/4
60.00
298.45
12.42
273.60
269.88
9559510260
5303940350 (11B)
9559512260
9559513260
13-3/8
54.50
339.73
9.65
320.4
316.46
9559510310
5303940360 (13A)
9559512305
9559513305
13-3/8
61.00
339.73
10.92
317.9
313.92
9559510305
5303940360 (13A)
9559512305
9559513305
13-3/8
68.00
339.73
12.19
315.3
311.38
9559510305
5303940370 (13B)
9559512305
9559513305
13-3/8
72.00
339.73
13.06
313.60
309.65
9559510305
5303940370 (13B)
9559512305
9559513305
13-3/8
72.00
339.73
13.06
313.30
311.15
9559510305
5303940370 (13B)
9559512305
9559513305
Labels
mm
ID
mm
mm
Page 42 of 45
BPM
XTG SM
Appendix BSpare Parts List

1XTG140 Spare Parts List
No.
Part Name
Part No.
Qty./Set
Notes
1.1
Slip Die
9554500114
covering casing OD (mm) 114
1.2
Slip Die
9554500127
covering casing OD(mm) 127
1.3
Slip Die
9554500140
covering casing OD(mm) 140
1.4
Cushion
9554500007
for center pipe
1.5
Hex. Socket Set Screw
4201030160
for center pipe
1.6
Hydraulic Hoses
9559500500
one set
1.7
Seals Pack
9556900900
one set, for actuating cylinder
Notes

No.
Part Name
Part No.
Qty./Set
2.1
Slip
9556910146
covering casing ID (mm)

150158
2.2
Slip
9556910158
1
158173
2.3
Slip
9556910178
1
173188
2.4
Slip
9556910188
1
188203
2.5
Slip
9556910198
1
203218
2.6
Slip
9556910215
1
218230
2.7
Thrust Ball Bearing
9557001200
for coupler ring
2.8
Hex. Socket Cap Screw
4202300010
for die block
2.9
Snap Ring
4206022580
for die block
Page 43 of 45
BPM
XTG SM
No.
Part Name
Part No.
Qty./Set
Notes
2.10
4201030840
for slip mandrel
2.11
Snap Ring
4206022010
for slip mandrel
2.12
Spring
0602020580
for slips
2.13
Hydraulic Hoses
9559500500
one set
2.14
Seals Pack
9556900900
one set, for actuating cylinder
Notes

No.
Part Name
Part No.
Qty./Set
3.1
Slip
9559510210

214228
3.2
Slip
9559510222
1
228240
3.3
Slip
3.4
Slip
3.5
Slip
3.6
Slip
9559510235
9559510245
9559510260
9559510270
240252
252263
266278
278288
3.7
Slip
9559510305
1
311320
3.8
Slip
9559510310
1
320326
3.9
Thrust Ball Bearing
9559510026
for coupler ring
3.10
Hex. Socket Cap Screw
4202300010
for die block
3.11
Snap Ring
4206022580
for die block
3.12
4201030960
for slip mandrel
Page 44 of 45
BPM
XTG SM
No.
Part Name
Part No.
Qty./Set
Notes
3.13
Snap Ring
4206022010
for slip mandrel
3.14
Spring
0602020660
for slips
3.15
Hydraulic Hoses
9559500500
one set
3.16
Seals Pack
9556900900
one set
Appendix COptional Auxillary System

No.
Part Name
Part No.
Qty./Set
Notes
C.1
Video Monitoring System
9556900510
Optional
C.2
Ex-proof Laptop
Computer (Casing
Running Operation
Software Installed)
3601060190
Optional, for torque and turns

monitoring and recording
Appendix DCorollary Tools

No.
Part Name
Part No.
Qty./Set
Notes
D.1
Corollary Tools
9556900913
Optional
Page 45 of 45

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Casing Running System (CRS)

Beijing Petroleum Machinery Co.

No. 41 Zhixin Road,Haidian District, Beijing 100083, China

13. Spare Parts and Corollary Tools ................................................................................... 35

CRS Operation Manual

The note symbol indicates that additional information is provided about

The caution symbol indicates that potential damage to equipment, or

The warning symbol indicates a definite risk of equipment damage or

CRS Operation Manual

4. Structure and Working Principles

CRS Operation Manual

1. Mandrel 2. Cylinder 3. Coupler Ring 4. Retainer Ring

CRS Operation Manual

1. Mandrel 2. Cylinder 3. Coupler Ring 4. Slip Housing 5. Links

CRS Operation Manual

1. Top Drive System 2. Elevator Links

CRS Operation Manual

Fig. 4 Self-locking Mechanism

CRS Operation Manual

Rated Hoist Load

Rated Torque Load

4 1/2 IF or 6 5/8 REG BOX

16MPa (rated), 10.5MPa (rated)

6. Hoisting and Storage

CRS Operation Manual

7. Installation and Testing

CRS Operation Manual

1 Hoist CRS with Shipping

2Adjust the Shipping Frame

Frame to Rig Floor

3Align the Connection Thread

to Fit with Rotary Table

4Make up the Connection

of the CRS and Top Drive

through Torque Wrench

CRS Operation Manual

Fig. 6 CRS Anti-rotation Bracket and Installation

CRS Operation Manual

8. Application and Operations

CRS Operation Manual

1. Protector of the Female Casing Thread 2. Casing Couping

CRS Operation Manual

8.2 Casing Running

CRS Operation Manual

(2) Casing Running Procedure:

Fig.8 Have the Casing Held in Elevator

Fig.9 Hoist the Casing and Prepare for Connection

CRS Operation Manual

CRS Operation Manual

9. Intelligence Aided Equipment

CRS Operation Manual

Fig.10 CRS Operation Software Interface

Fig.11 Video Monitoring System

CRS Operation Manual

10. Maintenance and Repair of the Internal Gripping CRS

Inspection and Maintenance during the casing running operation

CRS Operation Manual

Routine Inspection and Maintenance

Check the locations where grease is needed.

CRS Operation Manual