Case Study: Power Catwalk Handles 8,882m Ultra-Deep Well — Zero Safety Incidents Across 50,000+ Pipe Joints
At a Glance
- Customer: Western Drilling Engineering Co., Ltd. (CNPC), Team 90008
- Location: Tarim Basin, Xinjiang, China
- Well Depth: 8,882 m — Asia’s deepest onshore vertical well at the time
- Equipment: Jingtao Energy full-electric power catwalk, automated pipe handling system
- Deployment: 2018–present, 20+ drilling teams, 50,000+ pipe joints handled
- Key Result: Zero safety incidents, 99.2% system availability over 14 months, 40–60% faster rig moves
The Challenge
On a drilling rig, every meter deeper adds weight, complexity, and risk. At 8,882 meters — a depth where bottomhole temperatures exceed 180°C and drill string weight surpasses 200 tons — the margin for error vanishes. Traditionally, pipe handling at this depth requires 3–4 crew members working on the pipe rack and catwalk, manually rolling, aligning, and feeding drill pipe, casing, and tubing to the rig floor. Each joint weighs up to 2,100 kg. A single misalignment can damage threads, crush hands, or worse — and at these depths, a dropped string costs hundreds of thousands of dollars in fishing operations and non-productive time.
Team 90008, operating under CNPC’s Western Drilling Engineering Co., faced exactly this scenario. The Tarim Basin’s ultra-deep wells — often exceeding 7,500 m — demanded a pipe handling solution that could operate continuously in temperatures ranging from -30°C winter nights to +50°C summer days, with zero tolerance for downtime. Manual handling was not just a safety liability; it was the bottleneck limiting drilling speed and rig move efficiency.
The Solution
Jingtao Energy deployed its full-electric power catwalk — a fully automated pipe handling system that replaces manual labor across the entire pipe transfer chain, from the pipe rack to the rig floor.
The system is built on a modular, all-electric servo drive platform:
- Pipe range: Drill pipe 2-7/8 in to 5-1/2 in, casing up to 14 in, tubing — covering every tubular on a drilling rig
- Maximum single-joint weight: 2,100 kg (standard arm) / 5,000 kg (heavy-duty arm option)
- Rated depth capacity: 12,000 m — validated in the field at 8,882 m
- Drive: Full-electric servo motors, delivering full rated torque from -30°C to +50°C without performance degradation
- Control: IP65 positive-pressure explosion-proof cabinet with independent CAN bus nodes per axis, enabling real-time fault isolation
- Integration: Compatible with iron roughneck, pipe racking system, and automated driller’s cabin
The catwalk is manufactured under ISO 9001 / 14001 / 45001 certified quality systems, backed by 10+ patents and a joint R&D program with China University of Petroleum, Provincial Academy of Sciences, and Shengli Drilling Technology Research Institute. Annual production capacity exceeds 200 units, servicing both Sinopec and CNPC drilling operations.
Implementation
Western Drilling Engineering began deploying Jingtao power catwalks across its fleet in 2018. The rollout prioritized ultra-deep well teams operating in the Tarim Basin, where well depths exceeding 7,000 m are routine and the financial consequence of downtime is highest.
Team 90008 received the system as part of its rig upgrade package for the landmark 8,882 m well. Installation was completed during a scheduled rig move, without extending the mobilization window. The catwalk’s modular skid-mounted design — pre-wired, pre-commissioned at the factory — meant the rig crew could begin using it within 48 hours of positioning.
Over the 14-month campaign at this depth, the system operated at 99.2% availability. The only downtime events were scheduled preventive maintenance — lubrication checks and CAN bus node diagnostics — each completed in under 30 minutes without interrupting drilling operations.
Results
| Metric | Before (Manual) | After (Jingtao Catwalk) |
|---|---|---|
| Crew per pipe handling shift | 3–4 workers | 1 operator (remote) |
| Rig move duration | 15–20 days | 7–10 days (40–60% faster) |
| Safety incidents (pipe handling) | Industry avg: 3–5/year per rig | 0 — across all deployments, 50,000+ joints |
| System availability | N/A | 99.2% (14 months, Team 90008) |
| Pipe thread damage | 2–4% rejection rate | Below 0.2% (precision servo alignment) |
| Single ultra-deep well cost saving | — | $412,400 (NPT + crew + rig day savings) |
Across the broader fleet — 20+ drilling teams operating in Xinjiang, Sichuan, and offshore Bohai Bay — the power catwalk has handled over 50,000 pipe joints with zero safety incidents. Rig move efficiency gains of 40–60% translate directly into more wells drilled per year per rig, compressing the break-even timeline for ultra-deep exploration programs.
Why This Matters
- Human cost eliminated. Every joint that the catwalk handles is a joint a crew member doesn’t have to physically manipulate — at 2,100 kg per joint, that is a catastrophic-injury risk removed 50,000 times over.
- Ultra-deep wells unlocked. As operators push past 10,000 m, manual pipe handling becomes physically impossible. The catwalk’s 12,000 m design rating makes it a prerequisite, not an option.
- Faster rig moves = more wells. Shaving 5–10 days off each rig move compresses the entire drilling program cycle. For a fleet of 20 rigs, this is equivalent to adding 2–3 rigs of capacity without capital spend.
- Supply chain ready. With annual production capacity of 200+ units and both Sinopec and CNPC supplier qualification, the catwalk is available at scale for international operators.
Explore Products
- Automated Pipe Handling Catwalk for Drilling Rigs — full specifications
- Oilfield Associated Gas Generator (JTF Series) — powering remote rig operations
- Contact Jingtao Energy — request a quote or schedule a video factory inspection
Related Resources
- Wall-Climbing Robots: 3 Years of Field Adoption Data
- Solving Oversized Motor Syndrome: SRM Motors for Low-Productivity Wells
- Case Study: JT Robot Eliminates Confined Space Risk
- Case Study: Associated Gas Power Solution — Middle East
Frequently Asked Questions
What is the maximum depth a power catwalk can handle?
The Jingtao Energy power catwalk is design-rated for 12,000 m and field-validated at 8,882 m — Asia’s deepest onshore vertical well, drilled by CNPC Team 90008 in the Tarim Basin. The system handles drill pipe up to 5-1/2 in, casing up to 14 in, and single-joint weights up to 2,100 kg (5,000 kg with heavy-duty arm option).
How does the electric catwalk perform in extreme temperatures?
The all-electric servo drive platform delivers full rated torque from -30°C to +50°C without performance degradation. The IP65 positive-pressure explosion-proof control cabinet protects electronics from dust, moisture, and hazardous-area gas ingress. Independent CAN bus nodes per axis allow real-time fault isolation.
What certifications does the catwalk carry?
The system is manufactured under ISO 9001 (quality), ISO 14001 (environmental), and ISO 45001 (occupational health and safety) certified management systems. Jingtao Energy holds 10+ patents related to automated drilling support equipment and is a qualified supplier to both Sinopec and CNPC.
How fast can a power catwalk be deployed on an active rig?
The modular skid-mounted design is pre-wired and pre-commissioned at the Jingtao factory. After positioning on-site, the rig crew can begin operations within 48 hours. The system is typically installed during a scheduled rig move — no additional mobilization window is required. Standard lead time for new orders is 12 weeks.
What is the total cost savings per ultra-deep well?
Based on Team 90008’s operational data, a single ultra-deep well (8,000+ m) saves approximately $412,400 through reduced non-productive time, crew reduction, faster rig moves, and near-zero pipe thread damage. For a drilling program of 5+ ultra-deep wells, the catwalk pays for itself within the first two wells.