E!i!!

4s

Society of Petroleum Engineers

SPE 46052
High Strength Coiled Tubing
Robert P. Badrak, P.E. / Precision Tube Technology

Cor@ght

189S, Scclety

of Pelmfeum

Engfneem,

The advances in coiled tubing diameter, coiled tubing

length, strength level, quality, and corrosion resistance have in
many instances been the impetus behind new suticessfhr
applications. There are two purposes of this paper (1) to
inform the reader of the characteristics of these new high
strength grades of coiled tubing and the potential limitations
which must be considered when selecting them and (2) present
the specifics of the high strength grades developed by
Precision Tube Technology. For the purposes of this paper,
high strength coiled tubing is considered to be 90 ksi (620
MPa) minimum specified yield strength and higher.

Inc.

This paper wss preparwd for presentation at the 1998 SPE/lCoTA

held in Hcvslon, Teas, 15-18 April 1998.

Coiled

Tubing

Roundteble

This psper was sefected for presentation by an SPS Pregrsm Ccmmittee following review of
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Abstract

History and Status of Coiied Tubing Strength

An overview of higher strength coiled tubing is presented with

the advantages and disadvantages associated with the higher
strength grades. The advantages include increased tensile
load, torsion, burst and collapse limits. These increased limits
permit coiled tubing to be used to higher pressures, longer
lengths and increased applications. The disadvantages include
decreased ductility and toughness with increased susceptibility
to environmental cracking.
Knowledge of these advantages and limitations permit safe
use of these higher strength grades of coiled tubing. Data is
presented on a commercially available 90 ksi minimum yield
strength grade with initial test results of a new generation 100
ksi and 110 ksi yield strength grades.

The advances in the coiled tubing strength levels have

come periodically through the years starting with 50 ksi (345
MPa) minimum yield strengths in the early 1960s up to
commercially available 90 ksi (620 MPa) and 100 ksi (690
MPa) grades in the mid - 1990s. A new 110 ksi (758 Mpa) is
being scheduled for introduction this year. The advances in
the strength level of coiled tubing as a function of year is
presented in Figure 1.
The materials used in the manufacture of coiled tubing have
evolved over the years, starting with plain carbon steels in the
1960s and ending with varying grades of low alloy steels in
the 1990s. The attention that needs to be placed on the
material characteristics increases as the strength level
increases. More and more is being demanded of the material.

Keywords: burst pressure, coiledtubing, collapse pressure,

torsion, high strength steel, high strength low alloy steels,
HSLA, mechanical properties, fatigue resistance, sulfide stress
corrosion, SSC

Materiai Property Trends as a Function

Leveis

of Strength

It is evident that the steel grade defines the minimum yield

strength. It is also somewhat evident that, as the yield strength
increases, so does the tensile strength. What is more diftlcult
to predict is some of the other material characteristics which
also have roles in defining the limitations for a particular
grade of material. These characteristics include composition,
ductility, toughness, high cycle fatigue life, low cycle fatigue
life, hardness, type of microstructure, and weldability.
These characteristics change (or trend) in specific ways as a
function of coiled tubing strength level. These characteristics
are also intertwined in that they change together or effect one
another. Three of these characteristics (composition, ductilit y,
and hardness) are discussed below.

Introduction

The search for increased capability and performance in

coiled tubing has been one of fie hot topics in tubing
materials. Many of the new applications in coiled tubing are
dependent upon pushing the boundaries which include
strength level. It is the availability of larger, stronger coiled
tubing that have permitted many of the new applications.
Coiled tubing has expanded into diverse activities such as
drilling, well logging, gas lift, acidizing/fracturing, injection,
production strings, and sand control, Coiled tubing or pipe
has also been also used for flo-wlineand pipeline applications.
209

RF. BADRAK

SPE 46052

directly with increasing strength levels. A 2 OD 0.175 wall

thickness has a 70,200 Ibs (31 840 kgf) minimum tube body
load based on yield strength of 70 ksi (482 MPa). This same
tube has a 110,300 lbs (50030 kgf) minimum tube body load
based on yield strength of 110 ksi (758 MPa). The tube body
load relates directly to the weight sustainable by the coiled
tubing before yielding and is the primary factor in determining
maximum length of the coiled tubing string.

Compositions. Aspreviously noted, thecoiled tubing

materials have evolved from the carbon steels to the high
strength Iow alloy steel categories over the years which have
allowed theuseofincreasing
strength levels. Though mostof
these alloy additions are very small, sometimes referred to as
micro-alloying, they htive a tremendous impact on final
delivered properties. In micro-alloyed steel, niobium, (Nb),
titanium (II) and vanadium (V) form carbides and carbonitrides in steel. Especially for the high strength grades of
coiled tubing, the controlled rolling sequence at the mill
becomes more important. The Nb, Ti, & V carbides and
carbo-nitrides will precipitate as a function of rolling
temperature. These fine dispersions control grain size and
increase strength levels. Most of todays coiled tubing will be
in the high strength low alloy class of steels and will contain
one or more of the above micro-alloying additions.
Other additives, most notably manganese, chromium,
molybdenum and tungsten, are added in controlled amounts to
increase strength levels. These strengthening additives
kcome increasing important as the wall thickness increases.
The higher strength grades will contain increased quantities of
these strengthening additives.
There are elements which are added to the steel which,
while not strongly affect ing the strength level, plays a major
role in defining the ranges of ductility, toughness and
corroskm resistance. Two of these elements are nickel and
copper. The higher strength steels should contain one or both
of these elements to enhance these other properties at the
higher strength levels.

Torsional load increases in a similar manner, using the same

tubing described above (minimum wall thickness condition),
coiled tubing would exhibit a torsional yield of 2741 ft-lbs
(3716 J) based on a 70 ksi (482 MPa) yield strength whereas
this torsional yield value would increase to 4307 tl-lbs (7919
J) based on a 110 ksi (552 MPa) yield strength.
When combined loading is considered, the yield strength
combined with geometric effects also determines the collapse
and burst limits under tensile stresses. For a background on
the mathematical treatment for calculating combined loading
effects on burst and collapse, the reader is directed
elsewhere234.The burst and collapse pressures are calculated
as follows:
Pcollapse=-(-o + SQRT(4YS2-3 2)/2c

And
Pburst=W f * (O (b-l)+ SQRT(O z (b-l )+4f(YS-02))

Hardness. Hardness is directly related to tensile strength. As

the strength grade increases, the tensile strength and, therefore,
hardness increases. The potential problem with the higher
strength grades, especially the 100 ksi (690 MPa) and 110 ksi
(758 MPa) yield strength grades, is that the hardness may
increase to a level at which other properties degrade
appreciably notably ductility, toughness and resistance to
sulfide stress corrosion cracking. Typical and maximum
harnesses as a fimction of coiled tubing strength grade are
presented in Table 1,

Where

o = load on tubing
YS = yield strength
b = (OD2+ID2)/(OD2-ID2)
c = 20EW(OIY-1D2)
f= W+b+l

Using the above equation for burst on the same tube example
(constant OD of 2 and wall thickness of O.175) and varying
the yield strength from 70 ksi (482 MPa) to 110 ksi (758
MPa), we obtain the relationship between burst pressure and
yield strength that is presented in Figure 2.

There are many factors which relate to ductility,

but, as a general trend with all other things being equal, as the
strength level increases, the ductility decreases. This trend can
be observed in coiled tubing manufacturers specifications and
in recognized industry standards such as the ASTM
specifications. A generic listing of typical minimum tensile
elongation for coiled tubing is presented in Table 2. This
decrease can be dramatic and has implications extending to
probability for fracture, defect tolerance, fatigue life, etc.

Ductility.

High Strength

Using the previously presented equation for collapse with the

same tube geometry and varying the yield strength from 70 ksi
(482 MPa) to 110 ksi (758 MPa), we obtain the relationship
between collapse and yield strength that is presented in Figure
3.
From the above relationships, it is appeam that the operational
boundaries are directly related to limitations in yield strength.
This is somewhat true but tempered by the effects of tensile
strength, ductility, toughness and corrosion resistance. These
other attributes impose restrictions that limit the applicable
strength range.

Coiled Tubing Advantages

l%edrivers behind increasing coiled tubing strength levels are

the corresponding operational advantages that result. For
example, the tube body load bearing capacity increases
210

HIGH STRENGTH

SPE 46052

High Strength

Coiled Tubing

COILED TUBING

and Gas Industry to predict and ensure adequate resistance to

SSC. The NACE Standard MR01755 requires a 22 Rockwell
C hardness maximum for carbon and low alloy steels for
service in sour H2S containing environments. The API
Standard 5C@ for oil country tubular goods requires the
hardness to be 23 Reckwell C maximum for L80 grade and
25.4 Rockwell C maximum for C90 and T95 grades designed
for sour service. The hardness, as previously presented, is
related to the material strength level.
One researcher demonstrated that in a three point bend test
for 90 ksi (621 MPA) minimum yield strength casing steels
designed for sour service, the SSC resistance decreased as the
hardness increased. This relationship is presented in Figure 4
where Sc is a measure of SSC resistance (higher numbers
equate to higher resistance).

Disadvantages

The disadvantages of higher strength coiled tubing relate to

decreases in ductility and toughness and increases in
susceptibility to environmental cracking. There are generally
cost implications as weIl; tubing and operational costs are
higher. The cost of the tubing supplied generally increases
with increasing yield strength due to processing and material
costs related to the manufacture of the tubing. The operational
costs are generally higher with the very high strength grades
because of decreased_product life due to the limitations that
correspond with the high strengths such as lower fatigue life,
susceptibilityy to environmental cracking, and lower fracture
resistance.
he ductility and toughness constraints limit the use of high
strength coiled tubing. As an example, it is for this reason that
pipeline applications are strength limited. The limitations
there are based upon ductility, field welding and toughness;
the consequences of a brittle failure are too great to justify the
risk. For downhole applications, the constraint is less but is
present because premature failures crwrya price tag that may
not justify the use of coiled tubing at or above 100 ksi (690
MPa).
This ductility/toughness constraint is exasperated by the
trend towards thinner walls with increasing strength levels.
As the thickness decreases, the size of the flaw and percentage
of the remaining wall thickness becomes much more
important; the critical flaw size, as a percentage of wall
thickness, increases. The critical flaw size is the size of a flaw
that results in rapid fracture. In practical terms, increasing
strength and decreasing wall thickness deereases the size of a
flaw or defect at which rapid fracture or failure can occur, In
practical terms, this means that a 1/32 (0.8 mm) flaw size
which is acceptable and inconsequential at 80 ksi (621 MPa)
with a given wall thickness may need to be reduced to 1/64
(0.4 mm) at 100 ksi (690 MPa). The problem is obvious when
a tube inspection is performed using 1/16 or 1/32 calibration
standwds on a 100 ksi (690 MPa) grade of coiled tubing
which may contain undetected critical sized flaws which could
result in premature failure.
An additional, and very often the most limiting, problem
with higher strength materials is the increased susceptibility to
environmental cracking, Though other environmental
cracking failure mechanisms are possible, sulfide stress
corrosion (SSC) cracking is the one that most concerns us that
supply low alloy steel products to the Oil and Gas Industry.
When metals are exposed to an environment containing HzS,
the metal can become embrittled and crack or fail. This
embrittlement is called SSC. For SSC to occur, a combhation
of a susceptible material, an environment containing H2S, and
stress are required. Whhin the 011 and Gas Industry, most
producing wells contain at least a small amount of HZS. Most
structures, including coiled tubing, are subjected to high stress
levels during service. Therefore, the resistance of the coiled
tubing to SSC and the factors that govern the materials
resistance are important to our industry.
The hardness of a material has been widely used in the Oil

Development

of High Strength

Coiled Tubing

The development of a new generation of high strength

coiled tubing materials was focused on minimizing the
disadvantages of high strength coiled tubing previously
discussed rather than focusing on achieving a specific yield
strength goal. As a resuIt several materials/processing
candidates were developed and are reported herein.
The trends between H2S, yield strength, tensile strength and
hardness indicated that a 90 ksi could be developed
maintaining good resistance to SSC whereas a 104Iksi grade
or higher yield strength grades would predictably exhibit a
reduced resistance to environmental cracking. Because of
this, the ensuing investigation centered in two areas. The first
area was modifying existing chemistry and manufacturing
processes in a manner that would result in a 90 ksi (621 MPA)
coiled tubing grade and the second area was taking a fresh
look at materials technology to produce a 100 ksi (690 MPa)
and 110 ksi (758 MPa) grades of coiled tubing.
The results of this research with respect to SSC resistance,
ductility, hardness, and fatigue life are presented below.
SSC Resistance. The current class of HSLA steels used to
make the 70 ksi (482 MPa) and 80 ksi (552 MPa) specified
minimum yield strength levels from have been tested and
found to exhibit very good resistance to SSC*9. There exists a
Lwgeamount of successful field experience with these two
strength levels. These materials have controlled strength and
hardness levels that are in compliance with NACE MR0175.
It was also demonstrated that a 90 ksi (621 Mpa) coiled tubing
that is also manufactured with controlled strength level range
and hardness range toNACEMRO175 demonstrated excellent
resistance with threshold stress levels to SSC up to the actual
yield strength9. In that recent study both 4 point bent beam
tests and C-ring tests in accordance with NACE TM0177
Method C*(but using ID tensioning) were used in the
standard NACE environment composed of 1 atmosphere H2S,
5% sodium chloride, 0.5% acetic acid in deionized water that
yielded an initial pH of about 2,7.
C-ring tests were conducted on the new 100 ksi (690 MPa)
grade of coiled tubing in this same aggressive environment

211

R.P. BADRAK

and the results indicated a threshold stress that was at least

90% of the specified minimum yield strength. However, these
same tests indicated that the threshold stress in the weld region
was below this 90% value. The results of these tests are
presented in the Table 3.

SPE 46052

3)

4)

Fatigue Resistance. Though fatigue tests are still in progress

as of press time, initial results are very promising with the 100
ksi (690 MPa) grade exhibiting excellent fatigue resistance.
The fatigue tests on the 110 ksi (758 MPa) have just staxted as
of press time. The initial fatigue results are presented in
Figure 4.

References

1)

The 100 ksi (690 Mpa) coiled

tubing grade development has been very promising with a 105
ksi (724 MPa) actual yield strength coiled tubing resulting in
maximum base tube harnesses of 22 I-EW and maximum
weIdmetal/heat affected zone harnesses in the 21-24 I-EW
range. The fill tube tensile tests have resulted in elongations
over 30%. The 110 ksi (758 MPa) coiled tubing grade
development tests results show elongations of about 25% with
an actual yield strength of115 ksi (793 MPa). As expected,
the harnesses in this grade were higher with maximum tube
harnesses of 24 HRC and maximum weldmetal/heat affected
zone harnesses in the 23-26 HRC range.
Ductility and Hardness.

2)
3)

4)

5)

6)

Discussion

llough the results reported herein are very promising, they

are based on several small trial batches of coiled tubing and
two gage thicknesses (0. 134 and O.156) of a full production
heat. The final properties ranges that will finally be produced
and marketed may change once the variations between heats
are more fidly documented. Therefore, the information is
presented as results that we have to date and not published
guarantees of minimum properties.
The other caution is a reiterated one; there is a sacrifice that
is made when higher and higher strength levels are achieved;
this is a sacrifice in ductility and resistance to environmental
cracking (SSC). Though the results are very good in the high
strength grades developed and reported herein, they still
represent decreases in ductility and SSC resistance. The
successful applications of these very high strength grades
requires additional upfront analysis to prevent premature
failures.

7)

8)

9)

10)

Conclusions

From the investigation of higher strength coiled tubing, the

following conclusions have been made:
1)

2)

resistance.
There is a commercially availabIe 90 ksi (621 MPa)
SMYS coiled tubing that exhibits good ductility and
resistance to SSC.
Initial results of new 100 ksi (690 MPa) and 110 ksi
(758 Mpa) scheduled have been very promising.

There is a need for higher strength coiled tubing;

longer tubing strings and higher pressure capability
result in increased applications for coiled tubing.
There are disadvantages associated with high strength
coiled tubes that include decreased ductility and SSC
212

ASTM Standard A607, Specification for Steel, Sheet

and Strip, High-Strength, Low-AIloy, Columbium or
Vanadium, or Both, Hot-Rolled and Cold-Rolled,
American Society for Testing and MateriaIs,
Philadelphia,PA
Coiled Tubimz Technical Har@!zQ& Precision Tube
Technology, Houston, TX, January, 1997.
API Bulltin 5C3, Bulletin on Formulas and
Calculations for Casing, Tubing, Drill Pipe, and Line
Pipe, failures in Coiled Tubing, 6th cd., API,
Washington, D.C., 1994.
Ken Newman, SPE 323131, Coiled Tubing Pressure
and Tension Limits, Offshore Euro~e Conference
Aberdeen, United Kingdom, September, 1991.
NACE Standard MR0175, Sulfide StressCracking
Resistant Metallic Materials for Oilfield Equipment,
NACE International, Houston, TX
API Specification 5CT, Specification for Casing and
Tubing, American Petroleum Institute, Washington,
D.C.
A. Ikeda et al, Development of High Strength OiI
Country Tubulrw Goods Highly Resistant to Sulfide
Stress Corrosion Cracking, reprinted in~
~ rrosion in il an
tin___
of Classic PaDer,s,edited by R.N. Tuttle and R,D.
Kane, NACE International, Houston, TX, 1981, p.
548-557
M.S. Cayard and R.D. Kane, SPE 38410
Serviceability of Coiled Tubing for Sour Oil and
Gas Wells, 2ti SPWICOTA North American Cu
Tubing Roundtable, Montgomery, Texas, April,
1997.
R.P. Badrak, High Strength Materials for Coiled
Tubing, 6th International Conference on ~w~
Tubing Technologies, October 27-29, Houston, TX
NACE Standard TM0177, Laboratory Testing of
Metals for Resistance to Sulfide Stress Cracking in
H2S Environments, NACE International, Houston,
TX.

HIGH STRENGTH COILED TUBING

SPE 46052

TABLE 1: Harnesses Associated With Yield Strength

Yield Strength

Figure 1: Chronology of CT Strength Increase

Typical Hardness Range

100

80

85-94 Rockwell B

70 ksi (483 MPa)

I

80 ksi (552 MPa)

90-98 Rockwell B

90 ksi (621 MPa)

94 HRB-22HRC

100 ksi (690 MPa)

20-25 Rockwell C

110 ksi (758 MPa)

22-28 Rockwell C

Note: All hardness values are rough estimates.

I

20

o
65

70

75

80

85

90

95

Year

TABLE 2: Elongation Trend With Yield Strength

Yield Strength

Minimum Elongation

70 ksi (483 MPa)

30%

80 ksi (552 MPa)

28%

90 ksi (621 MPa)

2570

100 ksi (690 MPa)

22% (see note)

110 ksi (758 MPa)

18% (see note)

Note: Elongation estimated for 100 and 110 grades.

Figure 2: Burst Pressure as a Function of YS

22000-

TABLE 3: SSC Test Results on HSI 00 Grade

~

Applied
Stress
90 ksi

Sample Description

non-welded
C-ring
non-welded
C-ring
welded Cring
welded Cring
I

C-ring

Results

Actual YS

no cracks

105 ksi

C-ring

70 ksi

105 ksi

no cracks

C-ring

90 ksi

105 ksi

cracks

210C0

;lm

-.

. . ..-.

. . . .

- ,--170eo

15cN)o-

llcxx)rtcoo-t

213

---

%
\

150cQ200c04sOoo

70

ksi

--90ksi

--%.

glsooil.

no cracks

105 ksi

70 ksi
I

.
-.

_-

600007mm

Tubing Load, psi

C-ring

-..

.llOksl

R.P, BADRAK

SPE 46052

Figure 3: Collapse Pressure as a Function of YS

Tubing Load, pal

15000 30000

45000

60000

75000

90000

ksi

70

- 90 ksi
.-.
-11 Oksi

*.
**-18000 1

..

figure 4:

19

20

Hardness vs SSC Resistance

21

22

23

24

25

26

27

28

29

HRC

Hardness,

Figure 5: HSI 00 Fatigue Results

!5
5
u)
g .~
z Q
c
$

5000
4000
3000
2000

1000
o
o

200

400

600

Cycles to Failure

800