SPE 89505
Reverse Circulation With Coiled Tubing - Results of 1600+ Jobs
Michel, Charlie (BP); Stephens, Rodney (BP); Smith, David (Oxy); Crow, Walter (BP); King, George E. (BP)
Copyright 2004, Society of Petroleum Engineers Inc.
This paper was prepared for presentation at the SPE/ICoTA Coiled Tubing Conference and
Exhibition held in Houston, Texas, U.S.A., 23–24 March 2004.
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Abstract: Reverse circulation has always been viewed
with some level of suspicion and reverse circulation with
coiled tubing has often been avoided at all costs. Yet,
results of over 1600 CT operations involving reverse
circulating in Alaska's oil fields, with just a handful of
failures, has proven reverse circulation to be a reliable
procedure for a specific range of solids removal that is
extremely effective in removing sand fill from wells
with very large tubulars and in high deviations. Results
from North Sea, Colombia, California and the US GoM
are also included. This paper presents the basics of
reverse circulation designed specifically for coiled
tubing; including necessary surface equipment, BHA
nozzle design, pump requirements, fluid rates, and
procedures to reduce the potential for problems. The
procedures and job overviews contained here were
contributed during an ICOTA panel discussion on
reverse circulating, held September 18, 2003, in
Houston, TX.
Introduction: Reverse circulation utilizing coiled tubing
provides many opportunities to improve interventions,
lower cost and reduce operation time. As with any
process, there are both risks and rewards. Reverse
circulating is an accepted method of fluid handling in
certain operations such as drilling1, cementing 2-5,
pickling, free protection and fracturing6, however, the
accepted operations commonly utilize jointed tubing.
Even some experienced coiled tubing users are not
aware that reverse circulating through coil is a common
process and sufficiently widespread to have gained
exposure in most parts of the industry. The results in
this paper cover approximately 1600 jobs in Alaska,
over 28 wells in the North Sea, 36 jobs in Colombia
(deepest is over 16,500 ft), 4 jobs in California, and
several in the US GoM. Of these wells, problems with
reversing were limited to 3 collapses and 2 pinhole
leaks. No loss of well control was experienced and no
coil was stuck in any of the wells that were reversed.
Interestingly, when comparing coil reverse circulating
with forward circulation cleanouts, risk of sticking the
coil in the well is virtually eliminated when using
reverse circulating.
Increasingly, coiled tubing services are called upon to
deliver well work in more demanding areas. CT has
carved out a large niche of common use for well clean-
outs, well kick-offs, and fluid placement. Traditionally,
the mode of use for these operations involving CT has
been forward circulation, i.e. down the coil and up the
coil/production tubing or coil/casing annulus. In many
cases of large casing, heavier fill, deep wells, low
pressure wells and increasing well deviation, normal
circulation does not provide enough circulation rate to
effectively lift particles in the annulus. In many of these
cases, the smaller diameter coil available for a platform
with crane lifting limits, access weight restrictions, local
availability or other limits, is not capable of delivering
the necessary threshold cleanout rate or the cost of
horsepower to overcome friction is too high. In these
cases, reverse circulation opens up potential for CT
application, provided that the risks associated with
reversing through coil can be managed.
One specific example from the North Sea highlights the
capability of reverse circulating with CT in a well where
conventional cleanout, if even possible, would have been
extremely high risk. In a 60o deviation, very low
pressure well with 9-5/8” casing and 3-1/2” tail pipe, fill
was covering a depleted zone and a potential lower pay
zone. Reverse circulating with 1-3/4” coil removed the
debris and uncovered the zone, allowing perforating and
a return to production.
2 SPE 89505
There are significant risks with conventional circulation
through coil when applications on the edge of capability
are attempted. For example, circulation cleanout by 1-
1/2” CT of 7” casing requires relatively high liquid rates
or conversion to more expensive foam systems to enable
lifting of solids in the large annulus. In many cases,
even 1-3/4” coil has experienced difficulties in cleaning
out 7” or larger wellbores. If the well is deviated, lift
difficulty becomes enormously complicated, especially
in the Boycott settling range of 30o to 60o. Without the
fluid-particle coupling benefits of string rotation,
circulation cleanout problems in large annuli or deviated
wells can easily become so severe that cleanouts are not
possible with conventional circulation. In addition,
exposure to equipment/pump failures that can result in
solids fallback and sticking can be reversed by
reverse circulation.
Risks with reverse circulation are certainly present, but
the risks, through engineering knowledge, procedures
and tool design, can be minimized and in most cases
risks are less than for conventional (forward)
circulation cleanout.
Major risks for reverse circulation with coil include well
control concerns when the check valve on the bottom of
the coil is eliminated and coil collapse (pressure
imbalance). Like all processes, reverse circulation is not
a cure-all and candidate selection discipline must be
exercised. Wellbore hydraulics are key to lift of debris
from a wellbore.
Justification for reverse circulating may involve many
factors, including economics. The decision to reverse
circulate may also involve making the job possible and
lowering risk when compared to forward circulation.
Reversing may also produce less total well downtime,
less coil fatigue, and elimination of expensive
circulating fluids.
Reversing actions and basic safeguards are similar in
most applications. In simple terms, a checklist of
actions is useful for outlining the reverse
circulation process
1. There must be sufficient injection to establish a
minimum of 1500 psi surface pressure to
maintain circulation and prevent formation
fluids from entering the wellbore. Cleanout with
reversing technology is possible in low pressure
wells as long as the annular injection is
sufficient to cover losses and still build surface
annular pressure.
2. The rate of penetration, ROP, of the coil through
the debris must be controlled to a rate acceptable
with debris removal from the well. This
requirement is essential in preventing bridging
within the coil. Safe ROP is estimated by
ROP=((return rate in bpm)/(Y*capacity of hole
of casing in bbl/ft)), where Y is a minimum mix
ratio of fluid volume to solid volume, e.g.
usually from about 10 (standard “safe” solids
content to around 6 (heavier solids content). The
mix ratio may be as low as 6 if the velocity in
the CT is above 150 ft/min.
Example - if cleaning out 29 lb/ft, 7" casing
with internal capacity of 0.0371 bbls per ft., the
return fluid rate is 1 bpm, and a mixture ratio is
10 (10 parts fluid and 1 part solids by volume),
then the maximum rate for penetrating through
the fill is: 1.0/(10 * 0.0371) or = ~2.7 fpm, while
a mix ratio of 6 would yield a penetration rate of
about 4.5 fpm.
Monitor the return rate and pressure (if possible)
continuously. As the return fluid (inside the CT)
loads up with solids, the annulus (supply)
pressure will have to rise or the return rate will
slow. At the first sign of an unexplained drop in
return rate or pressure, raise the coil and, after
determining that the coil is still within the work
envelope, continue reversing until pressure
stabilizes. Go to a slower ROP when cleanout
continues. A safe operations rule for most
operations is to allow about 10% of internal
volume of the coil to be filled with solids at any
time. Slightly higher concentrations may be used
with experience and in specific circumstances.
3. The water supply rate must be uninterrupted and
capable of delivering higher rate should a new
zone open up and take a significant portion of
the supply fluid during reversing cleanout.
Consider using injection water supply instead of
pump for reliable, uninterrupted supply of water
for the annulus feed.
4. Return fluid velocity (up coil) needs to be about
150 ft/min with an absolute minimum of 100
ft/min as the lowest threshold.
5. The type of debris removed: cuttings and fill,
frac sand, milling debris, rubber (elastomer)
seals, emulsions, etc. require different
circulating fluids, nozzle designs and techniques.
Size of the particle admitted to the coil is as
important as rate of admittance. Nozzles are
SPE 89505
used to improve velocity effects around the end
of the tubing and limit particle size entry. The
size of the entry holes should also not be so
small that they bridge off with solids.
6. Lower shear and viscosity liquids may be run in
reverse circulating than in normal circulation,
but differential pressure effects and wellbore
hydraulics must be understood.
7. Precautions to prevent coil collapse are
mandatory. These include continuous
monitoring of pressures and rate and the use of
pressure relief valves in the surface pressure
supply systems. If using injection water supply
system, be certain that the maximum supply
pressure and know how this relates to coil
collapse limits. Pressure control an a pressure
relief valve is required if the maximum possible
supply pressure is too high. To minimize the
possibility of collapse, forward circulation may
be done while pulling out of the well or in other
operations where coil tension is increased.
8. Ability is required to quickly switch from
reverse circulating to forward circulating to
remove a developing bridge (indicated by
pressure and rate behaviors). This can be
achieved with the surface manifold system of
Figure 1.
9. Modeling and monitoring of the job is essential
for risk reduction, both from planning
and execution.
Barriers
Reversing through the coil does require extra
precautions in well control. Hydrocarbons and high rate,
high perm gas wells should not be reversed because of
potential risks to well control. Also an extra BOP may
be needed to conform to barrier requirements.
In general, on a reversing operation, the barriers on a
coil unit include the stuffing box, BOP (CT BOP and/or
drilling BOP – depends on set-up) and usually, but not
always, a full column of kill weight fluid. Contingency
plans in remote locations may require kill weight fluid
on location.
3
Candidates
The best applications of reverse circulation are in
quickly removing sand fill and some other debris from
large wellbores. Reversing also has potential in dressing
off sand plugs to a specific height and removing
rubber pieces.
For very hard deposits, jet through with a gelled fluid
that limits leakoff to the zone and then reverse out. Use
of two way or combination nozzles permit forward
jetting and reverse circulation on the same trip with just
a quick change of valve position in the
surface equipment.
Wells that are not candidates in most instances include:
wells where hydrocarbon could enter the coil during
reversing, multi-zone oil wells with potential cross flow,
wells that are not killed by a column of the workover
brine that must be used (excluding water injectors),
wells that produce but cannot inject (must ensure
overbalance), deep or bad dog leg wells (where pick-up
is near the maximum allowable for the coil), very low
pressure wells where a large amount of water loss would
be significantly damaging in the long term and HPHT
wells (simply no experience in this area).
Risks
There are several specific and usually manageable risks
associated with reverse circulation and some advantages
that reduce risks compared to forward circulation.
Potential for coil collapse is the main risk in reversing.
Bridging in the coil was not reported in any location.
Bridging possibility is minimized by: control of particles
entering the coil (i.e., nozzle entry hole size); control of
particle volume loading of fluid or mix ratio (a control
on the ROP of coil through the fill); control of the
amount of solids in the coil at any time; selection of the
type of particle to be reversed; high velocities in the coil
that assure particle lift; use of a fluid with high support
and low shear; ability to quickly move from reverse to
forward circulation and back; and reliable fluid supply.
Nozzle size should not be too small because of
possibility to plug the smaller nozzles in the jetting tool.
Collapse pressure (also a major factor in normal
circulation with coil), can be controlled with strict
monitoring and redundant pressure release valves at the
surface. Coil is far weaker in collapse than burst and
precautions are required to keep outside pressure
minimized. The effect of tension on the coil must also be
considered. A CT string containing particles is heavier
4 SPE 89505
than the same string with just the carrier fluid. If the
string weight increases towards a preset limit during
reverse circulating, simply stop running the hole and
continue reversing until the weight drops. The velocity
of fluid movement within the coil should clear fill
very quickly.
Collapse of coil is a function of internal and external
pressures, OD, ID, material strength, ovality, pickup
loads (weights and frictions), buoyancy, coil condition,
rate of load increase, etc. The manufacturers
engineering data tables are for round pipe, not oval CT.7
Use real time modeling, if possible, to further
minimize risk.
Although the flapper valve at the bottom of the coil is
eliminated in reversing, presence of the other barriers are
usually adequate for control in all jobs. There are check
valves that can be used in reverse circulation, but at the
time of this writing, they are new to the market and are
mainly designed for fracturing operations.
Operational advantages of reversing over normal
circulation include:
• Sharp reduction of the possibility of sticking the
coil, since the there is no sand in the annulus;
• Maintaining clean fluids in the annulus;
• Elimination of fill drop out at crossovers and
deviation changes;
• Ability to establish a very accurate sand/fill top
by eliminating fall back of particles.
• Reduction of time on the well cleanout –
particularly those in large wellbores – and
• Minimizing nitrogen costs for foams.
Operational disadvantages of reversing compared to
forward circulation include:
• Limited ability to break through hard fill without
awitching to forward jetting.
• Remote potential to fill and.or plug the CT
Coil and Equipment Requirements
Surface equipment, Figure 1, with the exception of the
valve manifold set up for rapid flow path switching is
similar to conventional CT support equipment. When
surface pumping equipment is used or supply pressure
peaks may be above safe limits, redundant pressure relief
valves in the surface equipment are required to help
prevent high surface pressure spikes on the CT annulus.
Most coils from 1-1/4” to 2-3/8” or larger can be used
for reverse circulating. Smaller ID coil is obviously
more prone to bridging than the larger coil, but jetting
nozzles are still considered the best preventative control.
Use the optimum size of coil, based on modeling runs,
location and well limitations.
For maintaining strength margins, the coil should ideally
have less than 40% fatigue wear and less than 4%
ovality (1 – ((OD max – OD min) / OD max) = or >
0.96). In addition, there should be no corrosion, pits, or
other damage.
The nozzle, Figure 2, may be one of various designs
from a combination of small jets to a single large jet. A
large OD helps prevent bypassing solids in the annulus,
but ROP must be critically controlled. The entrance hole
of the nozzle must be smaller than any restriction in the
system above the nozzle. Knowing the type and variety
of fill is a significant advantage. When cleaning
exclusively frac sand, the nozzle design and risks are
sharply reduced. Cleaning odd shaped materials
(bridging potential is higher) and items such as rubber
may dictate a reduction in the nozzle diameter. Multiple
use nozzles with utility for forward and reverse jetting
often have small ports useful for generating large impact
force when the large port is closed by mechanical action.
These nozzles have forward circulation capacity while
retaining capacity for reversing the fill after a bridge
is jetted.
Reverse circulating venturi junk baskets may be required
for removing pieces such as under-reamer arms and gas
lift valve latches. These tools are run on a separate run
using forward circulation. In other cases, circulating
junk baskets may be adequate for junk removal.
Planning
Design considerations include eliminating the potential
for reverse circulation of hydrocarbons by pushing all oil
and free gas out of the wellbore and into the formation
(an estimate of displacement is 2 to 3x the well tubular
volume). By maintaining an overbalance, potential
encroachment of these fluids is minimized.
There should be contingency plans for well flow,
including emergency shutdown and procedures for
handling a kick.
Consider the type, size, composition and variety of
solids. Most return fluids are flowed to a tank for
separation and disposal. Returned fluids are rarely
recirculated. A continuous, uninterrupted fluid supply of
injection fluid, preferably from a produced water
injection stream is preferred.
SPE 89505 5

Conclusions 4. Shaughnessy, J., Helweg, J.: “Optimizing HTHP

Cementing Operations,” IADC/SPE 74483,
The results of reverse circulating in over 1600 wells Dallas, 26-28 February 2002.
have been considered and the learnings condensed to 5. Griffin, J.E., Nix, D.Q, Boe, G.A.: “Reverse
considerations for candidate selection, job planning and Circulation of Cement on Primary Jobs
execution. Specific recommendations are: Increases Cement Column Height Across Weak
Formations,” SPE 25440, Prod Op. Symposium,
1. All reverse circulation jobs must monitor and Ok. City, March 21-23, 1993.
control pressure differentials across the coil. 6. Connell, M.L., Howard, R.G.: “New Downhole
Modeling software should be used to estimate Tool Can Solve Depth Control Problems in
limits at each stage of the operation. Coiled-Tubing Fracturing Operations,” SPE
2. Wellbore hydraulics cannot be left to chance. 74834, SPE/ICOTA CT Conf., 9-10 April 2002.
Hydraulics must be understood for 7. Newman, K.R.: “Collapse Pressure of Ovaled
all operations. Coiled Tubing,” SPE 24988, European
3. Frac sand removal, establishing accurate sand Petroleum Conference, Cannes, France, 16-18,
tops in sand plug placement and water injector Nov 1992.
fill are the most common targets, but other
cleanouts are possible with the right equipment Acknowledgements
and planning.
4. Circulation fluid rate, ROP and jet nozzle size This paper was generated from presentation material
must be appropriate for the material that will supplied by the authors to an ICOTA luncheon panel
be removed. discussion, September 18, 2003, in Houston.
5. Contingency plans for well control and
understanding of barriers is necessary.
6. Prevention of bridging by rapid switching from
reverse to normal and back to reverse must be
possible. The frequent need for switching back
and forth between forward and reverse jetting
can be significantly reduced with a well planned
and executed operation.
7. The use of combination nozzles that allow
forward jetting and reverse circulation are highly
efficient at removing bridges, even in very
large tubulars.

References
1. Hand, R.J., Bishop, W.W., Perking, G.S.:
“Reverse Circulation Under-Reaming Utilizing
Air Lift,” SPE 7970, Ventura California, April
18-20, 1979.
2. Xiao, Z, Shahin, M., Hosein, P. Lungwitz, B.,
Samuel, M.: “Laboratory Investigation and Field
Use of a Novel Sand Cleanout Fluid System for
High Temperature Wells,” SPE 84887,
International Improved Oil Recovery, Asia
Pacific, Kuala Lumpur, Malaysia, 20-21
Oct, 2003.
3. Moore, R., Bour, D.L., Reed, S., Hernandez, R.:
“High Temperature Wells with Lost Circulation
Demands and Reverse Circulation Placement
Technique Using Foamed Cement Systems: Two
Case Histories,” SPE 84563, Annual Technical
Conf., Denver, Oct 5-8, 2003.
6 SPE 89505

Figure 1 - Basic surface set up for circulation. The

multiple pressure relief valves, PRV, provide secondary
control to prevent coil collapse. Valving must be capable of
quickly changeable to move from reversing to forward and
back to reversing.

Figure 2 – One example of a reversing nozzle (Baker Oil

Tools, Aberdeen). Going from reverse circulation to normal
closes the flapper and opens the ports. Other, simpler nozzles,
have no moving parts. The key activity is allowing jetting
(normal circulation) through hard bridges and then reversing
out the suspended fill.