Coiled Tubing Introduction

Surface equipment
BHA assemblies
Some problems and observations

World Wide CT Records

Largest CT in Use
3-1/2"
Max Depth
24,000'
Max Horizontal
17,000' (80 deg)-Wytch BP
Longest BHA
1500' - perf guns - UK
Longest Strings
23,000' of 2-3/8"
28,000' of 1-1/2
Max Wellhead Pressure 9800 psi
Max Deployment Press 4500 psi
Max BH Temp
700F - Mex, 780F Japan
Max Acid at Temp
28% at 280F in Dubai
CT in H2S
75% in Greece
98%/300F- Gulf of Mexico
(string used one time)
CT in CO2
15% - (string ruined)

Typical CT Layout
wind
Operators Cab

Transports
and Pumpers

Reel

Injector

Power Pack

CT Reel Configurations
CT Reels available in number of configurations
Truck mounted (fixed) - permanently fixed to the truck chassis
Truck mounted (skid) - may be changed out
Skid mounted - for offshore operations
Trailer mounted - for large capacity (length) or heavy weight
strings
CT logging reel - fitted with electrical swivel/collector
Special application reel - typically for completion applications

Local conditions/nature of CT operations determine type

of reel required

Coiled Tubing Rig up

in Alaska. Two wells
on the same pad are
being.

CT Equipment Basics
Components

Coil
Power pack
Component Controls
Reel
Injector (with guidearch)
Well Control Components

Coil Types and Availability

CT diameters
CT wall thickness
CT tapered strings
CT strength ranges
CT metal choices
Composite CT

CT Diameters

1/2, 3/4 and 1 early diameters

1-1/4 and 1-1/2 workhorses (1-3/4)
1-3/4 to 2-3/8 larger workstrings (3-1/2)
3-1/2 and 4-1/2 (and larger) - flowlines

CT production for For 1996

1
1.25
1.5
1.75
2
2-3/8
2-7/8
3-1/2
4&4.5

1.52 MM ft
14.2 MM ft
6.2 MM ft
3.3 MM ft
1.22 MM ft
0.56 MM ft
0.43 MM ft
0.45 MM ft
0.125 MM ft

Tapered Strings
Common is I.D. taper - weld area taper
Uncommon is O.D. taper - deeper wells,
some hydraulic problems

Butt Weld early

string joiner and
common repair weld.

Junction weld
in flat strip

The bias weld offsets

the weld ends on the
strip as it is formed into
a tube much stronger.

Bias weld
in flat strip

Field Welds
Always a Butt weld.
Can decrease tensile strength of CT by 50%
or more.
Quality of field welds varies enormously
Avoid field welds when you can.
Upper part of tubing is worst place for a butt
weld.

Material Strengths
55,000 psi (limited)
70,000 to 80,000 psi (still in use)
100,000+ psi (now very common)

Trade-Offs

strength vs cost
ductility/weakness vs strength/cost
corrosion possibilities
strength vs service life

In general, high strength CT lasts longer and is more

fatigue resistant. But, what about corrosion?
Hardness matters. Stress Corrosion cracking and
embrittlement.

Analysis of Coiled Tubing

Carbon
Manganese
Phosphorus
Sulfur
Silicon
Chromium
Nickel
Copper
Molobidum
Cb-V

Mod A606
0.08-0.15
0.60-0.90
0.030 max
0.005 max
0.30-0.50
0.45-0.70
0.25 max
0.40 max
0.21 max

Mod A607
0.08-0.17
0.60-0.90
0.025 max
0.005 max
0.30-0.45
0.40-0.60
0.10 max
0.40 max
0.08-0.15
0.02-0.04

New CT Properties

Yield Strength
(psi)
50,000
70,000
80,000
90,000
100,000
110,000
SPE 46052

HRB

HRC

Min. Elong.

22
85-94
90-98
94

22
20-25
22-28

30%
28%
25%
22% est.
18% est

Corrosion Resistance vs Hardness

Hardness vs SSC
20
18

SSC Resistance, Sc

16
14
12
10
8
6
4
2
0
19

20

21

22

23

24
Hardness, HRC

25

26

27

28

29

Composites

Limited Use
Composites lighter/more flexible than steel.
More costly than steel
Limitations:
Creep under load
Temperature
Downhole Buckling resistance

Surface Equipment

Power Pack
Reel
Controls
Injector
Seals

Power pack usually diesel driven hydraulic pumps.

Requirements set by equipment in use.

Typical Layout of Control Cabin

Controls and Instruments (1)
C LO S E

IN J E C TO R O U T S ID E
TE N S IO N P R E S S U R E
1 5 0 PSI M A X

O PEN

C LO S E

La y e r 1
O PEN

IN S ID E TR A C TI O N
P R E S S U R E D R A IN

IN J E C TO R I N S ID E
T R A C T IO N P R E S S U R E
1 5 00 PSI M A X

B
O
P

S L IP R A M
C LO S E

EM ERG EN C Y
TR A C TI O N S U P P LY

B L IN D R A M

SHEAR RAM
C LO S E O P E N

A IP S U P P LY
P R E SSU R E

O PEN

C LO S E

E N G IN E
S TO P

O N

P IP E R A M
O PEN

O FF
PR ESSUR E

BLEED

O N

TO P
O N

O FF

TU B I N G W E IG H T I N D IC A TO R
O FF

O FF
C I R C U L A TIN G P R E S S U R E

W E LLH E A D P R E SS U R E

O FF

BO P P RESSUR E

IN S ID E TR A C T IO N
S U P P LY P R E S S U R E

O N

S T R IP P E R
# 1

IN S ID E T R A C TIO N
P R E SSU R E
O FF

A IR H O R N
P R I O R I TY P R E S S U R E
2 ,0 0 0 P SI M A X

S c h lu m b e rg e r
D o w e ll

IN J E C TO R D I R E C T IO N A L
C O N TR O L V A LV E
P IL O T P R E S S U R E

R E E L P R E SSU R E

PR ESSUR E A D J UST
IN

R E TR A C T

N E U TR A L

PA C K

R E TR A C T

N E U TR A L

# 2
S TR IP P E R

B O TTO M
# 1
S TR IP P E R

IN J E C TO R C H A IN
L U B R I C A TI O N

PA C K
UP

S TR IP P E R S Y S TE M P R E S S U R E
5 0 0 0 PSI M A X

TH R O TTL E

REEL BR A KE

B O P S U P P LY P R E S SU R E
M ID D L E

S TR IP P E R
# 2

60 G PM
PUM P

PR ES SU R E

O N

B O P S U P P LY

EM ER G EN C Y
S TO P

3 0 G PM
PUM P

O N

P RESSUR E
O FF

L E V E L W IN D
ARM
DO WN

H IG H
IN J E C TO R
SPEED
LO W

O UT

IN J E C TO R
M O TO R P R E S S U R E

IN J E C TO R M O TO R
P R E SSU R E A D J U ST

IN J E C TO R
C O N TR O L

STR IP P E R
P R E SS UR E A D J UST
A IR R E G . C O N T R O L

R E E L P R E SSU R E
A D J UST
L E V E LW IN D
O V E R R ID E

R E E L TU B I N G
L U B R IC A TIO N

R E E L C O N TR O L

Looks more complex, but main data is from load, wellhead pressure
and annular pressure.
Main controls are injector head and coil spooling.

Principal Gauges
Wellhead Pressure Gauge
displays wellhead pressure at the BOP pressure port

Circulating Pressure Gauge

displays pressure at the reel-manifold pressure sensor

Weight Indicator
displays weight exerted by the tubing on the injector head

Electronic Equipment
Following equipment used to monitor CTU, tubing,
and well data:
Electronic Depth Sensors
provide remote depth displays and signals to a PACR unit

Electronic Pressure Sensors

monitor wellhead pressure, circulating pressure and tubing weight

Tubing Monitoring Equipment

gives remote display of tubing condition and may record life
statistics
data may be recorded

Running Speeds
First time into a well - 40 to 70 ft/min
Normal run in operations - 50 to 100 ft/min
Spool-out? depends on the well, the BHA,
coil equipment, friction and operator.
Runaway - experienced 800 to 900 ft/min.

Typical CT Reel - Side View

Whats Different Than Jointed Pipe?

All fluids injected from the
surface enter the CT at the
bed-wrap end. All fluid has
to travel through all of the
coil.
That influences friction since
friction is near constant w/
CT whether you a injecting
fluid at 1 foot into the well or
10,000 ft into the well.

Some of the extra fittings in the

input plumbing allow a ball to be
inserted and dropped (pumped
through the coil). The ball travel
may take several minutes to clear
the coil and enter the well.

A flow control manifold. This one allow reverse circulation through

coiled tubing.

Reel Drum Capacity

Freeboard
A

Freeboard is normally not much

of an issue, but can become very
important if the CT is not spooled
tightly and the drum is nearly full
for a deep well CT job.

Reel Capacity Variables

Reel diameter
Reel width
Hub diameter - set by CT OD
Pipe OD
Tightness of wind (operator expertise)
Weight?

Selected Reel Diameter Information

Reel Information for Various Sizes of CT
CT Diam.
(in)
0.75
1
1.25
1.5
1.75
2
2.375
2.875
3.5

Reel Hub Diam. Guide Arch (Reel Width) Approx. Capacity

(in)
(in)
(in)
(ft)
48
60
72
84
96
96
108
108
120

48
48-54
48-72
(48)-72
72-96
72-96
90-120
90-120
90-120

117
128
148

17500
15000
18000

Spooling Yield
Coiled Tubing is yielded as it is spooled
Radius to produce yielding is:
R=E(D/2)/Sy
where:
R=bend radius, ft
E= elastic modulus, 30x106 psi
D = tubing diameter, in
Sy = yield strength, psi

The level-wind (like a bait-casting fishing reel) helps

feed the coil onto the reel.

Depth Measurement Equipment

Depth measuring equipment -Electronic or mechanical

Frequently mounted on injector head
Depth information commonly acquired by two methods:

Friction-wheel counter between injector

chains and stripper

Encoder assembly on injector-head chain drive shaft

Injector Guide Arch

Guide arch

Turn tubing through angle between wellhead and

CT reel
CT supported by rollers at 10-in. intervals
around gooseneck
guide arch radius significantly affects fatigue in CT
string

Comparison of Guide Arch Sizes

120-in. radius
(HR 480)

72-in. radius
(HR 260)
50-in. radius
(HR 240)

Recommended Guide Arch Radii

Coiled
Tubing OD
(in.)

Typical Reel
Core Radius
(in.)

Typical Guide
Arch Radius
(in.)

0.750
1.000
1.250
1.500
1.750
2.000
2.375
2.875
3.500

24
20-30
25-36
30-40
35-48
40-48
48-54
54-58
65-70

48
48-54
48-72
48-72
72-96
72-96
90-120
90-120
96-120

CT Injectors
Injector Evolution
wheel, chains, chain and back to the wheel

Gripper Design and Effect on the Tube

Power Requirements
Load Cells
Wear and Failure Points
Control vs micro control

Injector Head Components

Principal components of injector head:
Drive and brake system
Chain assembly
Traction and tension system
Guide-arch assembly
Secondary or support systems:
Weight indicator
Depth sensor mounts
Stripper mount

Injector Head Drive and Brake

Systems
Drive and brake systems can exert high forces on
CT string
tubulars
wellhead equipment
CTU operator must
Be aware of system design and layout
Be familiar with control and relief valves
Understand limitations of CT string
avoid application of excessive force

Injector Head Drive Systems

Injector heads hydraulically driven
Two or four hydraulic motors
Motors connected/synchronized through gear system
Drive directed to chain drive sprockets via drive shafts
Rotation/speed of motors controlled by valve on power

pack
Hydraulic system pressure/rate controlled from CTU
control console
Pressure relief/crossover relief valves
protect tubing/hydraulic components

Typical Injector Head

Gooseneck or guide-arch
Injector drive motor

Stripper assembly

Typical Injector Head Support

Substructure

Arco

Injector Head Brake Systems

Brake hydraulically controlled
Hydraulic pressure required to release brake
fail-safe in operation

Application of brake is automatic

controlled by drive system hydraulic pressure
applied when hydraulic pressure below preset value

Some hydraulic motors have high/low gear option

Selected remotely from the CTU the control console
Allows injector head to operate more efficiently

Injector Head Chain Assembly

Most injector heads have two sets of opposing
endless chains
Series of gripper blocks mounted on each chain
Gripping profile of each block suits a specific tubing size
Entire CT string load held by face of the gripper
block or insert
Often achieved under significant force
Selection/operation/maintenance of chain components
should minimize risk of damage to CT string

Injector Head Chain Gripper Inserts

Removable gripper inserts on most injector heads

Run range of tubing sizes without removing/replacing

entire chain assembly
Reduce time/effort required to reconfigure injector head
when running a different size of CT string
when running a tapered CT string

Reduce cost of replacement when worn

Ribbed injector
block.

Smooth faced
injector

SS800 Chain Assembly

Bottom sprocket on injector.

Inside Chain Tensioner System

Inside chain tensioner system
Also known as skate system or traction tensioner system
Provides force for adequate grip on tubing string
force is applied to the back of the chain assembly

Chains fitted with bearings

Roll smoothly over tensioner system while transmitting
load
Enable chains to rotate easily with high loads

Traction and Tension Systems

Injector head traction or inside chain tensioner system
Also known as skate system
Provides force to securely grip tubing
Force applied through 3 separate sets of hydraulic cylinders
reduces risk of major operating failure if component fails

Outside chain tensioner system

Ensures adequate tension in chain section outside vertical
drive plane
Tension provided by hydraulic rams

Backpressure Adjusted to
Provide Suitable Tension
Incorrect

Correct

BJ Services
Coiled Tubing
Deployment
Deployment BOP

BHA
Deployment BOP
179.4 mm, 35 MPa

Gate Valve,
179.4 mm
Locating
Ram
Upper
Pipe Ram
Lower Pipe
/Slip Ram

Flow Line,
101.6 mm

Conventional
Rig BOP

ESD
(Tester)
Coiled Tubing BOP
179.4 mm, 35 MPa
Drilling Spool,

Wellhead

179.4 mm, 35 MPa

Kill Line
, 50.8 mm

Flow Spool
Annular
Preventer
Blind/Shear Ram
Slip/Pipe Ram
Flowline,
101.6 mm

Physical Brace
If there is a long space (length is a variable
with pipe diameter, wall, and buckling
force) then a brace between the bottom of
the injector and the first seal is necessary.

Snubbing/Stripping Forces on CT
Force to push CT through stuffing
box/stripper (opposite running)
Force on CT from Well Head Pressures (upward)
Force to overcome friction (opposite
running)
Force from weight of CT & BHA
(downward)

Load Necessary to Pull Wireline into Wellhead

100
90

Load Necessary, lbs

80

0.108

70
60

0.108"
0.092"

50

0.082"

40

0.072"

30

0.072

20
10
0
0

2000

4000

6000

8000

10000

Wellhead Pressure, psi

Problem in rig up height and lubricator length.

12000

Load Necessary to Pull Cable into Wellhead

800
700

5/16"

Load Necessary, lbs

600
500

7/16"

7\16

400

5\16

3/16"

3\16

300
200
100
0
0

2000

4000

6000
Wellhead Pressure, psi

8000

10000

12000

Snubbing Force on CT at Wellhead

Pressure Induced Snubbing Force VS Well Head Pressure for Various Coiled
Tubing Sizes, (Must add stripper friction force)
160000

Base Snubbing Force, lbs

140000

1" CT
1-1/4" CT

120000

1-1/2" CT

100000

1-3/4" CT
2" CT

80000

2-3/8" CT

60000

2-7/8" CT
3.5" CT

40000
20000
0
0

2000

4000

6000

8000

10000

Well Head Pressure, psi

12000

14000

16000

Gap between the

injector and the
stuffing box The
pipe in this area is
very susceptible to
bending Note the
brace around the CT.

Weight Indicator
What negative weight will cause injector to
lift off load cell?

Weight Indicator Equipment

Front weight
sensor

Rear weight
sensor

Seals
Stuffing Box - Primary sealing mechanism
for isolating the wellbore. Positioned above
the BOP, just underneath the injector head.
A connector attaches the box to the BOP.
BOP - multi-level control for closing in the
well, shearing the CT, sealing around the
CT and gripping the CT. May be used in
pairs in extreme applications.

CT BOP
Blind
Shear
Pipe
Slip

Typical Loads: 1.5 CT, 5000 psi

snub force = (1.767 in2 x 5000 psi)
=8835 lb
stuffing box friction (drag force
=2000 lb
total
at start of the CT run-in

=10835 lb

Load Changes w/CT inserted

1.5:, 0.109 wall, 1.623 lb/ft
one foot of CT in well
= 10833 lb
1000 CT in well=10835-(1000 x 1.623)
=9212 lbs
10,000 CT in well= 10835-(10,000x1.623)
= -5395 lbs
this assumes no wall friction

Selecting a CT size for a well

application.
Clearances:
For circulation
For passing debris through the CT-tubing annulus
What happens when CT collapses? Does it stick itself
in a profile or other close clearance? What is diameter
of collapsed CT.
What happens when the well tubulars are much larger
than the CT? Can it buckle? What if it collapses?

Working Tensile Loads of Conveyances

Wireline
0.072
0.082
0.092
0.108

Working Load
720
930
1160
1827

Weight of Wire/Tube
0.014
0.018
0.023
0.031

Running Speed
100-150 ft/min

CT
1.25
1.5
1.75
2.375

21900
26600
31440
49520

1.332
1.623
1.915
3.011

50-100 ft/min

Tubing
2.375
2.875
3.5

57,000
79,200
119,200

4.6
6.4
9.2

5 - 15 ft/min

3-1/2" DP

189,000

15.5

Job Design Factors

Well control must be maintained
Personnel safety - perform tasks using required
safety equipment
Operation designed/executed within operating
limits
Operating standards

operation executed in accordance with operating

practices, regulations and safety standards. These may
vary with the task, company and location.

Design Software
Typical job design software/modelling

Tubing forces
Fatigue tracking software
Operating limit software
Wellbore simulator
Friction pressure
Foam cleanout

Tubing Forces Software

Key features/functions
Analyses loads applied to CT
Predicts
weight indicator readings
point of helical buckling and lock-up

Principal functions
confirm workstring can be run to desired position in wellbore
verify toolstring will pass doglegs/wellbore anomolies

W E IG H T IN D IC A T O R R E A D IN G ( lb f)

Weight Indicator Load Verification

9000

M e a s u re d
R IH ( m o d e l)
P O O H (m o d e l)

4500

500

4 ,0 0 0

8 ,0 0 0

M E A S U R E D D E P T H O F S T R IN G (ft)

Fatigue Tracking Software

Key features/functions
Predicts remaining useful life of a workstring
operates in conjunction with database for each reel

Principal functions:
predict life remaining in each workstring element
confirm operation can be completed safely
minimize risk of tubing failure during operation

P R E D IC T E D L IF E R E M A IN IN G (% )

CT String Life Tracking

60

W e ld L o c a t io n

50

P re v io u s L ife
C u r r e n t L ife

40
30
20
10

2 ,0 0 0

4 ,0 0 0

6 ,0 0 0

8 ,0 0 0

1 0 ,0 0 0

D IS T A N C E F R O M D O W N H O L E E N D O F S T R IN G (ft)

Support Slides

Operating Limit Software

Key features/functions
Determines pressure/tension limits under
anticipated conditions
Calculates collapse pressure limit
takes string ovality into account

Principal function
graphically depicting safe pressure/tension limits for
workstring in given wellbore and conditions

Injector Head Weight Indicator

Load cell located on lower front edge of injector head
Information transmitted to display electronically or
hydraulically
Injector-head typically comprises inner and outer frames
Pivot points between frames
enable accurate measurement of force between assemblies

Force may act upward or downward

CT Reel Features
Main components of CT reel
Reel drum
Reel drive and brake systems
Reel swivel and manifold
Levelwind assembly
Depth measurement accessories
Tubing lubrication equipment
Crash protection frame

Reel Drum
Reel drum generally consists of:
Drum
Axle
Flanged connection on axle
allows swivel to be connected

Chain sprocket on the axle

drives the drum

Second chain sprocket on the axle

drives the levelwind leadscrew

Facility to lock reel drum while being transported

Reel Drive/Brake Systems

All reels hydraulically driven
Control system/motor type vary
Most reels can be powered in "in-hole" and "out-hole"
only "out-hole" mode used

Pressure in hydraulic drive system controls torque output

of motor

varies tension on the tubing between gooseneck and reel

Reel brake systems air or hydraulically operated

Reel brake should be applied when tubing is stationary

Maintaining Correct Tension

Only sufficient tension to keep tubing straight between reel
and injector head should be applied
Pressure required to achieve satisfactory tension depends on:
Amount of tubing on reel
Distance from gooseneck
Applying excessive tension may result in:
Premature failure of hydraulic and drive components
Damage to tubing

Hydra-Rig HR 480 Injector Head

Hydra-Rig HR 440 Injector Head

Stewart and Stevenson SS 400

Stewart and Stevenson SS 800

R T- 2 0
M A R I TIM E H Y D R A U L I C S (C A N ) L TD .
C A L G A RY , A L BE R T A , C AN A D A

DRECO Chain Assembly - Open

DRECO
Closed

Chain

Assembly

Injector Head DRECO Chain

Assembly
DRECO chain and drive system
Unique single chain system
Hinged gripper assembly
ensures gripping force isolated from drive chain

Chain assembly aligned with tubing axis

reduces eccentric loading on chain/gripper components

Smooth operation and long component life

Gripping force applied through hinged gripper block
cam rollers forced closed by pressure beams
hydraulic rams control force applied by pressure beams

HR240/260
Assembly

Chain

Tension

Typical CT Reel - Front View