Coiled Tubing Surface Equipment PDF

Coiled Tubing Introduction
• Surface equipment
• BHA assemblies
• Some problems and observations
George E. King Engineering

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Coiled Tubing Introduction
• Surface equipment
• BHA assemblies
• Some problems and observations

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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
3/14/2009 15% - (string ruined)
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Typical CT Layout
wind
Injector
Operator’s Cab Reel
Transports Power Pack

and Pumpers

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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
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Coiled Tubing Rig up in
Alaska. Two wells on the
same pad are being.

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CT Equipment Basics
• Components
– Coil
– Power pack
– Component Controls
– Reel
– Injector (with guidearch)
– Well Control Components

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Coil Types and Availability
• CT diameters
• CT wall thickness
• CT tapered strings
• CT strength ranges
• CT metal choices
• Composite CT

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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

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CT production for For 1996
• 1” 1.52 MM ft
• 1.25” 14.2 MM ft
• 1.5” 6.2 MM ft
• 1.75” 3.3 MM ft
• 2” 1.22 MM ft
• 2-3/8” 0.56 MM ft
• 2-7/8” 0.43 MM ft
• 3-1/2 0.45 MM ft
• 4&4.5” 0.125 MM ft

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

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Butt Weld – early
string joiner and
common repair weld.
Junction weld
in flat strip

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The bias weld offsets the weld
ends on the strip as it is formed
into a tube – much stronger.
Bias weld
in flat strip

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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.

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

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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.

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Analysis of Coiled Tubing
Mod A606 Mod A607
Carbon 0.08-0.15 0.08-0.17
Manganese 0.60-0.90 0.60-0.90
Phosphorus 0.030 max 0.025 max
Sulfur 0.005 max 0.005 max
Silicon 0.30-0.50 0.30-0.45
Chromium 0.45-0.70 0.40-0.60
Nickel 0.25 max 0.10 max
Copper 0.40 max 0.40 max
Molobidum 0.21 max 0.08-0.15
Cb-V
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New CT Properties
Yield Strength HRB HRC Min. Elong.

(psi)
50,000 22
70,000 85-94 30%
80,000 90-98 28%
90,000 94 22 25%
100,000 20-25 22% est.
110,000 22-28 18% est
SPE 46052
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Composites
• Limited Use
• Composites lighter/more flexible than steel.
• More costly than steel
• Limitations:
– Creep under load
– Temperature
– Downhole Buckling resistance

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Surface Equipment
• Power Pack
• Reel
• Controls
• Injector
• Seals

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Power pack – usually diesel driven hydraulic pumps.
Requirements set by equipment in use.

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Typical Layout of Control Cabin
Controls and Instruments (1)
EMERGENCY
SHEAR RAM BLIND RAM TRACTION SUPPLY
INJECTOR OUTSIDE
CLOSE OPEN CLOSE OPEN TENSION PRESSURE CLOSE Layer 1
150 PSI MAX
OPEN
INSIDE TRACTION
PRESSURE DRAIN AIP SUPPLY
INJECTOR INSIDE PRESSURE
TRACTION PRESSURE ENGINE EMERGENCY
B 1500 PSI MAX STOP STOP
O ON
SLIP RAM P PIPE RAM
30 GPM
CLOSE OPEN CLOSE OPEN OFF PUMP
PRESSURE BLEED
ON
60 GPM
TOP OFF PUMP
TUBING WEIGHTINDICATOR
ON PRESSURE
OFF OFF THROTTLE
ON CIRCULATING PRESSURE WELLHEAD PRESSURE
REEL BRAKE
OFF
INSIDE TRACTION
BOP SUPPLY SUPPLY PRESSURE
AIR HORN
BOP PRESSURE BOP SUPPLY PRESSURE
MIDDLE INSIDE TRACTION
PRIORITY PRESSURE INJECTOR DIRECTIONAL Sc hlum berger
ON PRESSURE 2,000 PSI MAX CONTROL VALVE
STRIPPER STRIPPER PILOTPRESSURE Dowell REEL PRESSURE
#2 #1 OFF PRESSURE ADJUST
IN INJECTOR CHAIN
LUBRICATION
RETRACT NEUTRAL PACK RETRACT NEUTRAL PACK
UP HIGH
STRIPPER SYSTEM PRESSURE BOTTOM

5000 PSI MAX LEVELWIND INJECTOR OUT
ARM SPEED INJECTOR INJECTOR MOTOR
#2 #1 ON PRESSURE MOTOR PRESSURE PRESSURE ADJUST REEL PRESSURE REEL TUBING
STRIPPER STRIPPER INJECTOR ADJUST LUBRICATION
OFF LOW
DOWN CONTROL LEVELWIND REEL CONTROL
STRIPPER OVERRIDE
PRESSURE ADJUST
AIR REG. CONTROL
Looks more complex, but main data is from load, wellhead pressure and annular pressure.
Main controls are injector head and coil spooling.

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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

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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.

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Typical CT Reel - Side View

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What’s 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.

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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.

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A flow control manifold. This one allow reverse circulation through coiled tubing.

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Reel Drum Capacity
Freeboard Freeboard is normally not much of an issue,
but can become very important if the CT is
A not spooled tightly and the drum is nearly
full for a deep well CT job.
B
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Selected Reel Diameter Information
Reel Information for Various Sizes of CT
CT Diam. Reel Hub Diam. Guide Arch (Reel Width) Approx. Capacity
(in) (in) (in) (in) (ft)
0.75 48 48
1 60 48-54
1.25 72 48-72 117 17500
1.5 84 (48)-72 128 15000
1.75 96 72-96 148 18000
2 96 72-96
2.375 108 90-120
2.875 108 90-120
3.5 120 90-120

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The level-wind (like a bait-casting fishing reel) helps feed the coil onto the
reel.

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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

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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

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Comparison of Guide Arch Sizes
72-in. radius
120-in. radius (HR 260)
(HR 480)
50-in. radius
(HR 240)

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Recommended Guide Arch Radii
Coiled Typical Reel Typical Guide
Tubing OD Core Radius Arch Radius
(in.) (in.) (in.)
0.750 24 48
1.000 20-30 48-54
1.250 25-36 48-72
1.500 30-40 48-72
1.750 35-48 72-96
2.000 40-48 72-96
2.375 48-54 90-120
2.875 54-58 90-120
3.500 65-70 96-120

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CT Injectors
• Injector
• Gripper Design and Effect on the Tube
• Power Requirements
• Load Cells
• Wear and Failure Points
• Control vs “micro” control

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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

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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

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Typical Injector Head
Gooseneck or guide-arch
Injector drive motor
Stripper assembly

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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

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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

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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

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Ribbed injector block.

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Smooth faced
injector

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SS800 Chain Assembly

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Bottom sprocket on injector.

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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

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Backpressure Adjusted to Provide
Suitable Tension
Incorrect
Correct

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BJ Services
Coiled Tubing
Deployment
Gate Valve,
179.4 mm
BHA Locating
Ram
Deployment BOP Deployment BOP Upper
Pipe Ram
179.4 mm, 35 MPa
Lower Pipe
/Slip Ram
Flow Line,
Flow Spool
101.6 mm
ESD
Conventional (Tester)
Annular
Rig BOP Coiled Tubing BOP
Preventer
179.4 mm, 35 MPa
Blind/Shear Ram
Slip/Pipe Ram
Drilling Spool,
Wellhead 179.4 mm, 35 MPa Flowline,
Kill Line
101.6 mm
, 50.8 mm

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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.

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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)

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Load Necessary to Pull Wireline into Wellhead
100
90
80
0.108”
Load Necessary, lbs
70
0
60
0
50
0
40 0
30
20 0.072”
10
0
0 2000 4000 6000 8000 10000 12000
Wellhead Pressure, psi
Problem in rig up height and lubricator length.

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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
140000
1" CT
Base Snubbing Force, lbs
120000 1-1/4" CT
1-1/2" CT
100000
1-3/4" CT
80000 2" CT
2-3/8" CT
60000
2-7/8" CT
40000 3.5" CT
20000
0
0 2000 4000 6000 8000 10000 12000 14000 16000
Well Head Pressure, psi
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Gap between the injector and
the stuffing box – The pipe in
this area is very susceptible
to bending – Note the brace
around the CT.

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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.

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Weight Indicator Equipment
Front weight Rear weight

sensor sensor

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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 =10835 lb
at start of the CT run-in

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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

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Coiled Tubing Introduction

• Some problems and observations

George E. King Engineering

• Some problems and observations

George E. King Engineering

Transports Power Pack

George E. King Engineering

George E. King Engineering

George E. King Engineering

George E. King Engineering

George E. King Engineering

George E. King Engineering

George E. King Engineering

George E. King Engineering

George E. King Engineering

George E. King Engineering

George E. King Engineering

• In general, high strength CT lasts longer and is more

George E. King Engineering

Yield Strength HRB HRC Min. Elong.

George E. King Engineering

George E. King Engineering

George E. King Engineering

STRIPPER SYSTEM PRESSURE BOTTOM

George E. King Engineering

– Circulating Pressure Gauge

George E. King Engineering

• Runaway - experienced 800 to 900 ft/min.

George E. King Engineering

George E. King Engineering

All fluids injected from the surface

George E. King Engineering

George E. King Engineering

George E. King Engineering

George E. King Engineering

George E. King Engineering

•Depth measuring equipment -Electronic or mechanical

George E. King Engineering

George E. King Engineering

George E. King Engineering

George E. King Engineering

George E. King Engineering

•Secondary or support systems:

George E. King Engineering

George E. King Engineering

Injector drive motor

George E. King Engineering

•Some hydraulic motors have high/low gear option

George E. King Engineering

•Entire CT string load held by face of the gripper block

George E. King Engineering

– Run range of tubing sizes without removing/replacing entire

George E. King Engineering

George E. King Engineering

George E. King Engineering

George E. King Engineering

George E. King Engineering

•Outside chain tensioner system

George E. King Engineering

George E. King Engineering

George E. King Engineering

George E. King Engineering

George E. King Engineering