SPE-173659-MS

Performing Riserless Subsea Operations Utilizing Coiled Tubing in Open

Water
Beau Lasseigne, BJ Lindsey, and James Larke, Baker Hughes

Copyright 2015, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE/ICoTA Coiled Tubing & Well Intervention Conference & Exhibition held in The Woodlands, Texas, USA, 24 –25
March 2015.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written
consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
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Abstract
Due to the versatility of modern coiled tubing (CT) operations coupled with the increasing demand for
deepwater activity, CT is becoming a common conveyance method to perform subsea operations without
the need of a marine riser or lubricator connected to the subsea wellhead. These operations utilize the CT
string as an umbilical deployed through the moonpool of a dynamically positioned multi-purpose support
vessel (MSV) to provide a variety of services to the operator without CT entering the wellbore. Without
the need for a conventional deepwater rig or riser-based vessel, operations utilizing CT as an umbilical
become a valuable time- and cost-saving option to perform subsea intervention work. Job objectives
include well stimulation, lower zonal abandonment, subsea dispersant application, subsea equipment
testing, flowline intervention, and hydrate-preventative blowout preventer (BOP) flushing.
From 2008-2012, an average of one CT umbilical job per year was performed. The method has
increased in popularity and over the past two years, nine CT umbilical operations have been successfully
completed. These successful operations include supplying nitrogen gas subsea to perform leak detection
testing, utilizing dual CT umbilical strings to perform subsea BOP flushing as a pump down and return
line, nitrified acid stimulation treatment, flowline hydrate removal, flowline purge to platform, and
cementing zonal abandonment.
The combination of increasing deepwater technology and the adaptability of CT increases intervention
and testing methods for operators. This paper will explain the techniques used, system improvements
(both operational and HSE), and it will provide an overview of various types of jobs performed.

Introduction
CT umbilical operations are performed on an MSV, also known as a light-well intervention vessel or
vessel of opportunity. Proper job design is required in this environment due to the unfamiliar stresses seen
on the CT string deployed from the vessel. High cycle fatigue and external corrosion are a few factors that
need to be accounted for when dealing with CT umbilical operations. For these riserless subsea operations,
CT is not used to enter the wellbore; therefore, the job may be performed from a vessel of opportunity
without the need of a riser system. Due to the ability to support its own weight, high collapse ratings, and
relative ease of deploying and retrieving, CT has many benefits when used as an umbilical from an MSV.
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The MSV is equipped with at least one moonpool which enables CT access to the open water through the
center of the vessel. Once CT is deployed from the vessel, the only step remaining is to complete the flow
path to subsea equipment by connecting the CT down line with the aid of a remotely operated vehicle
(ROV). These ROVs also act as a set of eyes for operators to view subsea operations and to monitor for
any potential issues. An entire CT unit spread is required with the exception of BOPs, which are not
needed since the CT is not entering the wellbore.

Vessel Types
According to Det Norske Veritas (DNV), offshore drilling and support units are classified based off of
multiple variables (Offshore Service Specification, 2013). For CT intervention purposes, the three main
categories for these classifications are mobile offshore drilling unit (MODU), well intervention unit Type
1, and well intervention unit Type 2.
Deepwater conventional rigs, also known as MODUs, are historically used for drilling and completing
wells but can also be used for CT well intervention, which requires a riser-based system. A MODU can
perform a variety of well interventions and does not have many limitations in regards to CT. This benefit
also comes with a downfall associated with the costs of operation.
Vessels classified by DNV as well intervention unit Type 2 have similar capabilities of deploying risers
from vessel to subsea tree but tend to have a lighter equipment setup than a MODU. Type 2 vessels also
have the ability to handle hydrocarbon returns to surface and CT well intervention can be completed
through a similar riser-based setup as with a MODU. Costs of operation may be slightly less than that of
a conventional rig but not as significant as the costs related to using a Type 1 riserless light-well
intervention vessel.
Type 1 vessels have historically been used as riserless wireline intervention vessels when dealing with
well intervention. These vessels create flexibility by enabling equipment to be temporarily installed and
used to perform subsea operations. CT is not typically associated with Type 1 vessels, but many subsea
issues can be solved by deploying CT from a Type 1 vessel.

CT Umbilical Overview
A substructure specifically designed for a CT injector head is placed over the moonpool of the vessel (see
Fig. 1) to allow access to the open water. This substructure must be able to support the weight of the CT
injector head in addition to the expected weight of CT being deployed from the vessel. CT umbilical
operations begin with loading all equipment onto the vessel dockside and sea fastening according to vessel
standards. After rigging up and sea fastening all equipment, the vessel can travel to location and begin
deploying CT subsea. At a depth slightly above the seafloor, CT is deployed and hung from the vessel
through the injector, enabling the operator to transport various types of fluids and/or gases to subsea
equipment. These fluids and/or gases may be conveyed into the wellbore, flowline, or simply into open
water. Once the operation is complete, CT and other auxiliary equipment are recovered and the vessel can
return dockside to offload equipment. An average CT umbilical operation lasts 1-3 weeks with longer
duration projects lasting 6-8 weeks.
SPE-173659-MS 3

Figure 1—Substructure spanning moonpool

The scope of work plays a significant role in the job design of CT umbilical operations. Parameters of
the job such as water depth, vessel size, job duration, fluids conveyed, pump rates, and pressures must be
reviewed to ensure the job can be performed in a safe and efficient manner. All parameters are input into
software to determine the CT string size and length. Once a string is selected, further prejob operational
planning can continue.
Prejob planning for CT umbilical operations is critical due to the fact that these operations are out of
the normal CT scope of work. Good communication between service companies, the operator, and vessel
personnel is critical. To begin prejob planning, all CT equipment needed to perform the scope of work is
identified as well as any auxiliary equipment such as fluid or nitrogen pumping units. Equipment layouts
are drafted to determine placement of equipment on the vessel and how each piece of equipment will be
secured to the deck. Once equipment layout is finalized the method of connecting CT to subsea equipment
must be selected.
The CT bottomhole assembly (BHA) is a critical component within the umbilical setup and will vary
depending on the job type. This assembly has a combination of rigid and flexible sections which are
required to create a connection between the CT and subsea equipment. Normal CT umbilical operations
utilize a standard CT connector combined with a clump weight sub and crossover to high-pressure
connection as the rigid section of the BHA. The clump weight is positioned below the end of the coil to
minimize current effects on the tubing. If currents are too strong, the CT will begin to drift against the
vessel, which can prevent deployment or retrieval and can also produce loads that have a negative effect
on CT triaxial stresses. The flexible section of the BHA is typically a 100 ft. high-pressure hose that is
incorporated between the end of CT and the subsea receptacle. This hose is attached to CT and is equipped
with a hot stab connector that enables ROVs to make up connections subsea. Depending on the job type
and water depth, prejob analysis of collapse pressure is required when dealing with these flexible hoses.
Once all prejob planning issues are resolved the job is ready to be mobilized to the dock to begin
equipment installation on the vessel.
All components of a typical CT unit are mobilized and rigged up onto the MSV while the vessel is
dockside to ensure all operations are performed in the safest, most efficient manner. An injector stand
specifically engineered for CT umbilical operations is used to safely make up any connections onto the
required BHA, rendering it ready for deployment once the MSV is on location.
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Once the MSV is on location, the only step to be performed before pipe can be deployed is to lower
the high-pressure hose into the water. Handling this long hose requires assistance from the crane and ROV
crew. Operations have been performed with hoses as long as 150 ft. and weighing roughly 225 lbs. ROV
hooks and straps are attached to the end of the hose to allow the crane to lift and deploy it through the
moonpool. Once underneath the vessel, an ROV disconnects the strap to free the crane while the opposite
end of the hose is secured to the CT. CT is now ready to be deployed to the seafloor while ROVs provide
supervision. Once CT reaches the depth needed for operation, CT weight is monitored for any abnor-
malities, especially if any other down lines are in the water. Once the ROV connects the hot stab to subsea
equipment and opens all valves necessary the job can proceed. To retrieve CT, all steps for deployment
are reversed, and once all equipment is secured, the vessel can return dockside for demobilization.
Case History 1
A customer requested a CT string be deployed subsea in order to perform subsea leak detection testing
in a deepwater environment. The goal of this testing was to determine if the leak detection system installed
on a semi-submersible vessel was able to identify gas leaks in 6,500 ft. of water. CT was to be deployed
from a well intervention unit Type 1 vessel and nitrogen was to be utilized as a medium for gas simulation.
The gas leak rate determined for testing was far below the equipment minimum rate; therefore, a subsea
manifold system was designed to regulate the rate of nitrogen gas. Since the scope of work did not require
high flow rates, pumping liquids, or connecting to a wellhead, a long 2 in. hose was not required in the
BHA. Instead, a panel was designed and installed onto the top of the clump weight in order to connect
the CT to the subsea manifold with the aid of an ROV (see Fig. 2). This panel incorporated a hot stab
female receptacle, which was connected to the CT via a short 1 in. high pressure hose before being
deployed subsea.

Figure 2—Clump weight panel

SPE-173659-MS 5

During prejob planning, an initial equipment layout was sent to all parties for review. Due to vessel size
and crane placement, the moonpool substructure was not able to be fitted directly across the moonpool,
leaving only enough room for the CT reel to be placed in line with the injector. The layout flexibility
allowed the substructure to be set up in a way to accommodate the vessel obstructions. Major delays were
avoided due to this equipment layout planning between vessel and CT personnel prior to mobilization.
A system integration test found that the injector head selected for the job was not fitted properly onto
the substructure. A slight modification was completed before the job loaded out eliminating any on-site,
non-productive time.
Once the job was ready to mobilize, all equipment was rigged up, sea fastened to vessel dockside, and
mobilized to location over the course of 48 hours. While on location, unfavorable sea states caused a few
delays while deploying non-CT equipment to seafloor. Once weather conditions subsided, the job was
performed successfully in 3 days. While retrieving CT to surface, the CT was contacting the vessel’s
moonpool wall due to strong currents and retrieval was halted. After the situation was analyzed, vessel
heading was adjusted to take into account the current’s effect on the CT. Once the CT was not in contact
with the vessel, it was retrieved without any issues.
Case History 2
The next case involves utilizing two CT down lines to enable circulation of monoethylene glycol (MEG)
through subsea pressure control equipment to prevent hydrates. Although all previous CT umbilical jobs
performed had involved only one CT down line, the use of a second injector over the moonpool was
investigated. After engineering analysis, a substructure was designed (see Fig. 3) to deploy two CT strings
from one well intervention unit Type 1 vessel. With the ability to deploy two CT down lines, a flow path
was created to allow circulation down one CT string and to return up the second.

Figure 3—Modified Substructure

During prejob planning, the customer requested the ability to pump a cement slurry through at least one
CT string for zonal abandonment in the event the riserless wireline operation could not successfully
6 SPE-173659-MS

perform the original scope of work. With the flexibility to utilize the most efficient sizes of CT, the strings
selected for this job were 1.5 in. and 1.75 in. OD CT.
While on the job, the customer decided to abandon the lower zone by squeezing off perforations and
also setting a balanced cement plug in the tubing. Cement slurry design needed to take into account
temperature changes from surface (80°F) to seafloor (39°F) and down to perforations (110°F). Once a
cement slurry was designed and tested, rheology numbers were used to determine if the slurry could be
pumped down CT without over-pressuring the system. Due to unique parameters of the CT umbilical job,
software simulations have to be carefully analyzed to ensure proper modeling. Modeling a worst case
situation of pumping the cement slurry with the entire CT string at surface, reel full of cement, and without
the aid of hydrostatic pressure, a pump rate of 0.5 bpm could be achieved with a pump pressure of 7,000
psi. The slurry was determined to be suitable to pump through CT. After the first slurry was squeezed into
the perforations and pressure tested, holes were punched in the tubing to create a flow path up the casing
and through the flowline. The flowline was flushed prior to pumping the balanced cement plug into the
tubing and casing. The maximum pump rate and pressure throughout the cement job was 0.6 bpm and
4,500 psi.

Operational Challenges and Improvements

With every CT umbilical operation completed, challenges are met and overcome, and improvements are
made in the process. Dealing with ocean currents and temperatures, combined with deploying CT through
an injector head not connected to a riser, make umbilical operations unfamiliar territory. Over the years,
these improvements have created a more efficient process while minimizing HSE risks associated with
these unfamiliar operations.

Minimizing Connections
Original CT umbilical jobs previously performed have used a standard external CT connector combined
with a clump weight sub, which is engineered with pad eyes to be able to hang the clump weight below
the end of the CT to keep tension applied to the pipe. In order to eliminate possible leak points at the
connections between the connector, clump weight sub, and high-pressure hose connection, a fit-for-
purpose CT connector is installed, which integrates these components into one assembly. Minimizing
connections provides multiple benefits such as a shorter BHA, fewer connections for possible leak points,
and less HSE exposure time for making up connections. Another method to shorten the BHA was to
incorporate pad eyes and a hose connection into the CT connector. When determining the connection
between hose and the CT connector, a couple of options exist. The 1502 connection, which is most
commonly used for CT operations, can be the connection of choice for the hose. The other option is to
use a clamp connection, which is commonly used in subsea applications. The main benefit of the clamp
connection would be the elimination of connections “backing off.” All connections made at surface will
typically be performed while dockside, which leaves the only connection left to be made up subsea by the
ROV. This hot stab style ROV connection is incorporated into the end of the hose not attached to the CT
BHA. This connection may have restricted flow paths; therefore, to prevent debris from plugging the
receptacle, the CT string should be acid pickled prior to the job.

Residual Curvature
When deploying CT subsea, the tubing has a residual curvature that does not allow pipe to be deployed
completely vertical into the water. To solve this issue, tension is applied by hanging a clump weight below
the CT BHA. The first clump weight had a square-shaped design, which was found to be a problem when
dealing with strong currents. A cylindrical clump weight was developed to minimize drag resistance
acting on the sides of the clump weight due to the current. Although the cylindrical clump weight aids CT
deployment, stronger currents may still cause an issue. In order to prevent CT contact with the vessel due
SPE-173659-MS 7

to CT curvature and excessive bending caused by currents, caution must be taken during deployment and
retrieval.
Deck Space
While performing subsea operations on Type 1 vessels, deck space may be limited due to vessel size and
the possibility of having to share one moonpool for multiple services which creates the need to be flexible
with the CT equipment layout. A rotating injector structure was designed to give multiple layout options
for the CT equipment allowing each individual injector to be rotated in order to have flexibility when
placing equipment on vessel.
Transferring Injector Head
As stated earlier, the process of transferring the injector head to the moonpool substructure can create
many safety risks. This process was especially problematic due to the length of high-pressure hose hooked
up below the CT injector head. Typical CT injector stands are four sided structures that allow the injector
to be secured above ground level. Utilizing a normal CT injector stand created additional risks by either
having to hook up the hose underneath a suspended load or by lifting the injector head (with the hose
attached) 100⫹ feet above the deck to place onto the moonpool substructure. When lifting loads this high
above the deck, operations may not be able to be performed on location due to sea states. To mitigate this
issue, a C-shaped, three-sided injector head stand (see Fig. 4) was engineered and built to lift the injector
head (with the hose attached) only a few feet above the deck and transfer to the moonpool substructure
for deployment. The improved injector stand design minimized safety risks associated with transferring
the injector and also created a quicker, more efficient process.

Figure 4 —Injector stands designed for CT umbilical operations

Second CT Umbilical
As subsea umbilical operations evolved, a need arose for a second CT string in the water. This second
down line created the ability to circulate down one string and return fluid back to the vessel with the other.
Having dual strings deployed also provides the option of increased fluid rate available for operations. The
challenge of adding a second injector over the moonpool was overcome by engineered modifications to
the existing substructure to allow for dual injector head support. The major benefit of dual string
8 SPE-173659-MS

deployment is to circulate hydrate preventative fluids through any subsea equipment where possibilities
of hydrate formation exist.
Mobilization and Rig Up
Mobilizing and rigging up equipment dockside enables safe operations because vessel movement is
extremely minimal. Most offshore crane operations are performed with a crane in a relatively stationary
position, but when performing crane lifts on a dynamically positioned MSV, crane operations can become
very challenging. As sea states begin to rise above 1-2 ft., extra safety measures must be put in place. If
the CT injector head needs to be transferred from the injector stand onto the moonpool substructure at sea,
a full job hazard analysis should be performed. Depending on the size of the vessel and sea states, some
lifting operations would have to be postponed until calmer conditions exist to safely perform the lift.

CT String Management
The utilization of CT in open water introduces factors that may affect CT life that are not encountered in
conventional CT operations. Currently being investigated are the effects of high-cycle/low-strain fatigue
and the corrosive effect of long-term exposure to seawater.
Existing CT fatigue models are able to track the cumulative fatigue that takes place during the
low-cycle/high-strain plastic deformation movements of the pipe from the reel, over the gooseneck and
into the well. While this type of fatigue tracking model is still used during riserless umbilical CT
operations, additional high-cycle/low-strain forces acting on the CT—such as direct wave forces, vessel
movement, and vortex induced vibrations—are not yet tracked using current fatigue models because the
effects of these factors on CT pipe are not fully understood. For this reason, safety factors are put into
place to take into account any unknowns. During initial job design, tri-axial stresses are predicted and CT
string selection is based on which string design results in the least amount of stress. Since higher tri-axial
stresses increase the effect of stress cycling on fatigue life, a maximum of 60% of tri-axial stress is used
for CT umbilical operations instead of the standard 80% for normal CT intervention. Along with
incorporating a safety factor during selection of CT strings to be used, additional monitoring ensures
external corrosion does not exceed acceptable limits.
Surface corrosion from long-term exposure to seawater will also affect the decision to retire a string.
Current practices are to visually inspect the pipe when it is retrieved from the water. Severe pitting is noted
and measured to determine if pits are approaching or have exceeded 10% of the nominal wall thickness—
the CT industry guideline used for retiring string due to pitting (MacArthur, Shearer, Crabtree, & Nelson,
1999).
Accurately tracking the effects of these new factors for individual CT strings may prove difficult. In
order to correctly model high-cycle/low-strain fatigue; either metocean data would have to be interpreted
to determine pipe movement or some type of strain/movement monitoring device would be required for
each deployment of CT in open water. Through bend fatigue testing of CT used in these types of
applications, a confident de-rating factor may be determined that can be applied to the current models for
low-cycle/high-strain pipe movement.
Previous low cycle testing has been performed for CT that was exposed to open water for a period of
44 days. A testing program for high cycle fatigue testing was conducted by an operator as part of a subsea
coiled tubing project for West Africa (Buitrago & Quigley, 2005) with positive results. Low-cycle
bending fatigue tests for this string resulted in failures occurring that tracked closely to the predicted safe
working life (safe working life defined as probability of 1 failure per 1000, without defects). Also, all
pitting depths measured were lower than the 10% guideline used for retiring strings. All pinholes formed
were associated with external pits. As of this writing, the longest period of time a CT string has remained
in the open water is 64 days. Multiple samples from this string are currently being examined for surface
corrosion severity, and are being subjected to low-cycle bend fatigue testing for comparison to safe
SPE-173659-MS 9

working life remaining based on current fatigue models. In the future, additional CT strings used on
umbilical applications will continue to be tested.
Conclusions
CT can be deployed from a vessel of opportunity as a viable solution to deepwater subsea problems. A
well-engineered approach to job design and operational tasks can be utilized to increase production,
advance technology, prevent environmental issues, and enhance intervention operations. Major benefits,
due to mechanical strength of CT, have been seen with successful operations performed at 8,000 ft. water
depth. CT umbilical operations provide the operator with a safe, time-saving, and cost-effective option to
remedy wellbore, flowline, or subsea equipment issues. With the added benefit of a second CT downline,
future stimulation treatments may have the option to pump twice the fluid rate previously achieved. With
the ability to deliver nitrogen gas subsea, many different options from dewatering to artificial lifting may
be looked into as a relevant solution. With the increasing need to reduce well abandonment costs, riserless
operations are becoming more and more frequent. With many deepwater fields coming online, the demand
for intervention work will continue to rise and CT umbilical operations give the operator one more tool
to use from a growing toolbox of solutions.

Acknowledgements
The authors would like to thank Baker Hughes for permission to publish this paper and all of the offshore
crews involved in making CT umbilical operations successful.

References
1. MacArthur, J., Shearer, C., Crabtree, A., & Nelson, R. (1999, January 1). Coiled Tubing NDT
Inspection: Implementation, Experience and Results. Society of Petroleum Engineers. doi:
10.2118/56940-MS
2. Buitrago, J., Quigley, S. (2005, November). High-Cycle Fatigue Qualification of Coiled Tubing
for Deepwater Subsea Intervention. Deep Offshore Technology Conference.
3. Offshore Service Specification. DNV-OSS-101. (2013). Rules for Classification of Offshore
Drilling and Support Units. Retrieved from https://exchange.dnv.com/publishing/Codes/
download.asp?url⫽2010-10/oss-101.pdf dnv well intervention unit