Introduction To Coiled Tubing

ALGERIAN PETROLEUM INSTITUTE
IAP spa
Introduction to
Coiled Tubing
Novembre 2008
Coiled Tubing et ses applications
Well Intervention Services

Coiled Tubing is a service used for Well Intervention in the Oil, Gas industries.
It is widely accepted as one of the Safest, fastest, and most economical means of
performing well stimulation, work over, and drilling operations.
History of Coiled Tubing
1944 – Allied Invasion Project
The concept of using a coiled steel pipe first came during the WWII. The allied forces
fighting in the Europe had to be supplied with fuel across the English Channel. So, they
took 4000’ steel pipe sections, butt welded them together and coiled them into spools.
The spools were then buoyed in water and towed behind cable ships. In this way they
layed about 23, 3” pipelines. Some of the pipelines were 30-70 miles long. This operation
was Called operation PLUTO i.e., Pipe Lines Under The Ocean
R^Khelil-SH-DP page.2 Novembre 2008

Coiled steel pipe was one of the options used here. They also had some rubber hoses
laid across the channel for the same purpose.
Now this historical background was important from the CT view because this was the
first time that steel pipe was coiled and used. It was the first practical use that proved
that steel pipes could be coiled and used effectively.
After years of research and technological advancements, this idea developed into the
CT operations we do now and is on a continuous improvement path
Origins & History of Coiled Tubing
History of Coiled Tubing 1960's
The fabrication techniques developed in Project PLUTO were applied in the early
1960s to develop small-diameter Coiled Tubing. The Great Lakes Steel Company and
Standard Tube Company butt-welded joints of pipe to manufacture Coiled Tubing.
Republic Steel manufactured the first tube in continuous lengths. They used a high-
strength, low-alloy (HSLA) steel, which is the basis for the steel used today.

In 1969, Southwestern Pipe began manufacturing pipe for Coiled Tubing use.
Although the steel had only 50,000 to 55,000 psi yield strength, the improvements in
manufacturing greatly increased pipe performance.
Coiled Tubing services for the oil and gas industry started in the sixties and soon
owned a very bad reputation. Although the advantages of using continuos tubing
strings were clear, the poor quality of the Coiled Tubing strings led to numerous
problems and failures in the field.
First Oilfield Application
The first oilfield CT operation was done in 1962 by California Oil company. The
equipment for the job was developed by Bowen Tools.
The operation involved washing out sand bridges in Gulf coast oil and gas wells. In
this operation, The 1-5/16” size tubing was used. The tubing was 15000’ in length and
made by butt welding 50’ pipe sections together.
The tubing manufacturing technology has come a long way since then and it is quite a
neat operation to see. The tubing sizes are much bigger now, the material used is
much better, strength has increase quite a bit and the reliability is far greater than it
used to be.
The tubing used by Halliburton is manufactured by Quality Tubing. They have their
plant in Houston and they supply tubing throughout the world from here. All the
material that they use for manufacturing tubing comes from a Japan.

In 1980, Southwestern introduced the first 70,000-psi-yield Coiled Tubing. Later, they
introduced quenched and tempered Coiled tubing using chrome-molybdenum steel.
This process not only increased the life cycle of the tubing, but also improved its
strength to 100,000-psi yield.
By 1982, Quality Tubing was supplying the entire Coiled Tubing industry. It used
Japanese-manufactured steel with better quality-control guidelines and sheets up to

3500 ft long to produce Coiled Tubing with better quality control than that of its
competitors.
In the late 1980s, Quality Tubing Inc. developed the bias-weld technique, eliminating
butt welds and allowing for a continuous-milled string of Coiled Tubing.
All these improvements led to more reliable Coiled Tubing operations in the field.
Operators gained more confidence in Coiled Tubing services as failure rates decreased
and the service became saver.
More and larger pipe sizes became available during this period.

In 1990-1991, Precision Tube Technology was founded by former employees of
Quality Tubing Inc. Using techniques similar to those of Quality Tubing, Precision
was the first to manufacture titanium Coiled Tubing.
In 1995 Schlumberger formed an alliance with Precision Tube Technology, making
them the preferred supplier of continuously-milled Coiled Tubing in diameters
ranging from 1 in. to 3 1/2 in. and in a yield strength ranging from 70,000 to 90,000
psi. Over the past years, the shift has been to higher strength materials, and currently,
the majority of the tubing used has an 80,000 psi yield strength.
Improved manufacturing processes and quality control, together with a better
understanding of the forces acting on Coiled Tubing strings led again to less failures
in the field and more confidence in the use of Coiled Tubing.
Operators and service companies started to expand the use of Coiled Tubing beyond
the basic pumping operations performed in the sixties, seventies and eighties. New
advanced applications as Coiled Tubing Drilling and Coiled Tubing Completions
emerged.

Injector Head History

One of the important CT surface equipment is injector that is used to run the pipe in
and out of the well. The concept of injector came from the submarines. In submarines
they deploy the radio communications and sonic detection antennae to the ocean
surface. Developed by Bowen Tools for US Navy in early 1960s
The antennae is held between grooved blocks secured to the two sets of chains. This
same concept was used for the injector later with 2 sets of chains to hold the pipe and
move it up or down.
Coiled Tubing Equipment

The basic configuration of a coiled tubing equipment package is dependent on:
 Operating environment
 Offshore, Arctic, Desert
 Primary applications
 Units prepared for CTD operations will typically be larger than conventional
service units
 CT string dimensions
 String length/OD and necessary reel dimensions

Basic Equipment Configurations

CT units designed to operate:
Onshore
 Paved road trucks (road legal for operating area)
 Off-road trucks (all-wheel drive, e.g., desert)
 Mobile mast units (special environment, e.g., arctic)
Offshore
 Skid mounted units (crash-frame protected, zoned)
 Barge mounted units (permanent placement)
 Jacking barge/tender vessel
The most obvious categorisation of operating environment is offshore or onshore. This

implies the equipment is either truck mounted, for onshore operations, or skid mounted
for offshore use. However, the flexibility of some skid mounted designs become apparent
when the skids are fixed to an appropriate truck or trailer body for use onshore.
Special designs such as mobile mast units or chasis mounted truck units are less common
and typically custom designed to meet the restrictions or requirements of the operating
environment (e.g., winterised arctic units)
The majority of offshore units are configured around a “standard” skid design with the
level of protection (crash frames and ruggedising) being determined by the placement of
the equipment, e.g., permanently mounted or mobile.

CTU – Paved Road
Trailer mounted CTU
Trailer mounted CTU configured from skid mounted equipment for flexibility. The
crash frame protection is removed (to reduce weight) when the skids are fixed to the
trailer, but can be fitted if the equipment is to be shipped offshore.
The configuration shown requires two trucks. The truck/trailer shown transports the reel,
control cabin, power pack and BOP. A smaller crane truck is used to transport the crane,
injector head and riser wellhead package (as required).
Weight restrictions (country, state or road capacity) and the required CT string
size/length (weight) are the key factors in determining if two trucks are required for the
CTU package.
CTU – Off-Road
Truck mounted (6 x 6) CTU
The equipment configuration shown is largely built directly onto the truck chasis. In
addition, the hydraulic power required to run the CTU is provided by the truck engine.
This particular example is intended for use in a desert environment with relatively
shallow intervention capability (note the small reel capacity).

CTU – Mobile Mast
Trailer mounted mast unit for arctic operations
The severe climatatic conditions encountered in arctic areas means special provision must
be made to portect equipment and personnel. The unit shown is specifically designed for
arctic operations and incorporates a number of unique features.
The cabin located on the tractor contains a high-pressure pressure triplex pump, driven
by the tractor engine for circulating fluid through the CT.
The workspaces and equipment compartments (reel, power pack and control cabin) are
fully winterised.
Injection systems are fitted to freeze protect internal and external CT string surfaces. In
addition, H2S inhibitors can be injected at the BOP/wellhead level.
The mast extends to 77 feet and can support 25,000 lbm.
CTU – Skid Mounted
Skid mounted for offshore operations
The primary restriction associated with offshore operations is the ability to get the
equipment on and off the rig or platform. For this each item of equipment must be within
the safe working limit of available cranes. Consequently, light-weight units are required.
However, the conditions under which the units are transported and lifted requires a high

degree of damage protection which in itself accounts for significant weight. Therefore,
the design of offshore equipment involves a trade off between weight and “survivability”.
In the example shown, the crash protection frame has been removed from the reel. This
option requires good weather conditions and a high level of confidence in the crane
operator!
The options available for equipment rig up are frequently limited offshore. Associated
equipment such as tanks or containers are often stacked.
CTU – Barge Mounted

The CTU equipment used on “permanent” or “semi-permanent” applications such as that
shown is typically skid mounted for flexibility and ease of positioning.
Lake Maricaibo barge mounted unit
CTU – Jacking Barge
Gulf of Mexico jacking barge
Barges are typically configured to enable the complete packeage of CT and associated
equipment - including chemicals and materials for mixing and pumping - to be shipped
on board.
Equipment and treatment lines are “permanently” rigged to enable a rapid final rig up
once on location.

Desirable String Characteristics

The desired characteristics of a CT string generally include:
 Mechanical strength
 Withstand forces applied under operating conditions
 Pressure capacity
 Withstand burst and collapse pressure differentials
 Longevity
 Exhibit predictable and acceptable life expectancy
 Service and maintenance

 Can achieve adequate utilisation and may be field repaired
 Economy
 Relationship between cost and the above factors
CT String Materials
 Almost all CT is manufactured from:
 Low alloy carbon steel – A606 Type 4, Modified
 Drivers for alternative materials include desire for:

 Improved working life or fatigue resistance ($/job)
 Higher strength to weight ratio
 Resistance to corrosion
 Alternative materials under investigation include:

 Quench and tempered chrome-molly alloy steel
 Titanium
 Composite materials
• Quench: Cool after heating: increase strengh
• Temper: reduce the stress and gives ductibility
Main Components
 Injector head
 Coiled tubing reel
 Control Cabin
 Power Pack
 Pressure control equipment

• The coiled tubing unit :

A continuous string which is pushed into/out of the well to convey tools or fluids down
hole to perform a certain function.
Power Pack to supply the required power by the different components.
The injector head holds the tubing ,by means of chains and hydraulic rams, and hydraulic
motors are giving the power to the chains.
A reel drum which is used to store the tubing orderly spooled and ready to feed/collect
from the injector head.Depth and tubing monitoring equipment are also included on the
reel assembly.
Control cabin from where the different components and the auxiliary systems of the unit
are fully controlled and monitored.
Unit can be either as separate modules for offshore applications, trailer mounted for land,
or either ways by means of crashing frames.
Injector Head – Principal Components

Primary components/functions include:
 Hydraulic drive/brake system

 Drive chains and tensioners
 Gooseneck or guide-arch
 Weight indicator sensor
 Depth system sensor
 Stripper mount
To provide the functions previously listed, CT injector heads are equipped with the
principal components shown. The design, capacity and method of operation may vary
between injector head models and manufacturers; however, these components are
common to all injector heads.
CT Reel – Primary Components

Typical reel components:
 Reel drum (1)

 Reel drive system (2)
 Levelwind assembly (3)
 Reel swivel and manifold
 Lubrication system (4)
 Depth counter (5)
Skid Mounted Reel
Skid mounted, crash-frame protected reels
Power Pack – Primary Components

Power Pack
 Engine
 Hydraulic pumps
 Hydraulic control systems
 Onboard accumulators
Control cabin
 System (CTU) instruments and controls
 Well/operation monitoring and recording equipment
La ye r 1 Hig h Exh au st L
o w O il Lo ss o f
T
Heigmp
h Ce oo
ra tu
la re
nt Tem p era tu re Pres sure Co o la nt
C oo la nt O il
Tem p era ture Pre ss ure
Eng ine
Pe rmis sive Ta c ho me te r
start
Sta rt
Eng in e Eme rg e nc y
Kill Kill Air
Pres sure

Control Console
Control console
Pressure Control Equipment

 Stripper
– generally permanently mounted on the injector head
 Blow-out preventers
– combi configuration most common in North Sea
 Riser, lubricator
– application dependent
 Ancillary equipment
– wellhead crossover(s), flow “T”, kill line and valves
 Downhole check valve

– preventing back-flow of wellbore fluids
Coiled Tubing and Workover Units

Standard Workover Unit
 Generally requires longer rig ups / Downs
 Longer RIH and POH.
 Need to stop circulation to make pipe connections.
 Generally need to kill the well for operations.

Coiled Tubing Unit

 Faster rig ups / Downs
 Live Well/ Min. production dowtime
 Continuous tubing / continuous circulation
 Enhanced Tubing Management
 Improve Safety (min. thread connections)
More Coiled Tubing Advantages

 Self-Contained unit, requires no rig
 Saves time and money - do not have to kill well
 Typically used on live wells so no kill fluids necessary. Reduced damage to
formation
 Act as tool transport for horizontal wells
Coiled Tubing Limitations

 Small Diameters
– Restricted Flow
– Reduced Rates
 Rotation of Tubing
 Limited Reach in Horizontal Wells

Coiled Tubing Service – Benefits

 Rapid mobilization capability
 Rapid rig-up and wellsite preparation
 Live well intervention (maintaining high degree of safety)
 Reduced trip time and well downtime
 Lower environmental impact
 Reduced crew/personnel requirements
 Lower cost with greater flexibility
Coiled Tubing Applications

 Conveying fluids
 Conveying tools
 Acquiring data
 Installing completion equipment
Several advanced applications combine these functions to further enhance the cost
and technical benefits of CT applications.
Applications – Conveying Fluids

 Kick-off (production initiation)
– Nitrogen or light-weight fluid circulation
 Stimulation treatments
– Wellbore, perforation or matrix treatments
 Squeeze cementing
– Including other treatments for zonal isolation
 Wellbore fill removal

– Chemical, jetting or mechanical
 Scale or paraffin removal

– Chemical, jetting or mechanical
Applications – Conveying Tools

 Sand control
– Thru-tubing tools and treatments
 Water control
– Thru-tubing tools and treatments
 Perforating
– Hydraulic actuated firing (alternative to CTL)
 CTD (coiled tubing drilling)

– New wells, re-entries and through tubing re-entries
Applications – Data Acquisition

 CTL (Coiled Tubing Logging)
– Conveying logging tools in deviated and horizontal wellbores – wireline installed
 Memory gauges
– Battery powered gauges for pressure, temperature and flowrate measurement
 DSP (Downhole Sensor Package)

– Realtime data acquisition during treatments
 Deadstring monitoring
– Monitoring downhole conditions while fracturing
Applications – Completion
 New installation/recompletion
– Use of CT and associated equipment as a primary conduit
 Remedial (temporary)
– To allow continued production until the next scheduled workover
 Remedial (permanent)
– Modifying hydraulic performance,l
Coiled Tubing Activity – 1998

 Fluid Conveyance
 Makes up 50% of all activity
 CT Drilling
 Sharp increase over 1996 (from 5% to 11%)
 New Services
 Water Control, Scale Removal, CT Perforating (all in Others) continue to increase

Others 30.3%
Cementing 2.7%
Drilling 10.9%
Pumping 20.1%
Logging 4.3%
Tools 5.2% Kick Offs 10.0%
Matrix 16.6%
World CTU Distribution October 1995

CTU distribution by geographical region:
 North America 288

 Africa 50
 Europe 76
 Far-East 70
 Mid-East 58
 Latin America 74
Total 616

CT Service Providers
CTU distribution by service provider:
 Dowell 135
 Halliburton 125
 Nowcam 79
 Nowsco 60
 Cudd Pressure Control 38
 BJS 21
 Transocean 5
 Others 150
Total 614
2003 World-wide Distribution of Schlumberger CT Units

Currently Schlumberger has over 200 coiled tubing units worldwide, making it the largest
provider of coiled tubing services in the world.
Africa & Mediterranean 22
Far East 20
Latin America 20
Middle East 30
North America 80
North Sea 36
Research & Development 1
Training 2
World CTU Distribution 2004

CT Quality Package
 UTIM (Universal Tubing Integrity Monitor)

 CoilCAT
 CoilCADE™ (Software)
TIM :
– A tool to monitor the pipe and keep a record track of its status. It also
help to predict intervals failure likely to happen so it can be
terminated and avoided.
PRISM
– A pc window based Coiled tubing job monitoring software.
CoilCADE :
– Tubing forces, friction, foam cleanout simulation to predict all
different parameters values to ensure the job success. CoiLIMIT
incorporating a database for pipe tracking.

Injector Head
Tubing Injector Head
 Guides and powers the tubing string in and out of the hole.
 The tractive components of the injector head are generally configured to drive two
opposing endless chains
 The gripper blocks are shaped to the size of the tubing being used.
 Hydraulic motors drive the chains,
Components
 Injector chains (not shown)

 Injector drive motor (1),and brakes
 Gooseneck or guide arch (2)and pipe straightener
 Inside traction and outside chain tensioners (3)
 Stripper mounting (4)
 Inside and outside frames
 Weight indicator/Limit bolt

Injector Head – HR 240
Injector Head – HR 480
Injector Head - Side view

The Injector head essentially consists of hydraulic motors (1) connected to chains (2) that
move the tubing. The motors actually turn the chains through a set of Timing gears to
synchronize the movement of both chains.

The injector consists of basically of two separate frames.
 The inner frame is attached to the base with a hinge on one side(3) and a dual-
acting electronic load cell (4) on the other side to measure the tensile and
compressive forces
 The Outer Frame which mainly consists of the Crash frame attached to the same
base as the inner frame, but by rigid connections
Hydra Rig Injector Head - View from Console
HYDRA RIG HR 240 INJECTOR

HEAD FRONT VIEW
Injector drive motor

Injector Head
lubricant reservoir
Hydraulic connectors
Stripper assembly
Weight indicator
Hydra Rig Injector Head - Side view
HYDRA RIG HR 240

INJECTOR HEAD SIDE VIEW
50” Radius
Gooseneck
Gooseneck
flared end
Injector Drive
Motor
Rear injector chain
tensioner sprocket
Front injector chain

tensioner sprocket
Inside chain tension
system
Accumulator

Injector Head - Typical Specifications

Injector Head Model
HR 240 HR 440 HR 480 SS Dr

Capacities
Min. tubing size 1 1-1/4 1-1/2 --
Max. tubing size 1-1/2 2-3/8 3-1/2
Max. pulling force
open loop(lbf.) 40,000 40,000 80,000 --
closed loop(lbf.) 40,000 60,000 100,000 --
Max. snubbing force (lbf.) 20,000 20,00040,000 --
Max. running speed (fpm) 210 240 150 --
Dimensions
Length (in.) 53 55 64 - -
Width (in.) 34 52 64 --
Height (in.) 65 80 109 - -
Weight (lbm) 3,400 7,800 12,650 - -
Chain System – Hydra-Rig

 Typical chain system includes:
 Drive sprocket/system (1)

 Inside tensioners (2)
 Outside tensioners (3)
 Lower idling sprocket (4)
3
3

Injector Head Selection

The important facts to cover in this circuit are:
 Accumulators that work as dampeners

 Emergency traction valve - Puts 2000 psi from priority circuit into skates by-
passing the pressure adjusting valve.
 Unloader valve - check valve - accumulator. circuits having hydraulic
accumulators have all these components in order to keep the pressure in the
circuit/accumulator independent of the pressure variations of the pump, which
downloads its flow through the unloader valve to the tank most of the time.
 Isolation valves and relief valves. The relief valve is set at about 2100psi and
avoids over-pressurizing the skate circuit that could cause the pipe to collapse. This
could happen due to dent in the gripper block's face or ovality of pipe.
INJECTOR SERIES HR - 125 HR - 240 HR - 240 HR - 260
Hydraulic motor Series H-25 Poclain H-25 Poclain H-30 Poclain H-30 Poclain
Traction System style “S” “R” “S” “R” “S” “R” “S” “R”
Maximum tubing size(in) 1 1/2” 1 3/4” 1 1/2” 1 3/4” 2” 2 3/8” 2” 2 3/8”
ANSI roller chain series 140 160 140 160 180 160/180 180 160/180
Number of gripper blocks 176 156 168 148 144 168/144 140 164/140
in complete chain set
Maximum rate 32 32 40 40 42 42 60 60
(lb x 1,000)
Injector Chain Components

 Links
 Rollers
 “S” type and “R” type
 Lubrication
 Gripper Blocks
 Non coated
 Coated (Tungsten carbide)
• Here are the main differences between the "S and "R" type chain manufactured by
Hydra-Rig.
• The performance of the "S" type chain has been greatly enhanced by adopting the
new single piece skate bar. This bar does not require any modification to the
Injector Head since it has the same anchoring points.
• Important to note that the "S": type chain is compatible with the Uniflex Injector
Head only requiring a smaller number of links.

Link pins
ROLLER CHAIN
(ANSI 140,160 OR
180)
Link plate Gripper Block

Cam Roller
Split pin
Injector Chains
This overhead shows the main contact in between gripper block /coiled tubing. It is
useful to show where the important points to check the gripper block - coating wear
during standard maintenance.
HYDRA RIG “S” TYPE HYDRA RIG “R” TYPE
Gripper Cam Roller tensioner

block roller assembly
Inside chain tensioners bars or skates Flat backed chain

Comparison “R” and “S” Types

 “R” Advantages
 Lower chain cost
 Greasable skate bearings
 Longer life
 Loads applied directly to gripper block not links/pin
 Available for handling bigger CT OD’s
 “S” Advantages
 Easier bearing changes/removal
 Slightly higher pull/psi of hydraulics
 Compatible with smaller injector head/Uniflex
 Performance with one piece skate enhanced (New)
 Gripper Blocks (Coated & Non-Coated)

There is no proof whether gripper block misalignment is detrimental or not to the CT
life. DS specifies that this misalignment should not be higher that 1/4" when the
injector is new. The alignment is a function of the different lengths between the two
chains, sprocket/teeth wear, timing gear wear etc. Generally speaking, as far as chains
stretch is concerned, both chains stretch at a very similar rate unless there is any
problem with the injector. To cure or to modify the alignment, the action in taken in
the timing gear. To find the correct positioning is necessary to change the relative
position between both timing gear relative to its splined shaft (15 teeth).
50,000
45,000
40,000
35,000
B)
IN
(L
30,000
O
C
U
E
P
T
L
L
J
25,000
20,000
15,000
10,000 Hydra Rig Coated

Hydra Rig Uncoated
10,000
5,000
100 200 300 400 500 600 700 800 900

INSIDE CHAIN TENSIONER HYDRAULIC PRESSURE (psi)

Injector Chain Vertical Misalignment

 The position of the middle shaft (connected to the outside tension) tells about the
stretch of the chains. When this shaft arrives close to the end of the stroke with
normal operational outside tension pressures the chains must be changed.
 This slide features the main points to mention about the inside tensioners, mention
that the single skate bar has greatly enhanced the "S" type chain performance. This
bar does not require any additional modification to the injector head since the
anchor points are the same. Also in the situation where one of the hydraulic
pistons is leaking the single bar will provide a more even distribution of stress.
 The injector manufacturer does not provide any reliable guide lines for hydraulic
pressure against pull capacity, since it is a function of so many variables such as
gripper blocks, coating, pipe ovality and cleanliness. The best is for the operator to
generate a pull test curve ie. Skates hydraulic pressure and pull attainable in order
to better evaluate the injector head capacity.
Gripper block offset
Misalignment should not be higher that 1/4" when the injector is new
The Chain Tensioner

Inside Tensioners
Gripper Cam
block roller
Inside chain tensioners bars

or skates
Inside Tensioners

Inside Tensioners (Skates)

 The Inside Chain Tensioners provide the force necessary for the chains to grip the
tubing. The Inside Chain tensioners, otherwise known as skates (1) are linked in
pairs with hydraulic pistons (2) which are energized to provide the force necessary
for the chains to grip the tubing.
 As the pipe is run deeper into the well, the load on the injector chains increases,
requiring an increased force to the gripper blocks to maintain efficient traction.
This is achieved by using the applied hydraulic pressure in the inside chain
tensioners.
 To reduce the vibrations to the hydraulic pistons there are shock absorbing
accumulators (3) mounted on the Injector Head
 Maintain gripper block pressure against CT via 3 sets of hydraulic rams

 “S” type and “R” type skates

 One piece skate for “S” type (new)
 Hydraulic pump (priority circuit) from power pack (up to 2000 psi)
 Manual back up (Haskell and Rucker pumps)
 Hydraulic pulsation dampeners (accumulators-350 psi)
 Emergency traction and runaway procedures
Recommended skate pressure

 Enough to cope with load run pull test
 Perform pull test curve
Outside Tensioner
It is important to stress the importance of the many times neglected outside tensioner
hydraulic pressure. In the past, failure has occurred due to excessive pressure which
caused lower sprocket/shaft failure as well as chain premature breakage. For this
reason, H-R installed a 150 psi limiting valve on the circuit. The normal operation
pressure are outline too, In the case of snubbing where the forces trying to push the
pipe out of the hole are high as well as the high friction forces due to stripper, it is
necessary to apply higher outside tension. While pulling out of the well the weight of
the pipe puts the chain in tension while in the case of snubbing the chain tends to be
squeezed, decreasing its efficiency if it is not stiff enough. Some curves where
generated by Hydra-rig taking into account size of chains, wellhead pressure and
stretch of the chains. This is only to be used as a guide line since it does not take into
account many factors such as gripper block conditions and stripper friction. As soon
as you gain some weight in the chains, the hydraulic pressure should be put back into
the normal operation range.

Outside Tensioners
 Maintain adequate tension in chain
 Hydraulic ram controlled from cabin
 Hydraulics adjustable up to 150 psi
 Normal operation : 73 - 100 psi
 Important in “Pushing” operation
 Use charts for snubbing
 Unnecessarily high hydraulic pressures damages chains, lower shaft/sprocket
efficiency and deteriorates skate’s force transmission
Outside Tension Snubbing Charts (HR-240)

14
13
IN JEC TOR SN U BBIN G FOR C E R EQU IR ED (lb x 1 000 )
12
11
10
1000 2000 3000 4000 5000 6000 7000 8000 9000 10,000
WELLHEAD PRESSURE (psi)

Outside Tension Snubbing Charts (HR-240)

13-1/4 in. 7 in.
Injector Head Center Line

Injector Chain
Tension Slot
14
13
12
INJECTOR SNUBBING FORCE REQUIRED (lb x 1000)
11
th
ng
10
Le
ain
Ch
9 th
um ng
Le
ain
m
Ch
ni
8
Mi
um
xim
Ma
7
100 200 300 400 500 600 700 800
OUTSIDE CHAIN TENSION SYSTEM PRESSURE (psi)
Traction Controls
Hydra-Rig console control layout, inside and outside chain tensioner systems.

Motors
 Make: Poclain
 10 piston radial piston motor
 HR Injector Poclain Motor
 125/240 H25
 150/260 H30
 Variable displacement motor

 5 pistons : High speed - Low torque
 10 pistons : Low speed - High torque
 Integral brakes
 Timing gears
Injector Head Mounting
Injector Head Two Speeds

 Motor displacement changes depending on number of active pistons
 10 pistons low speed/High torque
 (120 ft/m - 40,000 lbf)
 5 pistons high speed/Low torque
 (240 ft/m - 20,000 lbf)
 Hi/Lo speed actuator disable ports in distribution block
 All pistons share the load

Injector Head Brakes

 Integral mounting
 Spring loaded
 0 psi brakes on
 600 psi Brakes off
 Friction disk stack
 Steel discs fixed to bearing housing
 Sintered bronze disks fixed to shaft
 Manual-600 psi from priority circuit
 Automatic - 600 psi from injector motor circuit
The brakes for the injector head are located within the motor. They are of the disk type
being the disks mounted in the shaft made of sintered bronze while the one fixed to the
bearing housing is made of steel. They need 600 psi to be released since they are spring
loaded. This pressure comes from the priority circuit in the units with manual brake. In
the case of units with automatic brake, the pressure comes from the injector head
hydraulic circuit. Where no pressure is applied to the brakes they are on. Theoretically
the brakes when activated should be able to hold pipe in the hole with a weight equal to
the maximum pull capacity of the injector. (ie., 40,000 lbf to the HR 240). One way of
testing them is to make a pull test with CT or metal bar and record the hydraulic pressure
for that particular pull, remove the bar, close isolation valve in the brakes (needle valve)
to avoid the brake to be released, and apply the same hydraulic pressure in the circuit. In
this occasion the blocks will be holding the same pull./weight of tubing as the pull test.
Unfortunately the levels of pull should not be very high to avoid damaging gripper blocks
etc. Another way to test the brakes at higher pulls is to close the isolation valve and
apply high hydraulic pressure to the injector motor circuit with the brakes on. Although
brakes in good condition should not slip up to the maximum pressure attainable, ie., 3000
psi it is advisable not to exceed 2000 psi forcing the brake plates to slip against each
other can generate scratches on the surface. To avoid this, set the max hydraulic pressure
value to 2000 psi. If the injector chains move in this situation the brakes should be
checked.
Hydraulic Motor Brakes
Inlet
Port

Injector Head Hydraulics

 Features
 Two pumps : 28 and 56 gpm
 Two Poclain motors
 Relief valves set to 3000 psi
 Counterbalance valves
 Speed/Flow control
 Pilot PRV
 Directional/Flow Control Valve: HUSCO
Husco Valve
 Directional - flow control valve
 Two spools:
 Directional
 Pressure compensating
 Safety relief valve

 Incorporated: 3000 psi
 Hydraulic operated directional spool
 Munson Tison valve:

 0-450 psi output
 Pressure from priority circuit
This valve plays two important roles in this circuit, on being a directional valve in-out of
hole and the other a flow control valve ie. it is possible to control the flow to the motors.
This valve at the present time is being exclusively supplied by Husco to Hydra-Rig. The
valve has two spools: control spool and compensating spool. The direction and the flow
control are achieved by the control spool which is moved by pilot pressures ranging from
0 to 450 psi. The spool is spring loaded which will center the spool in the closed position
if no pressure is applied to the pilot ports. This pressure is supplied by the Monsun Tison
valve which is a kind of bi-directional pressure reducing valve receiving 600 psi from the
priority circuit and reducing it to any pressure between 0-400 psi according to the
position of the joystick in the control panel. Due to the springs and internal friction in the
main spool a minimum of about 30 psi is necessary to move the spool and 180 psi to start
to have flow through the Husco valve. Higher pressures applied will further move the
spool increasing the flow of oil to the motors. IN OH 30 and 31 it is possible to observe
the "metering control area" where the flow control takes place. The limit of 450 psi in
the pilot pressure is due to the pilot port chamber rating, in the Husco valve.
The other important feature in the Husco valve is the pressure compensating spool. Its
function is to keep the motor speed constant even when the load is changing. For
instance, when RIH the weight of the CT increases and the tendency would be for the CT
speed to increase; in this case the pressure compensating spool will act in such a way to
keep the speed constant. Assume P2 or being the pressure downstream to the Husco
valve and P1 being the pressure upstream (remember that the metering area is basically a
choke and that changes in load are transmitted as pressure waves from the motor
backwards to the directional valve\ and pump. In OH 30 it is possible to see that the
pump port is connected directly to the P-compensating spool.
The P-C spool works on internal pilot pressures (Pi pilot and P2 pilot) and a brass spring.
The pilot pressures work on both ends of the P-C spool causing the P-C spool to move
allowing port on all the pumps output into the tank gallery.
This system allows the flow that is not required b the working ports to return to the tank
at 75 psi above the pressure required by the working load. Any variation in the
downstream pressure (P2) will break this equilibrium inducing the P-C spool to direct
fluid to the tank in such a way as to re- establish the 75 psi ²P (also present across the
metering areas in the main spool). Where the main spool on the control spool is centred,
locking the load, the P-C spool opens completely allowing the full pump output to the
tank. This happens because of vent holes drilled in the main spool, sending pilot pressure
P2 to tank pressure.
Pilot Operated Counterbalance Valve

• Pilot operated counterbalance valve
– The function of the counterbalance valves in the injector circuit are:
a. Lock the load when injector is in neutral position.

b. Brake/regain control over injector chains in two situations.
i. CT runaway when RIH
ii. CT expelled from well by WHP when POOH
– The pilot operated CB valve is composed of a PRV and a check valve. The
PRV can be either open by applying pilot pressure through port X on
pressure in the cylinder port. Since the areas where the pressure acts in these
two ports is different, the pressure to open the PRV will also be different.
Actually in the CBV's used by Hydra-Rig, the area ratio is 10:1 and the PRV
spring setting is 4500 psi. Therefore a 450psi pilot pressure will be required
to start flow through the CBV. The valve will be closed until this pressure is
reached. This process will take place in the CBV installed in the return line.
The one in the suction line will be bypassed by the internal check valve.

X
Annulus
area
Cylinder
Port
Seat
area
Piston X
area Pilot Valve
Port Port
Power Auto Driller
The function of this system is to run the CT pipe either up or down at very low speeds.
This is not particularly easy to do with the normal injector head circuit. Speed fluctuation
and injector stalls, are common. .
Before continuing, stress the fact that this system has no automatic control to control
drilling, but just gives the operator the possibility to run at low speeds (0.9--> 2.0 ft/min),
it does not provide any control over the weight on the bit.
The PAD system, when activated disables the CBV's in the injector circuit by sending
tank pressure to the pilot lines. The fluid from the motors will return to tank via 1/4"
hose which has three choke devices in series.
 Velocity fuse
 Pre-set choke
 Adjustable needle valve

Depth System Sensor
Typical depth sensor mount (HR 480)
Stripper Mounting Point
HR stripper mount
Weight Indicator
• Mention that this is the most important instrument in the cabin. Its reading is a
combination of tubing weight, drag in the hole and stripper rubbers, buoyancy, reel
back tension, wellhead pressure and other factors.

• The weight indicator is always installed in between the outer and the inner frames.
The hydraulic type can be affected by changes in ambient temperature throughout
the operation which will lead to changes in the reading.
• There are electronic cells available such as the ERAD; they are dual acting cells
and are more accurate over broader conditions.
• Important to stress importance of the limit bolt when using single acting cells.
• In this set of overheads there are the main points stressing the importance of the
gooseneck in the life of the CT pipe.
• Mention the adjustments that can be done in the gooseneck position in order the
centre the pipe in the injector chains as much as possible. At UTC's unit this can
be done by the moving longitudinally the gooseneck as well as adjusting the last
roller above the chain. In some units there is what is called the pipe straightener
which is a set of three rollers mounted at the portion of the gooseneck right above
the chains to obtain a proper pipe centralization.
EXAMPLE OF DUAL LOAD CELL DUAL NEEDLE GAUGE
DUAL ACTING
LOAD CELL HYDRAULIC PORT
CHAMBER
BLADDER
HYDRAULIC HOSES
HYDRAULIC PORT
CELL STEM

Guide Arch - Gooseneck

API Recommendations
Tubing SizeRadius
(in.) (in.)
1-1/448 to 72
1-1/248 to 72
1-3/472 to 96
272 to 96
2-3/890 to 120
2-7/890 to 120
3-1/296 to 120
HR 240 - 72-
in.
HR 480 - 108-
in.
HR 240 - 50-
in.
Gooseneck
50” Radius
Gooseneck
Gooseneck
flared end
Injector Drive
Motor
Rear injection chain
tensioner sprocket
Front injector chain
tensioner sprocket
Inside chain tension

system
Accumulator
 Smooth guide to feed CT into Injector

 Mounted on outer frame
 Standard : Ø 72 in
 Old style : Ø 50 in

 Rollers
 Spaced at 10” intervals
 Lower rollers support pipe
 Upper rollers restrain pipe up movement
 Profiled with 120 “V”
 Materials:
 Polyurethane
 Aluminum
 Steel
 Gooseneck adjustment
Gooseneck Alignment
The Pipe Straightener

 Located immediately above chains
 CT is as straight as possible before chains
 Improves alignment CT Chains

Self-aligning
Accumulator guidance
rollers
Straightening
Roller
HR480 Features
 HR480 Injector Head Features:
 Open Loop - 80,000# pull / 40,000# snubbing force
 Closed Loop - 100,000# pull
 Four (4) hydraulic drive motors
 Excellent snubbing capabilities - recommended for HPCT
 Chain “inserts” can easily be changed to accommodate 1 1/4” - 3 1/2” CT
HR 480 Injector Chain
HR480 Outside Tension

 Outside Chain Tension
 Same mechanical setup as HR240 /260
 Minimum outside tension - 150 psi
 Maximum outside tension - 500 psi
 Accumulator is charged to 150 psi
 Refer to chart for snubbing requirements

Outside Chain Tension - HR 480
Chain Tension Pressure VS Snub Load
HR480 Inside Chain Tension

 HR480 Inside tension is NOT mechanically the same as HR240/HR260:
 Minimum inside tension - 500 psi
 Maximum inside tension - 2000 psi
 Hydraulic functions are operated the same as HR 240/260 (emergency traction,
 Accumulators are charged to 400 psi
 Refer to chart for recommended pressures - Always perform pull test and graph to
know pressure vs. load for a particular head
Inside Chain Tension - HR 480
Injector Pull VS. Traction Pressure

Reel Theory
Tubing Reel
The primary function of the CT reel is to store and protect the Coiled Tubing.
Incorporates equipment which perform several functions
 Reel Drive System (1)- Maintains proper tension between the reel and Injector
 Levelwind Assembly (2) - ensures close, even and efficient spooling of the CT
string back onto the reel drum.
 Reel Swivel (not shown) - Allows fluid to be pumped through the reel while it is
rotating.
 Tubing Lubrication System - Application of inhibitor or protective coating.
 Mechanical Counter - Back-up CT depth measurement system.
 Crash frame
Typical reel components:
 Reel drum (1)

 Reel drive system (2)
 Levelwind assembly (3)
 Lubrication system (4)
 Depth counter (5)

2
Side View of CT Reel
 Side view of current generation Hydra-Rig CT Reel
 Reel Drum
 Reel drive and brake system
 Crash protection frame

Front View of CT Reel

 Front view of current generation Hydra-Rig CT reel
 Tubing measurement accessories
 Levelwind assembly
 Tubing lubrication equipment
Tubing measurement accessories
Reel swivel and

manifold
Levelwind assembly
Tubing lubrication equipment

Reel Drum
Levelwin
d
drive
sprocket Reel
drum
securing
points
Tubing access &

Reel drum guide to reel
drive core
motor/sprocket
Reel drum
Reel
drive
Reel drum drum
sprocket
lifting liftin
point g
Drive chain tension point
adjustment Levelwind drive
sprocket Swivel
flange
on
Reel drum drive axle
sprocket
Calculating Reel Capacity

Tubing OD (in) K Value
L= (A+C) (A) (B) (K),
1.00 0.262
• Where
1.25 0.168
L = Tubing capacity (ft)
1.50 0.116
A = Tubing stack height (in)
1.75 0.086
B = Width between flanges (in)
C = Reel drum core diameter (in) 2.00 0.066
K = K value for different tubing sizes
Freeboar
d
C MINIMUM RECOMMENDED FREEBOARD

Tubing OD (in) Freeboard (in)
1.00 and 1.25 1.5
1.50 and 1.75 2.0
2.00 3.0
B
Reel Drum Capacity

Example of Calculating Reel Capacity

Tubing OD = 1.50 in; therefore the freeboard is 2.0 in
 A = 22 in (24 in drum rim height minus 2 in freeboard)
 B =72 in
 C = 72 in
 K = 0.116
 L = (22 + 72)(22) (72) (0.116)
 L = 17,272 ft of 1.5 in tubing
Tension
Reel drive back pressure adjusted to provide suitable tension between injector head and
reel
INSUFFICIENT BACK TENSION ALLOWING TUBING TO SAG
INCORRECT
CORRECT
SUFFICIENT BACK TENSION APPLIED TO KEEP TUBING STRAIGHT
The Reel drive motor hydraulic pressure should be adjusted to keep the tubing straight.
If not enough reel back tension is applied the tubing will sag, causing the tubing reversal.
This increases the fatigue effect on the coiled tubing, since the curvature of the pipe is
reversed twice every pass.
Be advised that the reel back tension affects the weight indicator readings.

Hydra-Rig Reel Drive System

General:
 Hydraulically driven
 In hole-out hole positions
 Tension on tubing
 Reel drive motor
 Reel brake system
Typical control panel layout of reel controls (Hydra-Rig)
The reel drive system is hydraulically driven because of two major advantages of the
hydraulics systems: a) It can stall, holding a constant load (Tubing tension), and b)
Provides flexibility on the relative positions between the power source and the driven
components.
Though the Reel drive motor is fully reversible, and can spin the drum in the POOH and
RIH directions, for CT operations it’s always trying to turn the reel drum in the POOH

direction, even when the pipe is been fed to the injector head. This is so that it will
always keep the tubing in tension.
The reel brake system can act either on the shaft of the motor itself, or on the rim of the
reel drum. It can either be hydraulically or pneumatically actuated.
Hydra-Rig Brake Systems

 Current models
 Hydraulic brake
 Earlier models
 Pneumatic brake)
Reel drum
rim
Caliper secured to reel
chassis
Actuator
push rod Air Actuator
HYDRA -RIG PNEUMATIC BRAKE
Reel Swivel and Manifold

 Latest design
 Integral SLP 11
 Full bore balls darts
 Earlier design
 Threaded connections
 Small OD holes

Grease point (may be connected) to central lubrication station)
Face seal between

swivel and reel
shaft
Swivel secured to reel shaft

2 in 1503 union by studs, lock washers and nuts
Hydra-Rig Reel Swivel and Manifold
10 1
1 1
2
Hydra-Rig Reel Swivel (Type 4)

1. Swivel Housing
2. Mandrel
3. Grease seal
4. Extrusion ring
5. Bearings
6. Mandrel retainer
7. Packing assembly
8. Backup ring
9. Face seal
10. O-ring
11. O-ring
12. O-ring
13. Set screw
14. Grease Nipple
15. Wing half 1502
16. Bearing housing
Hydra-Rig Reel
Hydra-Rig reel , external manifold
Hydra-Rig Levelwind Assembly

Tubing measurement accessories

mounted on Levelwind travelling head
Levelwind leadscrew
drive sprocket and override clutch
Levelwind travelling
head/yoke assembly
driven by lead screw
Levelwind override Levelwind travelling head/yoke

Levelwind pivot motor assembly driven by lead screw
points
Levelwind leadscrew drive sprocket and override clutch
Levelwind driven by sprocket on reel axle
Levelwind Assembly
Benefits
 Cross spooled
 Max. capacity of reel
 Corrosion protection
 chain drive (1).
 The Levelwind head (2) follows a lead screw, which is rotated by the levelwind
drive system. The hydraulic motor (3) is activated (forward or reverse) to advance
or retard the lead screw.
Tubing Measurement Accessories

 Friction wheel depth counters/encoders
 Mechanical counters (backup to electronic counters)
 TIM
Counter Slide mount for
wheel mechanical counter Mechanical counter
drive
Spring forces
counter wheel
against tubing
Counter wheel
assembly pivot
point
Counter head hinged
to assist with
installation over-centre
catches secure
Mechanical counter
drive
Friction facings
Disk spring
Setscrew and key

Adjustment
bolts (3)
Levelwind shaft
Adjustment nut
Clutch hub
screwed onto
clutch hub
Sprocket
Maintenance-Reel Drive & Brake Systems

 Check general condition of hoses, connections and components

 Ensure motor drive mounts are secure and that general alignment of drive chains
have not been disrupted in transit.
 Check drive chain tension
 Function test brake and drive systems,
 Grease main bearings with grease and lubricate drive chain.
STEM II
 Check efficiency of brake and motor

 Check retaining bolts and set screws
 Remove and inspect drive chain
 Check operation and setting of system relief valves and pop-off valves
Reel Swivel and Manifold

 Stem 1
 General condition
 Grease bearings
 Grease valves
 Check debooster
 P-Test swivel and manifold 5000 psi
 Stem II
 Replace gears and packing
 Check operation of debooster
Depth Measurement Accessories

 Stem 1
 Lubricate bearings, chains and pinions on the counter head

 Check the spring mechanism which maintains counter wheel contact with tubing
 Check mount and alignment of depth counters or sensors
 Stem II
 Check condition of all bearings on the counter head
 Remove measuring wheel from counter heads, check for wear on the running
surface by accurately measuring wheel diameter.
 Check for excessive wear or play in the counterhead chains pinions.
Tubing Lubrication System

 Stem I
 Check reservoir level
 Function test system and adjust flow as required
 Stem II
 Check operation and setting of pressure regulators and relief valves
 Inspect pressure vessel (pressure vessel and associated safety valves, any required
periodic certification. Check local requirements).
Chain Identification
 If the chain is in service and complete, count the link pins. The number of link
pins equals the number of pitches.
 If the chain is broken and laid out, ignore the last link plate hole
Master link or
connecting link
Pitch
Alternative connecting
link assembly using
spring lock


Lubricator Block Mounting Position
Hydra Rig Depth Counter
Mechanical Display
Friction Wheel
Tubing
Tubing Guide
Spooler Head Assembly

Well Control
Equipment
Well Control Equipment
Provide pressure control in live well operation
 Stripper assembly
 Primary Barrier for annulus
 Blow out preventer

 Secondary Barrier for annulus
• Downhole check valves

 Tandem
 Barrier for inside CT pipe
Stripper Assembly
The Stripper is generally considered as a dynamic seal around the Coiled Tubing pipe
achieved by applying hydraulic pressure to a set of elastomeric elements. This ensures
that the CT pipe can be safely inserted and extracted from a well while containing the
well pressure. The stripper control system is hydraulic and controlled from within the
CTU control cabin
Stripper Assembly Specifications

 Hydraulic actuated
 10,000 psi WP
 15000 psi test pressure
 H2S NACE MR 01-75
 Connections
 Pin Collar at Bottom ( Bowen Connection )
-CB34, CB44, CB54 Depend on the Bore ID.
 Lock Pins at Top ( If Tandem Stripper, will be Pin Collar Box )
 Wellhead pressure port
 HP port below packing, for fluid injection
Stripper Assembly
 Rating : 10,000 PSI WP
 Hydraulic circuit: 0 to 5,000 psi
 Conventional assembly
 Side door assembly
 Tandem assembly ( conventional or side door )
 Radial Striper assembly
Stripper Assembly Main Components
 Body
 Lower and upper bushings
 Energiser
 Acting as Coiled Spring
 With or without internal spring
 Stripper inserts
 Inside Energiser
 Seal around CT
 Non extrusion ring

 Prevent the insert to extrude through upper bushing by pressure
Note: For Side door assembly, Energiser, Stripper insert and Non extrusion ring are
integrated as a single piece, called Stripper Packer.

Stripper Components
Retainer pins
and clip pins
Split cap and

upper bushing
Non-extrusion ring
Packing Inserts
Energiser
Interlock Inserts
Lower bushing
Packing Insert
 Conventional type.
 Interlocking type.
 Require less Hydraulic pressure. ( The manufacturer claims 4 times less than
conventional inserts needed ).
 Less excessive insert wear.
 Various Materials
 They are characterised by their wear, temperature and chemical resistance
 Urethane
 Nitrile
 Viton
 EPDM
Packing Insert Materials
 Urethane : Longest wearing material
Temp range : -40F to 200F, Deteriorates above 200F
 Nitrile : Good for oil and water resistance
Temp range : 100F to 350F
Not good for H2S
 Viton : Excellent resistance to oil,gas, H2S and chemicals
Temp range : 0°F to 400°F
 EPDM : Excellent resistance to Hot steam (geothermal wells)
Decomposed easily by hydrocarbons
Temp range : 20°F to 500°F
H2S resistance.
Stripper Assembly
 Conventional 2.5” Bore
 Used up to 1.75” CT
 Connect to 3 1/16” BOP with CB 34 connection
 Side Door 2.5” Bore

 Side Door 4 1/16” Bore

 Used up to 2 7/8” CT
 Side Door 5 1/8” Bore

Conventional “Top-Loader”
Packing arrangement
Stripper retract port
Stripper pack port
Wellhead pressure port

Side Door Stripper
Hydraulic Port - PACK
Tubing Support
Hydraulic Port - RETRACT
Side Door with Stop

Guard in place
Quick Union

Side-Door Tandem
Chemical Injection Port
Hydraulic Port - PACK
Port - RETRACT
Weep Hole
Wellhead Pressure Port
Stripper Controls
WHP and Hydraulic Pressure

 WHP exposed to lower bushing
 Convention Type
 Pressure packs from Bottom
 Wellhead pressure help to pack.
 Side Door Type

 Pressure packs from Top
 HYD force ( Pressure x area ) - WH force = net pack force
 Need less Hydraulic Pressure than WHP due to more surface area on the top
Radial Stripper
 Completely Different design and principle
 Access Packing from beside.
 BX169 Flange connection , Both top and Bottom.
 5 1/8” Bore
 Is the most recent stripper configuration. shorter and capable of running a greater
range of CT sizes.
 The stripper elements are energized from the side (radially) which enables a
relatively large insert to be used.

Blowout Preventers - BOP’s

 Rating: 10,000 psi WP
 Hydraulic circuit: 1,500 to 3,000 psi
 Quad BOP
 Combi BOP
 Shear-seal BOP
 Annular BOP (ABOP)
Quad BOP
Bore Sizes: 2.5” / 5,000 psi (old)
2.5” / 10,000 psi
3” nom (3 1/16”) / 10,000 psi
4” nom (4 1/16”) / 10,000 psi
The 4” BOP was developed to allow the construction of stronger rams,mainly slip and
shear rams to more effectively handle bigger and thicker coiled tubing strings.
Combi BOP
Bore Sizes : 3” nom (3 1/16”) / 10,000 psi
4” nom (4 1/16”) / 10,000 psi
Shear-Seal BOP ( tertiary barrier )

Bore Sizes : 5 1/8” / 10,000 psi
6 3/8” / 10,000 psi
This BOP is flanged at the top of the well head as an additional safety device mainly
in fixed platforms where the CT BOP is connected to the well head by a long riser.
The SSBOP is only used as a very last resort. It has just one set of rams and is
featured with a 2” pumping port as well as an equalizing valve.
It has to have its own hydraulic accumulator and control panel.

Annular BOP
The annular BOP used by DS is manufactured by BEMAG and it is used in the
pressure deployment technique. TOT also offers a similar product.
Characteristics: 10,000 psi WP

Bore 4 1/16”
Sealing range : 4 1/16” to open bore.
Although it can be optionally featured with rubber polymers that allow stripping, it is
currently considered as tertiary barrier.
BOP Features
 Blind ram
 Shear Ram
 Slip ram
 Pipe ram
 Equalizing valves
 2” side port
 WHP Sensor Port

Top Pressure Port

Connection Manual Lock
Blind-Ram Handle
Equalizing Valve
Blind Rams
(Ram No. 1)
Shear Rams
(Ram No. 2)
Slip Rams
(Ram No. 3)
Pipe Rams
(Ram No. 4)
Pipe-Ram Hydraulic
Equalizing Valve Actuator
Bottom Flange
Side Port (Kill Port) Connection
Bottom Pin and Collar Connection

Quad BOPs typically consist of the following:
 Blind rams - seal the entire wellbore,
 Shear rams - mechanically cut the Coiled Tubing,
 Slip rams - mechanically hold the Coiled Tubing,
 Pipe Rams - seal the annulus around the Coiled Tubing,
 Equalizing valves,
 Top and Bottom connections,
 Kill port, and
 Pressure port (Wellhead Pressure port).

Ram Components
 Bonnet
 Actuator assembly
 Cylinder
 Ram body
 Actuator rod and ram guides
 Piston and piston guide
• In the past the shear ram blades were manufactured with very sharp edges that
basically allowed the blade to perform just one cut in the pipe before being replaced.
Improved blade material and ram design allowed for construction of blades with less
sharp edges that had prolonged life. However, after every cut the blades have to be
carefully inspected. With the start of CT operations in high WHP new heavier walled
pipes began to be used and surprisingly the current rams was unable to cut thru some of
them under normal conditions. To successfully cut thick pipe :
• a. Put pipe under tension. Can only be done if the power pack is working during
the emergency situation and the pipe is not broken/deformed below the injector head. The
table in SLIDE** shows this effect
• b. Design better shear blades. The design presented in SLIDE*** has several
advantages :
• Multi cut ( Dowell policy ,however,remains unchanged)
• Tubing much less ovalized in comparison with old blades making it easier to fish
• Design is more effective to cut logging CT with wireline cable.

• c. Increase the system hydraulic pressure. The problem of this is that the BOPs
are currently working with hydraulic pressures close to the max rating. Secondly, the
increased force would make the teeth marks of the slip rams even worse.
• d. Install hydraulic booster cylinders only in the shear rams.
• e. Design BOP with bigger rams ( 4 1/16” Quad BOP )
Blind Rams
Rear Seal
Blind Ram Body
Front Seal
Retainer Bar
Pipe Rams
Rear Seal
Ram Body
Retainer Bar
Integral Tubing Guide

Ram Front Seal
Blind and Pipe Rams

 Sealing rams: Wellbore Annulus
 Front seal
 Rear seal in body rams
 Seal rubber material
 Equalising valves features in BOP body
Slip Inserts
 Bi directional
 Teeth marks and integrity of CT
 New developments
Slip Rams
Downward force of slip is

Ref ram transferred directly to the
Body profile ram body
Ref ram
Body profile
Upward force of
slip is transferred
directly to the ram body
SNUBBING LOAD
HANG OFF LOAD
Shear Rams
 Blades construction compromised

 Two different ram bodies(right and left)
• Care needed when assembling shear rams
 Lower ram efficiency at high WHP
 Hydraulic system pressure and booster cylinders
 New shear blade design

Shear Blades 2.5”Quad BOP
New New
Old
BOP Hydraulic and boosters

 Hydraulic pressure rating: 3000 psi
 Dowell operation: 1500 - 2700 psi
 Not enough to cut thick CT’s or CT at high WHP
 Booster cylinders:
 Only available for 2.5” and 3.0” BOPs .
 Not needed for 4 1/16” BOP,Quad BOP 4” is strong enough.

Booster cylinder models:
BC01: Cutting force 2.34 times higher.

No modification required to original ram.
Maximum hydraulic limited to 2,500 PSI, to avoid bending connecting rod.
BC03: Cutting force 2.92 times higher
High forces require new ram piston, rod and guide
Hydraulic pressure up to 3,000 PSI
Different rod for 2.5” and 3.0”
BC05: Cutting force 3.99 times higher
New piston, rod and guide needed
Ram Assembly
HYDRAULIC
PASSAGES DRILLED CLOSING
ADAPTER RETAINER TUBE ELBOW
THROUGH BONNET
SET SCREW &
WOODRUFF HEX
KEY RETAINER INDICATOR
ACTUATOR
ROD
SLEEV RETAINER
E BEARING
SEAL PISTO PISTO
CYLINDE NUT ASSEMBL
N
N R KE Y
RO STE
SEAL GUIDE Y
PISTON D M
RETAINENUT
HYDRAULI
R C
BONNET CAP

Actuator Booster
PACK
RETRACT
Note: Atmosphere vent must be open
3.0” BOP Performance - Shear Arm
BOP HYDRAULIC
WHP PRESSURE
WHP WHP BOOSTER FORCE
OD WALL TYP BLADE 0 psi 5k psi 10k psi 10K WHP (lBF)
E
1.25 0.087 OLD 2000 2556 3111 1069 14,138
1.25 0.087 70 NEW 1500 20056 2611 897 10,604
1.25 0;087 70 NEW 1600 2156 2711 932 11,310
1.25 0.087 80 NEW 1800 2356 2911 100 12,724
100
1.25 0.109 NEW 1500 2056 2611 897 10,604
1.25 0.109 70 NEW 1400 1956 2511 863 9897
1.25 0.109 70* NEW 900 1456 2011 691 6362
70**
1.5 0.095 OLD 2700 3256 3811 1310 19,086
1.5 0.095 70 NEW 1700 2256 2811 966 12,017
70
1.5 0.156 OLD 4250 4806 5361 1842 30,043
1.5 0.156 70 NEW 3200 3756 4311 1481 22,621
70
(* 10,000 lbf pull ** 20,000 lbf pull)

Combi BOP
 Advantages
 Lower overall height power pack not needed to secure well
 Stronger arms
 Disadvantages
 Less flexible operation
 Difficulty to pump through crimped CT
Stud-Up Top Connection

Manual Locking Handles
Blind/Shear Rams
Side Port
Pipe/Slip Rams
Ram Bonnet and Actuator

Open-Flange Bottom Connection
Combi “Slip/Pipe” Rams
O-Ring
Compression Pin Rear Seal
Retainer Ring
Slip Insert
Actuator Rod
Rocker Retainer Pin
Front Seal Rocker
Pipe/Slip Retainer Bar Pipe/Slip

Ram Body Ram Body

Combi “Blind/Shear” Rams
Cap Screw Rear Seal
Blade Retainer
Right Hand
Blade/Seal Assy.
Left-Hand
Left-Hand Right-Hand
Blade/ Seal Assy.
Ram Body Ram Body
Shear Seal BOP

Manual Lock
Hydraulic Actuator
Rear view of a
typical shear seal
BOP assembly
Bonnet Ram Position Indicator
Stud-Up Top Flange

Side view of a
Equalizing Valve
Hydraulic typical shear seal
Connectors BOP assembly
Side Port
Open Bottom Flange
Shear Seal BOPs are used as tertiary barrier and only operated as last resort. They are
mounted on the top of the well head. Although they are basically the upper ram of a
combi bop they are stronger and offered with bigger bore sizes as shown in the slide

Shaffer Heavy Duty 10,000 psi Shear Seal BOP Assembly
All major components to API and NACE H2S Standard

Capable of shearing 2.5 in solid bar
CTU Hydraulic Systems
 Stripper
 Main : Huskell air pup
 Back up : Rucker hand pump
 These two pumps are used as back up for BOP and Skate tension hydraulic systems
 BOP
 Main: Independent circuit with hydraulic accumulator
 Back-up: Accumulator (10 gal) Huskell and Rucker pumps manual action
Hydraulic Accumulators
 Storage of hyd fluid under pressure
 Energy available function of
 N2 Pre-charge
 Volume of bladder:
 Back up hydr system for BOP in case power pack failure

Annular BOP ABOP

Annular BOPs are connected on the top of the well head and work as tertiary barrier.
Currently this procedure is used in the new deployment technique. The ABOP used in
deployment is manufactured by Bemag.
CT Check Valves
 Ball and Seat
 Spring Loaded or not
 Spring attacked by H2SBall: Metal or rubber coated
 Bore obstruction to plugs or balls
 Can get plugged by solids
 Dart and Seat

 Similar as ball and seat model
 Flapper
 The recommended one
 Integral or cartridge
 Almost fullbore
 No restriction to plugs or balls
Wellhead Connections & Cross Overs

 API Flanges
 Open flanges - API 6B flange
 Close face - API 6BX flange
Top connection for
tandem check valve or Coiled Tubing et ses applications
CT connector
 Pin and collar unions

 CO OTIS ‘O’ Ring
 CQ TOT
 CB Bowen SeatSeat Removable
Seat Cartridge
containing flapper
RETRACTBall and seatdome
Castelated
Flapper seat to allow as an alternative to a
Castelated ball
Flange Types fluid to bypass
PACK OFF Bottom connection

Dowell standard
thread or similar
Standoff Close Face
R or RX Ring BX Ring
API 6B API 6BX Flange

Flange
Gasket Types

R Ring Gaskets – oval or octagonal in cross section.
Pressure
Passage
RX Ring Gasket – asymmetric, BX Ring Gasket – octagonal,

Only some have a pressure port all sizes are machined with a
passage machined pressure port passage
Risers and Lubricators

 Lubricator
 Allows tools to be conveyed under pressure
 Normally have pin-collar connections
 Between BOP and injector
 Risers
 Normally have flanged ends
 Used most in fixed platforms
 Installed between wellhead and CT BOP
High Pressure Wells
 Must Do 5000 - 6000 6000 - 7500

 10,000 psi rated equipment 1.25" 0.109" 0.134"
 Approved CT thickness: 1.5" 0.125" 0.156"
 CoilLIMIT to check limits 1.75" 0.156" NONE
 CoilLIFE to check life available
 Upper stripper W/long split cap (or side door preferred)
 Dial acting cell
 TIM
 Flanged connections
 Additional shear seal BOP on top of wellhead with remote control
 Choke manifold w/remote control
 Fire equipment (gas)

 Recommendations:
 Coiled tubing WITH LITTLE USE
 Zone II equipment
 Lub/Bleed port between strippers
 Tee sub below BOP
 Radio sets
 Wind indicator/gas detector

Introduction To Coiled Tubing

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Introduction To Coiled Tubing

Uploaded by

Copyright:

Available Formats

ALGERIAN PETROLEUM INSTITUTE

Well Intervention Services

History of Coiled Tubing

1944 – Allied Invasion Project

R^Khelil-SH-DP page.2 Novembre 2008

Origins & History of Coiled Tubing

History of Coiled Tubing 1960's

R^Khelil-SH-DP page.3 Novembre 2008

First Oilfield Application

History of Coiled Tubing 1980's

R^Khelil-SH-DP page.4 Novembre 2008

History of Coiled Tubing 1990's

R^Khelil-SH-DP page.5 Novembre 2008

Injector Head History

Coiled Tubing Equipment

R^Khelil-SH-DP page.6 Novembre 2008

Basic Equipment Configurations

The most obvious categorisation of operating environment is offshore or onshore. This

R^Khelil-SH-DP page.7 Novembre 2008

CTU – Paved Road

Trailer mounted CTU

Truck mounted (6 x 6) CTU

R^Khelil-SH-DP page.8 Novembre 2008

CTU – Mobile Mast

Trailer mounted mast unit for arctic operations

CTU – Skid Mounted

Skid mounted for offshore operations

R^Khelil-SH-DP page.9 Novembre 2008

CTU – Barge Mounted

Lake Maricaibo barge mounted unit

CTU – Jacking Barge

Gulf of Mexico jacking barge

R^Khelil-SH-DP page.10 Novembre 2008

Desirable String Characteristics

 Service and maintenance

 Drivers for alternative materials include desire for:

 Alternative materials under investigation include:

R^Khelil-SH-DP page.11 Novembre 2008

• The coiled tubing unit :

Injector Head – Principal Components

 Hydraulic drive/brake system

CT Reel – Primary Components

R^Khelil-SH-DP page.13 Novembre 2008

 Reel drum (1)

Skid Mounted Reel

Skid mounted, crash-frame protected reels

Power Pack – Primary Components

R^Khelil-SH-DP page.14 Novembre 2008

Pressure Control Equipment

 Downhole check valve

Coiled Tubing and Workover Units

R^Khelil-SH-DP page.15 Novembre 2008

Coiled Tubing Unit

More Coiled Tubing Advantages

Coiled Tubing Limitations

R^Khelil-SH-DP page.16 Novembre 2008

Coiled Tubing Service – Benefits

Coiled Tubing Applications

Applications – Conveying Fluids

 Wellbore fill removal

 Scale or paraffin removal

Applications – Conveying Tools

 CTD (coiled tubing drilling)