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Fatigue of Coiled Tubing and its Influencing Factors: A Comparative Study

Conference Paper · November 2016

DOI: 10.1115/IMECE2016-65972

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 Proceedings of the ASME 2016 International Mechanical Engineering Congress and Exposition
IMECE2016
November 11-17, 2016, Phoenix, Arizona, USA

IMECE2016-65972

FATIGUE OF COILED TUBING AND ITS INFLUENCING FACTORS:

A COMPARATIVE STUDY

Y. Q. Li, X.-L. Gao* L. D. Ni

Department of Mechanical Engineering, Southern GeoMark Technology, Inc., Missouri City,
Methodist University, Dallas, TX 75275-0337, Texas 77459, USA
USA

Q. F. Hu, Y. A. Xin
Jianghan Machinery Research Institute, CNPC,
Jingzhou, Hubei 434000, China

ABSTRACT it is necessary to understand the fatigue damage mechanisms of

Coiled tubing (CT) has been widely used in oil well
drilling and servicing. The operation of coiled tubing requires it
to travel through the reel and gooseneck repeatedly under high
internal pressure loading, which leads to bending fatigue
damage of coiled tubing. Hence, it is very important to
understand the mechanisms of the fatigue damage and to
predict the working life of coiled tubing. The fatigue damage
of coiled tubing has been extensively studied by using
experiments, finite element simulations, and analytical models.
It has been found that most of the fatigue damage of coiled
tubing happens under low cycle fatigue conditions. Both stress-
based and strain-based models have been employed to describe
the fatigue damage of coiled tubing. Due to the severe
operating conditions of coiled tubing inside a well, corrosion,
ovality, pre-bending, rotation, and mechanical damage should
all be considered in the fatigue analysis of coiled tubing. In this
paper, mechanisms and influencing factors for the coiled tubing
fatigue damage are reviewed, and existing models for the
fatigue of coiled tubing are comparatively studied.
INTRODUCTION
Coiled tubing has been widely used in the oilfield service
industry due to its low cost and high efficiency. However,
failure of coiled tubing caused by repeated bending on and off
the reel and gooseneck has been a big concern in coiled tubing
operations. In fact, the low-cycle fatigue induced by such
bending and internal pressure has been identified as the main
threat to the safe and reliable service of coiled tubing [1]. Thus,
coiled tubing and improve its service life. Since 1990, a lot of
studies have been conducted on fatigue of coiled tubing,
including fatigue mechanisms, experimental testing,
environment influences, and surface damage effects.
In Newman and Newburn [1], it was demonstrated by
comparing full-scale test data and fatigue model predictions
that decreasing the coiled tubing (CT) diameter or increasing
the bending radius leads to an increase of the CT life. Tipton
and Newburn [2] found that an incremental plasticity model
can predict the CT fatigue behavior well at lower internal
pressures. However, due to the hoop stress effect at higher
pressures, a valid nonlinear multiaxial damage criterion needs
to be implemented. Based on the equivalent strain, a coiled
tubing fatigue life model was proposed by Avakov et al. [3],
and their predicted results agree well with the full-scale test
data. Due to the limitation of higher pressures, Sisak and
Crawford [4] proposed a new fatigue damage model according
to full-scale fatigue test data. They found that under high
internal pressures, the fatigue occurs when the net axial plastic
strain in the CT reaches a critical failure strain; under low
internal pressures, the conventional fatigue approach can be
used to predict the CT fatigue life. Wu [5] studied different
influence factors on the CT fatigue and showed that increasing
the wall thickness and yield strength will lead to the increase of
the CT life, while high internal pressures, corrosive and butt-
weld connections will decrease the CT life. Based on the study
of Tipton [16], Rolovic and Tipton [6, 7] built a plasticity
model for CT to study the progressive growth of the tubing

*
ASME Fellow, corresponding author. Tel: +1-214-768-1378; E-mail: xlgao@smu.edu.

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 diameter when subjected to cyclic bending. Their model can
capture the behavior of coiled tubing during bending and under
an internal pressure and give more accurate results for coiled
tubing diameter growth.
For the rotation effect on the coiled tubing fatigue life,
Newman [8] used a rotational-orientation measuring device to
determine the rotational orientation of the seam weld, and
found that the CT rotation can increase the fatigue life. Based
on the conventional bending fatigue test of coiled tubing,
Tipton and Sorem [9] studied the additional rotation effect on
the bending fatigue of CT. Compared with the cycle bending on
the gooseneck, the bending strain due to the well curvature can
be neglected. However, the downhole rotating bending stress
cannot be ignored. They used the high and low cycle regimes
of the fatigue data and evaluated the potential high cycle
fatigue damage due to the downhole rotation. The results
showed that the damage can be neglected when compared with
the conventional CT fatigue. A fatigue life model for pre-bent Figure 2. Lab-scale fatigue testing machine for coiled tubing [13].
coiled tubing was proposed in [10], where a comparison
between the pre-bent coiled tubing fatigue and the straight In 1997, a full-scale fatigue test system for coiled tubing
coiled tubing fatigue was made. Their results showed that the was built at Halliburton Energy Services, Inc. [14] to provide
pre-bending coiled tubing can greatly improve the CT life. realistic experimental data and to validate the existing CT
Peng et al. [11] studied the CT diameter, wall thickness and fatigue models. This system is shown in Fig. 3. Another
internal pressure influences by using the back propagation purpose of building such a full-scale test system is to assess
artificial neural network, which is a new method to predict the handling and operational issues which cannot be adequately
coiled tubing life. addressed by using a laboratory-scale test machine.
The aim of this paper is to provide a review of afore-
mentioned works and other studies on the coiled tubing fatigue
and discuss some major influence factors for the CT fatigue
life.

EXPERIMENTAL STUDY
Due to the high cost and long time involved in performing
full-scale fatigue testing of any coiled tubing unit, Newman and
Brown [12] built a laboratory-scale fatigue testing apparatus in
1993, which is shown in Fig. 1. The testing machine can apply
a cyclic bending on a standard six-foot-long full size CT
sample with pressure caps at its ends. A photo of an updated
laboratory-scale testing system is displayed in Fig. 2.

Figure 1. Test fixture schematic [12]. Figure 3. Halliburton full-scale coiled tubing fatigue test unit [15].

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 FATIGUE DAMAGE MODELING is considered as one loading cycle, and the fatigue damage can
be evaluated using the Manson-Coffin equation. However, for
Fatigue damage model the fatigue life of CT subjected to different successive low-
The fatigue failure of coiled tubing due to the cyclic fatigue cycles, specific fatigue damage accumulation rules need
bending and internal pressure was first studied by Newman and to be applied. The most widely used rule is the Miner’s linear
Newburn [1]. They gave the critical yield radius of curvature damage rule [17], which can be expressed as
Ry as
n n
D   ni N i   ri , (5)
Ero i 1 i 1
Ry  , (1)
y
where D is the total fatigue damage, ni is the number of cycles
where ro is the outer radius of the CT, E is the Young’s of stress range occurred, and N i is the number of cycles of
modulus, and σy is the yield stress of the CT material. stress range to failure. Miner’s damage rule has been employed
Tipton [16] presented an analytical model for coiled tubing in industries as a basic rule.
fatigue based on the incremental theory of plasticity. The model Due to the limitations of Miner’s rule, two other fatigue
reads damage rules have been proposed and used to analyze CT
fatigue. The first one is the power-law damage rule [18, 19].
 a ,eff   a ,eq 1   m ,eq  ,
S
For two-step loading, the damage cycle ratio can be calculated
(2)
in sequence. For two stress levels, the damage cycle ratio can
be expressed as
where  a , eff is the coiled tubing fatigue damage parameter,
2 2
N10.4 N 20.4
 a , eq is the equivalent von Mises strain amplitude,  m ,eq is the  n 3  n 3
D 1   2  , (6)
equivalent von Mises peak strain, and S is an exponent.  N1   N2 
This strain-based fatigue damage model [16] can be used
to study the relationship between the strain and fatigue life, which can be rearranged to obtain
which is given by the Manson-Coffin equation [17]:
( N 2 / N1 )0.4

 f n1  n2 
 (7)
2N    f  2 N f  
b c .
 a   ae   ap  , (3) N1  N 2 
E
f

Eq. (7) can be used to assess two-step or multi-step CT fatigue

where  a is the strain amplitude, E  is the cyclic modulus of damage.
elasticity (measured at 50% life),  f is the fatigue strength The second rule is known as the double linear damage rule,
which is a linearization of the power-law damage rule [18, 19].
coefficient, b is the fatigue strength exponent, N f is the cycles According to this rule, the two linear relations listed below in
to failure,  f is the fatigue ductility coefficient, and c is the
Eqs. (8) and (9) can be used to describe crack initiation and
crack propagation, respectively. The double linear damage rule
fatigue ductility exponent. is schematically shown in Fig. 4.
Because of the coiled tubing rotation effect [9], the mean
0.25
stress should be incorporated in Eq. (3). As a result, the  n1   N1 
Manson-Coffin equation is modified as [9]    0.35   , (8)
 N1  knee  N2 
c b 0.25
 f   m   f   m   n2   N1 
 2N   2N 
b c
a    f 
    , (4)    0.65   . (9)
E
f f
 f   N 2 knee  N2 

where  m is the mean stress. Compared with the power-law rule, the double linear
damage rule is easier to implement. However, the knee point is
only validated by the experimental data for an elastic-to-plastic
Continuum damage approach
cycle ratio of 103, which is much smaller than that for coiled
When a coiled tubing unit undergoes the bending-
tubing [18].
strengthening deformation on and off the reel and gooseneck, it

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 n  1
2   n
H  Kn    , (13)
3 K 

where   is given by

  α  α max
 y  2 3 α , when 
   and  e  ( e ) max (14)

  y  0.5 3 α  αin , otherwise
Figure 4. Double linear damage rule [18, 19].
2

Incremental plasticity model

When a coiled tubing unit moves through the reel and in which α  is the deviatoric back stress tensor,  e is the von
gooseneck, the stress-strain behavior of the coiled tubing can Mises stress, and αin is the deviatoric back stress at the
be described by the classical Ramberg-Osgood relation:
beginning of the load reversal.
1 n
a 
a   a  , (10)
Implementation of fatigue damage model
E K  Based on the standard low cyclic fatigue damage model
given in Eq. (3), the strain-life relation can be divided into two
parts: The first term on the right hand side of Eq. (3) represents
where a is the stress amplitude, K is the cycle strength
the elastic part, and the second term represents the plastic part.
coefficient, and n is the cyclic strain-hardening exponent. In industrial applications, coiled tubing deformations are
An incremental plasticity model was proposed by Rolovic always in the plastic range. As a result, most of the CT fatigue
and Tipton [6, 7, 20] to study the growth of tubing diameter analysis software packages [20, 21] are focused on the plastic
during cyclic bending. One hardening rule and one plastic part only by ignoring the elastic contribution. The typical
modulus function were proposed. According to the proposed bending-straightening cycle on and off the reel and gooseneck
hardening rule, the motion of the center of the yield surface can is show in Fig. 5.
be represented by
 dσ dξ p 
dα  d   q , (11)
 dσ dξ p 


where d  is a scalar which can be determined from the


consistency condition F σ  dσ , α  dα ,  y  d y  0 , q is 
p
the hardening parameter, dσ and dξ are, respectively, the
stress and plastic strain increments, and dσ  dσ : d σ ,

dξ p  dξ p : dξ p .
The plastic modulus function H satisfies the plastic flow
rule:

1
dξ p   n : dσ  n. (12)
H
It is known that H  2 E / 3 , where E is the uniaxial
p p
Figure 5. Coiled tubing bending cycle events [30].
plastic modulus [6]. This can be combined with the Ramberg-
Osgood relation in Eq. (10) to obtain With the elastic part neglected, Eq. (3) can be rewritten as

 a   ap  2  f N .
c c
(15)

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 Eq. (15) can be converted to [3], after setting c   1 2 ,
2 Based on Eq. (16), the total number of cycles during one
N   
   KQ ,
Nm   m 
where K Q is the reliability factor, and N m , m are, respectively,
the empirical tubing median life (in cycles) and tubing median
fatigue strength determined from experiments.
From Fig. 5, for one stroke of the coiled tubing operation,
there are one bending-straightening cycle on the reel and two
bending-strengthening cycles on the gooseneck. Over the
gooseneck, the axial stress ag can be obtained as
do E
 ag  , (17)
2 Rg
where do is the CT outer diameter, and Rg is the gooseneck
radius.
Over the reel, the axial stress ar can be expressed as
do E
 ar  , (18)
2 Rr
where Rr is the current reel radius with spooled coiled tubing.
The additional stress component due to the internal
pressure is given by
2di2 pi
t  , (19)
d o  di
where pi is the CT internal pressure, and di and do are,
respectively, the CT inner and outer diameters.
The total stress can then be computed using the Miner’s
cumulative damage rule:
   a   tm ,
which gives the total stress on the reel as
 r   ar   tm ,
and the total stress on the gooseneck as
 g   ag   tm ,
where m is a constant determined empirically, a is cyclic axial
stress imposed on the outer fibers bent over the reel or the
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gooseneck, t is the loop stress on the outer surface induced by
the internal pressure pi.
tubing stroke can be obtained as [21]
(16)
 g 
2 2
 
N1  1  r   2   . (23)
m  m 
The coiled tubing fatigue life can then be evaluated using
the fatigue damage model described earlier.
FACTORS INFLUENCING COILED TUBING FATIGUE
In addition to the repeated bending and internal pressure
effects, there are many other factors that have influences on the
CT fatigue life, which include environmental and surface
damage, as described below.
Environmental influence
Since a coiled tubing unit is placed inside a well, it is
exposed to a sour environment. Thus, it is necessary to consider
the environmental influence on the coiled tubing fatigue life.
The main concerns about the environmental effects are the CT
resistance to sulfide stress cracking and hydrogen induced
cracking. In 2003, Luft [23] studied the 70 ksi and 80 ksi grade
coiled tubing fatigue life in a sour environment with and
without corrosion inhibitor protection. Their results showed
that the fatigue life of the coiled tubing without any inhibitor
can be reduced by 80 ~ 85% due to the environment effects,
while it decreases only by 1/3 of its original fatigue life after
adding the H2S corrosion inhibitor. Another study on 70 ksi and
80 ksi grade coiled tubing fatigue in a sour environment was
performed by Crabtree and Gavin in [24]. Their study found
that sour inhibitors play an important role in intervening
operations. Recently, Valdez [13] investigated the fatigue
performance of new high-strength coiled tubing in an H2S sour
environment. It was found that the new coiled tubing has a
longer fatigue life and a better H2S resistance than the
conventional coiled tubing.
Surface damage
(20) Since coiled tubing units operate inside wells with rough
and sour environments, the outer surface of CT is always
suffered from mechanical damage, which can have a great
influence on the CT fatigue life. Padron [25] studied the effects
(21) of different types of mechanical damage on the CT fatigue life.
Their results demonstrated that the external mechanical damage
on the CT surface can induce microcracks, which play a
decisive role in the CT fatigue damage and lead to a great
reduction of the CT fatigue life. Christian and Tipton [26]
(22) investigated the influence of surface defects on the CT fatigue
life by introducing a defect severity parameter to describe the
specific geometry of the defect. Besides mechanical defects,
Tipton et al. [27] also considered the straightener’s influence on
5 Copyright © 2016 by ASME
 the CT fatigue life. Their results revealed that the fatigue life
reduction can be as high as 30% for certain tubes.
ASSESSMENT OF CT FATIGUE
Due to the inside-well use of coiled tubing, it is very
important to know the real-time life condition of CT during its
operation. Nondestructive CT inspection methods have been
employed in the oil service industry. One of them is based on
the magnetic flux leakage (MFL) technology. Breidenthal et al.
[28] utilized the MFL inspection method along with the finite
element (FE) analysis to study the CT fatigue life. Their results
showed that the FE analysis can greatly improve the accuracy
of surface flaw dimensions measured by the MFL signals and
has the advantages of viewing of the entire 3-D flux leakage
field and repeatability. Liu et al. [29] quantitatively evaluated
the CT fatigue life reduction induced by surface defects using
the MFL method. Their new approach can achieve consistent,
automated in-line fatigue analysis during operation, and their
results compare well with experimental data.
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