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Section 10.
Coil Tubing.
Prepared by
Howard Crumpton
Date: 28/10/11
Proof reading
Anita Lee
30/10/11
Reviewed
Final Approval.
Contents
1. Introduction. ......................................................................................................... 1
2. Coiled Tubing Equipment. ....................................................................................... 2
2.1. Coiled Tubing The Pipe. .................................................................................. 3
2.1.1. CT Manufacturing. ...................................................................................... 3
2.1.2. Coiled tubing performance. ......................................................................... 4
2.1.3. Coiled tubing reel design. ............................................................................ 5
2.1.4. Repairing and Splicing Coiled Tubing. ........................................................... 7
2.1.5. Corrosion resistance. .................................................................................. 7
2.1.6. Inspection tools. ........................................................................................ 7
3. Surface Equipment................................................................................................. 9
3.1. Well Control Equipment .................................................................................... 9
3.2. Coiled Tubing Barriers. ................................................................................... 10
3.2.1. External Pressure control. ......................................................................... 10
3.2.2. Internal Pressure control. .......................................................................... 10
3.3. Stripper or pack-off. ....................................................................................... 11
3.3.1. Inline stripper. ......................................................................................... 11
3.3.2. Side door strippers. .................................................................................. 11
3.3.3. Radial strippers. ....................................................................................... 13
3.4. Coiled Tubing BOPs ....................................................................................... 14
Blind rams ........................................................................................................ 15
Shear rams....................................................................................................... 15
Slip rams.......................................................................................................... 16
Pipe rams. ........................................................................................................ 17
3.4.1. BOP operations. ....................................................................................... 20
3.5. Injector head. ............................................................................................... 21
3.6. Gooseneck. ................................................................................................... 25
3.7. Weight Indicator ............................................................................................ 26
3.8. Depth Measurement Equipment. ...................................................................... 27
3.9. The reel. ....................................................................................................... 29
3.10. The Power Pack. .......................................................................................... 30
3.11. Control Cabin............................................................................................... 32
3.12. Coil Tubing Lift Frame. .................................................................................. 33
4. Downhole tools and the Coiled Tubing BHA. ............................................................. 35
4.1. Coiled Tubing Connectors. ............................................................................... 35
ii
iii
Figures
Figure 1: Main coiled tubing equipment components: A typical offshore platform rig up for
fluid pumping...................................................................................................... 3
Figure 2: A typical land based coil tubing rig up. ........................................................... 3
Figure 3: Bending cycles during coiled tubing use. ......................................................... 4
Figure 4: External flush roll-on connector. The notched exterior profile is to allow the
connector to flex with the CT pipe. ........................................................................ 7
Advanced Completion and Intervention Well Control Manual.
Draft: Version 2
iv
Figure 40: Circulation sub: Burst disk (top) and Dual Circulating and Burst disk sub
(bottom) .......................................................................................................... 38
Figure 41: Straight bar. ............................................................................................ 38
Figure 42: MP Head Tool. ......................................................................................... 39
Figure 43: Liquid nitrogen storage. ............................................................................ 39
Figure 44: Corrosion caused by an acid puddle in the bottom of a wrap. ......................... 42
Figure 45: Coil tubing layout for a reverse circulation operation. ..................................... 45
Figure 46: Four way manifold.................................................................................... 45
Figure 47: Ball and seal allows rapid switching between direction of circulation. .............. 47
Figure 48: Gun deployment pressure control equipment and gun connector (right). ......... 49
Figure 49: Flanged side outlet valve (left). The hammer union (middle) is prone to damage
(left) ................................................................................................................ 51
Figure 50: Properly support and secure the injector head throughout the operation! ........ 52
Figure 51: Coiled tubing rig up. ................................................................................. 53
Figure 52: Pressure testing the surface lines. .............................................................. 55
Figure 53: Pressure testing the shear seal BOP ram. .................................................... 56
Figure 54: Testing the blind ram and riser. ................................................................. 57
Figure 55: Testing the reel........................................................................................ 58
Figure 56: Stripper test. ........................................................................................... 59
Figure 57: Testing the check valves by bleeding back through the coil - careful now! ....... 60
Figure 58: BOP blind ram test. .................................................................................. 61
Figure 59: Hydraulic actuator - capable of cutting coiled tubing with hydraulic assist. ...... 66
Tables
Table 1: Coil tubing applications. ................................................................................. 1
Table 2: Coil Tubing steel properties. ........................................................................... 4
Table 3: Example CT string design for 1.75" OD 80,000 psi minimum yield material .......... 6
Table 4. Specification for 80,000 psi yield coiled tubing (1.75 OD) used to constrict the
example CT string (table 2). ................................................................................. 6
Table 5: BOP and CT compatibility ............................................................................. 18
Table 6: Recommended Gooseneck radius. ................................................................. 26
Table 7: Single Particle Settling Rates Courtesy of George King. ................................. 41
Table 8: CT running speed ........................................................................................ 63
vi
1. Introduction.
ICoTA, the oil industry coil tubing association, define coil tubing as any continuously-milled
tubular product manufactured in lengths that require spooling on to a take-up reel, during
the preliminary milling or manufacturing process.
Coiled tubing has been used to service wells since the early 1960s. Thanks to continuous
improvements in both technology and reliability, coiled tubing is now a common and well
accepted intervention technique. Today there are over one thousand CT units in use
worldwide.
Coil tubing was developed to enable remedial work to be carried out in live wells. To enable
this to take place, three developments were required.
A method of running and retrieving the string into or out of the well against
pressure the injector
A method of sealing around the tubing both whilst moving and stationary the
stripper rubber (early coiled tubing used an annular type preventer).
The modern coil tubing unit is capable of many well intervention applications. The most
common ones are:
Growth applications.
Well Cleanout
Fracturing
Acid wash/Stimulation.
Subsea interventions.
Velocity string.
Fishing.
Pipelines/Flowlines.
Cement squeeze.
Well Logging.
Setting recovering plugs.
This chapter of the manual will describe the main components of a coiled tubing unit, with
the emphasis on pressure control equipment, followed by basic procedures for maintaining
pressure control during live well interventions with coil tubing. Operational procedures that
have a bearing (direct or otherwise) on well control and well integrity are included.
Section 10:
10 Coiled Tubing.
Figure 1:: Main coiled tubing equipment components: A typical offshore platform rig up for fluid
pumping.
If a metallic specimen is loaded beyond the yield point, subsequently unloaded, then loaded
in the opposite direction, the material yield point in the opposite direction is reduced. This
phenomenon is called the Bauschinger effect. Repeated bending and unbending therefore
reduces yield stress in the coiled tubing. Internal reel pressure increases the effect.
An important part of reel integrity and therefore pressure containment when using coiled
tubing is the ability to predict the deterioration in material yield caused by cycling and
fatigue. This can only be accomplished through detailed record keeping and analytical
computer modelling using proprietary software.
2.1.3. Coiled tubing reel design.
When in use, coiled tubing is under stress from internal and external pressure (burst and
Collapse) and multiple axial loads. In deep, highly tortuous wells, high axial loads are
generated at surface by a combination pipe weight and friction; surface tension is highest
during pick-up. Many coiled tubing strings are internally tapered with heavy (thick) wall
pipe at the top of the string (on the bottom of the reel) and light (thin) wall tubing at the
top of the reel the bottom of the well. A tapered string can work in deeper and more
tortuous wells that a non-tapered string of an equivalent length, since the heavier wall
tubing close to surface has a higher yield value. Tapered strings normally have multiple
sections each of a different ID. String design may be job specific, but is more commonly a
general design that can be used in a range of wells.
A simple method of designing a CT string considers only the wall thickness necessary for the
required mechanical strength at a given location and the total weight of the string. Only the
force of the buoyed pipe weight hanging vertically is calculated. Starting at the bottom of
the string and working up, the designer selects the wall thickness at the top of each section
that gives a defined stress for the corresponding tensile force at that location. For example,
suppose we wish to build a string of CT that limits stress to 30% of the material yield at the
top of each pipe section.
Using the manufactures tables, we can find the minimum yield for a given material yield,
pipe OD and wall thickness as follows
1. Select the wall thickness for the first (deepest) section of the string. In our example
we are using 0.116 wall 1.75 OD pipe. From the table we see that this has a
minimum yield of 47,600 lbs. 30% of this value is 14,280 lbs.
2. Calculate how much pipe (by weight) is equivalent to 14,280 lbs. 0.116 wall tubing
has a weight per foot of 2.029 lbs. 14,280/2.029 = 7037 ft. The weight of 7037 feet
of tubing hanging in the well (in air) will be equal to 30% of the pipe yield.
3. Add in the next section of pipe. In the example we are stepping up one size to a
0.125 wall pipe with a minimum yield of 51,100 lbs. 30% yield = 15,450 lbs.
4. 15,450 - 14,280 lbs (already in the well) = 1050 lbs to reach the yield value of the
0.125 pipe. 1050/2.175 lb/ft = 482 ft. We can add on 482 ft of 2.175 lb/ft 0.125
wall thickness pipe.
5. Repeated the process until the desired length of reel has been constructed.
6. The other (right hand side) of the table (table 2) shows how the stress on the string
at the top of each pipe section increases if a tapered string is constructed using
uniform length sections of increasing wall thickness.
Uniform Stress.
Wall
(in)
thickness
Length
(ft)
Weight
in Air
Uniform length
a/y
Length
(%)
(ft)
(lbs)
Weight in
Air
a/y
(%)
(lbs)
0.116
7037
14,280
30
2000
4058
8.5
0.125
482
1050
30
2000
4350
16.3
0.134
427
990
30
2000
4636
23.9
0.175
1515
4470
30
2000
5902
27.3
0.190
497
1560
30
2000
6274
33.8
0.204
431
1440
30
Total
10,389
23,790
10,000
25,220
Table 3: Example CT string design for 1.75" OD 80,000 psi minimum yield material
Table 4. Specification for 80,000 psi yield coiled tubing (1.75 OD) used to constrict the example CT
string (table 2).
Table Courtesy of Tenaris.
Supervisors at the wellsite should know how coiled tubing strings are constructed and
ensure that the CT crew has details of the string design. This is essential information when
setting operational tension limits.
Figure 4: External flush roll-on connector. The notched exterior profile is to allow the connector to flex
with the CT pipe.
Coiled tubing is joined using a Tungsten Inert Gas (TIG) weld. Only butt welds are possible
for repairing coiled tubing. Welds are also used to join together shorter sections of pipe as
it is spooled on to a large capacity reel. This normally happens when a long, large diameter,
reel is required to service a well on an offshore platform where the lifting capacity of the
platform crane is limited. Welds have a much lower fatigue life than the base pipe, as low
as 50% for even the best executed welds.
NOV Quality Tubing. Product Data Sheet. QT-16Cr Special Coiled Tubing Product.
Advanced Completion and Intervention Well Control Manual.
Draft: Version 2
Electro-magnetic proximity sensor. This tool measures the ovality of the pipe. Two
diametrically opposed sensors measure the distance from a probel to the surface of the
pipe. The distance between the probes is fixed, therefore the pipe OD can be measured. By
using multiple sets of probes arranged around the circumference of the pipe, the ovality can
be calculated. The CTES CT DOG and the Schlumberger UTIM (Universal Tubing Integrity
Monitor) are two examples of this technology.
Electro-magnetic flux leakage - This technology uses magnets to induce a magnetic field
into the pipe wall and measures wall thickness. The CT manufacturing facilities use this
technology to inspect new pipe. Several field deployable CT inspection devices have been
developed which use this technology, including the CT Scope from Tuboscope and the ACIM
from Rosen. To date, acceptance of this technology has been limited due to the expertise
required by the well site equipment operator as well as high cost.
Ultrasonic inspection. - Used in pipe manufacturing facilities to inspect new pipe. It is
able to accurately measure wall thickness, and to give indications of cracks, inclusions and
pits.
3. Surface Equipment.
3.1. Well Control Equipment
Well control equipment is required for CT interventions on live wells. The scope of
equipment will depend on well pressure, location, company policy and government
legislation. At minimum, pressure control equipment will consist of a set of CT BOPs and a
stripper. (fig 5 left) Whilst this may be suitable for some low pressure or sub-hydrostatic
operations, a more robust pressure control configuration is normally required.
Most
operations will include from bottom to top:
Quad (or dual ram combi) BOP with a pump in facility between the slip and shear
rams
The use of flanged connections is increasingly common and mandatory in some locations.
Xmas tree valves when deploying tools in and out of the riser. If a downhole
lubricator valve is fitted this would be the primary barrier when installing tools into
or out of the well.
Secondary Barriers.
BOP rams.
Tertiary Barrier.
Shear and seal capability in BOP. For many operations a shear/seal combi BOP will
be mounted immediately above the tree.
Some trees have been fitted with gate valves able to shear coil tubing.
Secondary Barriers.
BOP rams.
Tertiary Barrier.
Shear and seal capability in BOP. For many operations a shear/seal combi BOP will
be mounted immediately above the tree.
Some trees have been fitted with gate valves able to shear coil tubing.
Note: Some coil tubing operations use reverse circulation to clean out the wellbore. This
means no check valves are included in the BHA. In these circumstances primary internal
barrier is provided by the pipe body and the BOP.
10
11
Most injector heads have the stripper permanently attached to a flange on the lower frame
(fig 9). Permanent fixing helps maintain correct alignment with the injector chains and
simplifies rig-up procedures. It is important that the gap between the injector chains and
the stripper is minimised. This prevents buckling unsupported tubing where high force must
be used when running in hole (fig 10).
In most applications today, tandem strippers will be used, with well pressure being
controlled by the upper stripper. If a leak develops, the lower stripper and the pipe rams
will be closed (double barrier isolation) whilst the seal element is replaced.
Figure 8: Side door stripper (left) and Tandem Stripper (right). If two strippers are used the tandem
stripper will be made up below the conventional side door stripper. Bottom seals and Teflon nonextrusion rig.
12
Figure 9: The stripper is normally flanged to the base of the injector frame.
Figure 10: The gap between the injector chain and the stripper.
In the photo on the left the tubing has been braced to reduce bending.
13
Blind ram. Pressure is contained below the ram when the pipe has been removed
from the well.
Slip ram supports the weight of the coil tubing hanging in the well. Some slip rams
are bi-directional and can prevent pipe being blown out of the well.
14
Quad BOP
Ram configuration:
Blind Ram
Shear ram
Slip ram
Pipe ram.
Blind rams
Blind rams are sealing rams. They isolate well bore fluids and contain pressure when there
is no CT across the BOP. Blind rams consist of identical ram bodies positioned opposite
each other in a ram bore. Each ram assembly contains a ram body, front seal, rear seal and
a retainer bar. The flat front seal closes across the well bore with the rear seal containing
well pressure behind the ram body. Hydraulic pressure opens and closes all of the BOP
rams.
Shear rams.
Shear rams have blades designed to cut coiled tubing and wireline. Cutting blades are made
of hardened material and is NACE approved. The manufacturing process leaves the core of
the blade relatively soft giving the ductility required to prevent sulphide stress cracking
while still having the hardness needed to shear pipe. A single set of shear blades can cut
multiple times. More than 30 cuts have been made with one set of blades without damage.
15
Figure 13: After the cut. This reel was run with internal e-line (Smart coil).
Slip rams.
Slip rams are designed to support the weight of the tubing and prevent it from being
dropped in to the well. Some rams will also stop pipe being blown out of the hole by well
pressure. Slip rams have identical rams and slip inserts positioned opposite each other in a
ram bore. Slips should be capable of holding at least the yield load of the pipe in use. Slip
inserts are designed to minimize stress on the pipe. Insets (slip face) are machined out of
NACE quality material then hardened to enable them to grip and support the pipe. As the
slips are made from a hardened material they are highly susceptible to sulphide stress
cracking. Since the slips are sometimes exposed to H2S, the inserts are made with a soft
core and hard case. Although the hard outer case will be subject to cracking, the softer
inner core is more resistant to H2S attack.
16
Pipe rams.
Pipe rams seal around the pipe to isolate well bore fluids and contain pressure. Pipe rams
consist of identical ram bodies positioned opposite each other in a ram bore. The front seal
closes around the pipe with the rear seal containing well pressure behind the ram body.
Increasing hydraulic closure pressure deforms the seal element in the ram face, creating a
seal around the pipe.
The sequence for cutting and removing pipe from the well is illustrated below (fig 13).
Figure 15: Valve closure sequence for cutting and removing cut pipe from the well.
BOPs are available in a range of sizes that normally conform to API flange sizing. Table 5 is
a guide to the pipe diameter that can be used with a range of BOP sizes.
17
BOP Size
2.56
Coiled Tubing OD
0.75 2.00
3.06
4.06
1.00 2.875
5.12
1.25 3.5
6.375
7.06
Table 5: BOP and CT compatibility
Combi BOPs
Combi BOPs combine the blind ram and shear ram (upper ram) and a slip and pipe ram
(lower ram). The advantage is a saving in weight and height for the rig up. The
disadvantage is that the pipe ram cannot be closed in isolation to enable stripper packing to
be changed out.
Figure 16: Combi BOP. Shear/Seal upper ram and Pipe/Slip lower ram.
18
19
Section 10:
10 Coiled Tubing.
Note: Closing the BOP using the manual locks is not normally possible. The force needed to
move the ram against well pressure cannot be generated by turning the manual lock
threaded stem hydraulic force is normally needed. Do not be tempted to try to force
fo
the
manual locks using a pipe wrench or cheater pipe to obtain additional leverage; this will
only damage the manual lock and ram. If wellhead pressure is very low, or if an very small
BOP 2 (63.5mm) is used it might be possible to use the manaual lock to close a BOP
ram.
Unlocking and Opening the Rams
To unlock and open the rams.
1. Equalize across the rams.
2. Unlock the manual locks by rotating the hand wheel counter-clockwise.
counter clockwise.
3. Hydraulically open the rams. Most ram designs will not allow the manual opening
o
of
the rams.
The rams must be fully open so they dont interfere with the BHA.
20
Figure 20: A Coil Tubing Injector Head with goose neck attached.
Injector size and horse-power will be selected based on reel size, well depth and wellhead pressure.
Conventional injector heads are configured with two sets of contra rotating endless chains. Gripper
blocks are mounted on the outside of the chains and are sized according to pipe size. The gripper blocks
hold the pipe, either supporting its weight (stripping) while it is lowered and raised from the well, or
pushing the pipe into the well against pressure (snubbing). String load is held by the face of the gripper
block or insert. Traction and tension are adjusted in two ways. Injector head traction or inside chain
tension provide the force to grip the tubing. Force is applied through three sets of separate hydraulic
pistons. Having independent systems reduces the risk of operational failure. A second set of hydraulic
rams are used to tension the chain outside the vertical drive plane.
21
Figure 18 (below) illustrates the chain drive system for the widely used Hydra-Rig 240/260 injector head.
It shows the components of a classic skate chain tensioner system. One side of the injector head is cut
away for clarity. Hydraulic motors drive the chain through the top sprocket (1). The skates (2) are linked
in pairs with hydraulic cylinders which are pressurized to provide enough force for the chains to grip the
tubing.
The outside chain tension is controlled by a sprocket (3). It is necessary to keep both chains tight for
efficient operation and to prevent tubing damage (e.g., when running in hole the chain gripping the
tubing is being pushed by the drive sprocket - incorrect chain tension will tend to offset the chain links
and grippers to possibly damage the tubing surface)
Note: The injector head is symmetrical, i.e., the opposing chain set, not shown, is a mirror image of the
exposed side.
Grip force on the pipe may have to be very high. Correct selection, operation and maintenance of chain
components minimize the risk of damage to the CT string and optimize the life expectancy of
consumable components. Recent studies indicate that even relatively light damage on the string surface
has a significant effect on the predicted fatigue life of the string. Consequently, the effect of any
components and equipment in contact with the string surface should be understood and carefully
monitored.
The majority of chain systems are assembled from standard ANSI chain components and custom built
parts enabling relatively easy replacement of worn or damaged items.
22
Modern injector heads have a brake system that is part of themotor assembly. It is hydraulically
controlled. Pressure is required to release the brake so the system is considered fail-safe in operation.
Application of the brake is usually automatic and controlled by the drive system hydraulic pressure - the
brake is applied if the drive system hydraulic pressure falls below a preset value. Some early injector
heads are equipped with hydraulic brakes controlled manually from the control console.
The amount of snubbing force required to run tubing through the stripping rubbers and in to the well
will depend on the hanging weight of the coil already in the well, the OD of the coil, the wellhead
pressure and the friction of the coil passing through the stuffing box.
For example - With a wellhead pressure of 5,000 psi and 1.5 coil the force required to balance wellhead
pressure would be:
Area of 1.5 tubing = 1.767 in2. 5,000 psi x 1.767 = 8835 lbs force to push coil in to the well. It will be
necessary to add stripper friction, for example 2,000lbs, giving a total snubbing force of 10,838 lbs. As
Advanced Completion and Intervention Well Control Manual.
Draft: Version 2
23
the coil runs in to the well, the hanging weight will reduce the snubbing force required. At some point
the injector will be supporting the tubing weight, as opposed to pushing it in to the well.
To continue the example Empty 1.5 0.109 in wall tubing weighs 1.619 lbs/ft. In a gas filled well
(negligible buoyancy) the snubbing force would be balanced by 6692 feet of coil:
,
. /
= 6692 ft
In the unusual case of running a dry string into well filled with fluid 9ppg for example, buoyancy would
have to be accounted for:
= 1
Where
Wa
Pf
Ps
The buoyed weight reduces the weight helping to pull the tubing in to the well. The weight becomes:
= 1.619
9.6
1
= 1.4/
65.4
[ ](1)
4
12
(9 /)(7.48 /)3 = 0.612 lb/ft
This is weight added (per foot) by filling with brine. Net weight per foot would be:
1.4 lb/ft + 0.612 lb/ft = 2.012 lb/ft.
24
10,835
= 5385
2.012/
Let us now consider what will happen if the circulating fluid is switched from 9ppg brine to 16.4 ppg
cement.
.
(1( )16.4 ()7.48)=1.12
lb/ft.
As seen in the examples, the force needs will vary with well pressure, coiled tubing dimensions,
circulating fluid and well fluid densities. Frictional forces created by the flowing fluids (ignored here)
could also change the force loadings.
3.6. Gooseneck.
The gooseneck guides the pipe from the reel in to the vertical above the injector head. Rollers are built
in to the goose neck at intervals to reduce friction.
The radius of the gooseneck affects the fatigue lift of the reel as if controls the bend angle as the coil is
reels in and out of the well. Recommended gooseneck radius is listed below (table 3).
25
(in)
(in)
20 30
48 54
25 36
48 72
30 40
48 72
35 48
72 96
40 48
72 96
2 3/8
48 54
90 120
2 7/8
54 58
90 120
65 - 70
96 -120
26
In some injector heads a single pivot point is used. The calibration range for the load cell
will vary according to the construction of the injector head.
In Hydra Rig 240 & 260 units for example, the distance between the Hinge and the tubing is
equal to the distance between the load cell and the tubing, the load cell only measures half
of the actual weight supported by the injector head. The gauge on the control consul must
be calibrated to allow for this.
Another type of weight indicator is an electric strain gauge model. This type of weight
indicator measures the applied load by strain gauges, with output signals in mAmps (420mA) or Volts (0-5 V), which are converted in the cab to measure applied loads tension
(pulling) or compression (snubbing). The load is defined as the tensile or compressive force
in the coiled tubing just above the stripper. It is one of the most important measurements
used in the operation of a coiled tubing unit. Load may be effected by several parameters
other than the hanging weight of the coiled tubing;wellhead pressure, stripper friction, reel
back-tension, gooseneck alignment and the density of the fluids inside and outside the
coiled tubing.
Note: accurate depth determination with coil can be difficult. Friction wheel slippage,
encoder calibration errors and pipe stretch can combine to give significant errors.
27
28
By using a pressure tight swivel, pressure remains in the reel and pumping is able to
continue even when the pipe is moving a very useful feature.
Turning power for the reel comes from a small hydraulic motor. This is used primarily to
keep tension between the reel and the injector. When running in to the well it is normal to
keep tension by using back pressure, i.e. the reel motor is set to spool on to the drum but
with hydraulic pressure reduced. If sufficient back pressure is not maintained, the coil can
29
become slack on the drum. In addition the coil between the drum and the gooseneck will
bend, causing additional fatigue. (fig 29).
Figure 29: Tension must be maintained between the reel and the goose neck.
Left incorrect. Right correct.
A hydraulically operated level wind controls the pipe as it comes onto the reel, enabling the
operator to smooth wrap the pipe, minimising damage and maximising reel capacity.
Many coiled tubing vendors will mount a counter on the level wind.
30
The power pack needs to supply high-volume, low-pressure hydraulic fluid to dynamic equipment such
as the injector head whilst at the same time be able to deliver low-volume high-pressure hydraulic fluid
to static devices e.g. the stripper and BOP. As a consequence, most power packs have several hydraulic
pumps .
Electric motors have the advantage of a more favourable power to weight ratio. They are much quieter
to operate and normally require less upkeep (refuelling, oil changes). However, they have some
disadvantages. They can only be used where there is a readily available power supply. This means they
are most commonly found on large offshore platforms. Even here there can be limitations. An electrical
shutdown on the platform means no hydraulic power to the coiled tubing unit.. The motor must be
explosion proof and comply with industry (and Shell) zoning requirements. Electric power packs are
normally Zone 1 rated.
Internal combustion has the advantage of being able to operate independently of any external power
source. Diesel motors are normally used because they are more reliable than petrol and can be made to
function more safely in hydrocarbon hazardous areas (no spark plugs, contact breakers, distributors
etc). The exhaust can be fitted with an efficient spark arrestor. Also diesel fuel is widely available
offshore whereas petrol is normally not allowed.
Because the engine may have to operate in hazardous areas, an automated shut down system should be
fitted.
Safety Shutdown System for diesel motors.
Under normal operating conditions, engine oil pressure is supplied to the following equipment:
Over speed valve
Exhaust temperature valve
Fuel shut off valve
Control cylinder
Water temperature valve.
If engine oil pressure is lost, or seriously reduced, the fuel shut off valve and air intake D valve closes,
thus stopping the engine. Oil pressure losses at the fuel shut off valve can be caused by any of the
following:
Shortage of engine oil
Damaged or broken oil line
Oil pump failure
High exhaust gas temperature causing valve to open, thus dumping oil
High water temperature causing valve to open, thus dumping oil to sump
Engine over revving causing over-speed to dump oil to sump.
If the engine is over speeding due to incorrect operator control or to flammable gas entering the inlet
manifold, the D valve will close off the inlet preventing further entry of gas.
NOTE: Even if the fuel is shut off, the engine could continue to run on the flammable gas entering
the inlet manifold if the inlet manifold is not closed off.
31
The diesel engine should be properly maintained. Exhaust/spark arrester should be cleaned regularly. If
neglected, soot may form and render it ineffective. Hydraulic filtering systems must be checked and
cleaned regularly.
Diesel engine power packs must be positioned and operated only in areas designated as safe, in
accordance with IP model code of safe practise in the petroleum industry which classifies areas as:
Zone 0 - In which flammable atmosphere is continuously present or present for long periods
(More than 1,000 hours per year).
Zone 1 - In which a flammable atmosphere is likely to occur in normal operation (About 10 to
1,000 hours per year).
Zone 2 - In which a flammable atmosphere is not likely to occur in normal operation, and if it
occurs will exist only for a short period (less than 10 hours per year).
Many CT units will have electronic data monitoring and recording of parameters. Measurements can
include:
Pump discharge pressure
Wellhead pressure (coiled tubing annulus)
Depth
Reel speed
Weight
Stripper hydraulic pressure
Hydraulic power supply pressure.
32
Control cabins equipped with electronic equipment should be pressurised to prevent the ingress of
hydrocarbon gasses, except where the electronic components are explosion-proof. The cabin should
provide a safe and comfortable environment for the operators.
33
34
After the roll on connector has been pushed on the end of the coil, a crimping tool is used to
indent the coil into grooves in the connector thus securing the connector to the coil.
The dimple connector uses a hydraulic jig to indent the coil on to the connector. It takes
about 10minutes to make the connection and is acknowledged to be an improvement on the
roll on connector.
35
Grapple connectors use a slip arrangement to grip the pipe. Unlike the dimple and roll on
connector, there is no internal deformation or restriction in the pipe leaving a clear path for
drop ball operated equipment.
Figure 36: Dart check valve (top) and ball check valve (bottom) - single valve.
Figure 37: Double check valves: Dart/Ball (top) Double flapper (bottom).
36
With a check valve fitted, care needs to be taken not to allow annulus pressure to exceed
collapse pressure of the coil. There are a number of conditions where there is a risk of
annulus pressure exceeding collapse pressure.
During gas lifting operations where nitrogen is in the reel and fluid is in the tubing
especially if the gas pressure in the reel is bled off
Whilst running into a closed system i.e. un-perforated casing or liner. Pipe volume
fluid displacement will cause an increase in pressure. If not measures are taken to
bleed off the tubing will collapse.
37
After release the bottom hole assembly can be fished from the well. The assembly left in
the well has a standard internal or external fishing neck profile (depending on design) to
assist recovery.
Figure 40: Circulation sub: Burst disk (top) and Dual Circulating and Burst disk sub (bottom)
38
39
Ensure the coiled tubing is in good condition. Oval pipe has a much lower collapse
pressure.
Pump nitrogen as the reel is running in. This lightens the fluid column all the way
down keep pressure in the reel to prevent collapse.
At the start of the gas lift have the choke fully open and send flow to the (test)
separator at the lowest possible pressure.
The deeper the point of injection, the more efficient the gas lift will be.
Once flow begins and as the heavier fluids are lifted out of the well , tubing head
pressure will increase. Closing in the well once flow has stabilised will bring about a
further increase in wellhead pressure.
Ensure that internal coil pressure is
maintained.
Frictional losses can be significant when using large coil in small tubing and pumping
at too high a rate can result in nitrogen going to the formation.
If small OD coil is used in large ID tubing, slippage can prevent the Nitrogen from
lifting efficiently. It may be necessary to foam the Nitrogen.
Liquid nitrogen can crack decks if it leaks from the containers or transfer hoses.
Spill contingency plans are necessary. Ensure the crew is briefed.
If upwards flow is less than the settling velocity than solids will accumulate above the nozzle
and the pipe will get stuck. If the pipe is stuck, it might have to be cut to enable recovery
from the well making pressure control more difficult.
The settling rate for solids will depend on particle size, density and shape and the viscosity
of the lifting fluid.
40
Fluid
20 lb/1000 gal gel
20 lb/1000 gal gel
60 lb/1000 gal gel
Diesel
Water
Increasing the viscosity of the lifting fluid can be of some use (as illustrated by the numbers
in the table), but pump rates may be affected, particularly when circulating with coil. One
approach is to use a series of hi-viscosity sweeps, rather than continuous circulation of gel.
Once lifting begins, the pumps should not be shut down. Make sure there is enough fluid
available to perform the entire operation without having to stop pumping. If a problem
arises and you have to shut down the pumps whilst still on bottom and still lifting solids the
coil should immediately be pulled off bottom in a horizontal well, pull back above the heel.
Resume pumping as soon as possible.
Continuous lifting of solids is unadvisable. The coil is less likely to become stuck if small
bites are taken from the fill. Pick up frequently clear from bottom to ensure the reel is
not becoming stuck.
41
Spotting the treatment fluid with CT will help ensure complete coverage of the
interval. Using an appropriate diversion technique will help ensure uniform injection
of fluid into the target zone. Spotting the treatment fluid also avoids the need to
bullhead wellbore fluids into the formation ahead of the treatment.
Long intervals can be more effectively treated using techniques and tools that have
been developed for use with CT, e.g. a selective treatment system using straddlepack isolation tools. This is particularly important in horizontal wellbores
All acid used must be properly inhibited to prevent corroding the coil tubing (and the
completion tubular).
Pickle the internal surface of the CT work string before performing the matrix
treatment. This removes rust and scale deposits that, if injected, can damage the
formation. In addition, inhibition from the main treatment fluid is more effective if
the inhibitor is adsorbed a clean surface.
Only use H2S service equipment. A possible by product of the acid treatment is H2S.
If acid is simultaneously being pumped down the coil and down the production
tubing, the point of injection for the production tubing should be below any CT
pressure control equipment. In other words, dont inject through a tee on the riser.
It is better to pump in through the kill wing on the tree.
At the end of the treatment, ensure no spent acid is left in the reel. There have been
cases of acid accumulating on the low side of a reel and badly corroding the pipe.
42
jetting (pump pressure below 5,000 psi). Any jetting operations will mean having to
reciprocate the BHA across the scale deposit causing a high degree of fatigue to a relatively
short section of the coiled tubing.
Accurate data acquisition and real-time fatigue
monitoring are essential.
The high flow rate necessary to achieve annular velocity sufficient to remove solid scale
particles may not be achievable and there are risks of getting the pipe stuck if a velocity
high enough to carry solids cannot be maintained. The following measures are used to
reduce pressure loss in the system and increase pump rate.
Carry out hydraulics modelling before the operation. It is more difficult to keep the
hole clean in high angle wells with long tangent sections and where small coiled
tubing is run inside large diameter tubing.
The mud motor used to drive the mill will limit the circulation rate. A circulating sub
placed above the motor can be used to increase circulation rates.
Select a mill that produces fine cuttings.
Do not drill ahead continuously pick up at regular intervals and circulate bottoms
up to sweep the hole clean.
Viscous sweeps may be needed to lift the cuttings.
If a large amount of scale is being removed from the well, solids handling equipment
may be needed.
43
Conventional solids transport will not work because of low annular velocity (large
tubing/small coil)
Gel sweeps are problematic or simply inefficient.
Very low annular velocity
Possibility of plant up-sets
Low reservoir pressure situations where well is dynamically killed when pumping
conventionally fluid losses to the formation. It has been used successfully in 30
mbd injection wells.
Lack of produced fluid to assist long way circulation low flow rate.
High density solids, e.g. barium sulphate scale
Large quantity of solid to be removed e.g. tubing full of proppant
Situation where it is preferred that solids do not go through process plant
Offshore where dump overboard allowed
Onshore where separation easy .
The drawing below illustrates the hook up that would be used for a reverse circulation
operation. Fluid is pumped into the tubing to coil tubing annulus via a riser tee or in
through the kill wing on the tree if appropriate. Returns are taken back up the coil tubing to
the centre piping manifold on the CT reel. From there it is routed through a choke to a
manifold and disposal. Reverse circulation means the check valves normally placed in the
coil tubing BHA must be removed.
44
Section 10:
10 Coiled Tubing.
The removal of the check valves raises some well integrity issues. Does it mean the
removal of a well control barrier? Consider
onsider the implications. During most drilling and well
intervention operations there will be one primary barrier and one secondary (contingency)
barrier.
When
hen drilling the well the primary barrier is the mud, with the BOP the
contingency. For normal coil
il operations the primary barrier is the CT stripper/stuffing box,
the coil tubing BOP and BHA check valve acting as secondary barriers. In a reverse
circulating operation the well can still be closed in at the BOP. Moreover the direction of
circulation can be switched to pump down the reel at a one man operated 4 way manifold.
45
If necessary, the coil could be held in the slips, cut and removed from the injector head and
the blind rams closed.
Industry records show that reverse circulation operations have fewer problems than
conventional circulation. During the course of over 1,600 jobs there were three cases of
collapsed coil (too high an injection pressure) and two cases of pinhole leaks, There have
been (to date) no recorded cases of the pipe getting stuck. This is because some of the
risks associated with conventional operations diminish when reversing. For example:
Sufficient velocity in the coil to lift solids less chance of sticking pipe.
No solids on the back-side of the coil, so nothing to fall back if the pumps fail.
No change in flowpath ID instance.g. increasing ID at the top of a liner or tubing
cross-over.
The size of the cuttings is controlled by the nozzle port size.
Some wells carry a higher degree of risk so additional precautions must be taken if a
reverse circulation operation is to succeed. These include:
Fatigue life of coil should be less than 40% of the normal limit.
The coil should be in good overall condition.
High conformance to ovality limits (<4% - 2% better).
If hydrocarbons are in the wellbore, bullhead 3 full displacement volumes, or
circulate conventionally to remove them.
Carry out the circulation with the well overbalance to prevent hydrocarbon influx.
Configure the surface pipe-work to enable pumping down the coil at any time.
A PRV should be installed on the back-side (annulus) inlet to prevent coil collapse.
Crews should be familiar with the surface pipe configuration and what to do to
switch direction of circulation.
Limit the volume of solids in the reel to 10% of its volume. This means regulating
the rate of penetration in to fill. (Tubing and coil size dependent).
Kill weight brine should be available.
Monitor returns for any indication of gas or hydrocarbon in the reel at all times
(increase in return pressure).
The highest risks come from collapsing the reel. The collapse pressure is affected by the
coil wall thickness, material yield, string tension, temperature and ovality. Operators should
have a thorough understanding of the history limitations on the reel in use. In the North
Sea (UK sector) there is a general policy of not exceeding 1,500 psi differential from
annulus to coil.
5.6.1. Reverse circulation BHA selection.
When selecting a nozzle for a reversing operation the following points need consideration. .
Select a nozzle that will fit through restrictions in the completion.. A circumferential
clearance of at least is recommended to ensure minimum pressure drop around
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46
the nozzle. If a single hole is used it needs to be smaller than the minimum ID of
the swivel joint on the reel.
A pointed shape will help break up compacted and hard fill.
A single large hole in the centre is useful for lifting larger chunks of fill (but smaller
than the reel swivel joint ID)
Consider using a ball cage or ball drop jetting nozzle if hard fill needs to be broken
down.
Figure 47: Ball and seal allows rapid switching between direction of circulation.
The normal BHA for a reversing operation is CT connector - Straight Bar - Nozzle. It is not
thought necessary to run a disconnect. It is possible to a add venturi junk basket, mill or
under-reamer if conditions dictate.
5.6.2. Pumping Operations.
Experience has shown that the following guidelines work well during reversing operations:
Pump down the coil to clear the nozzle of any debris (3,500 4,800 psi depending
on reel type).
Pump down the backside up to 1,500 psi. Return rate depends on reel size and
length but 1 1.5 bbls/min is effective in standard intervention coil sizes 1 1/4 to
2.
Penetrate the fill to give about 5% solids fill in the reel the gradually build to 10%.
Do not exceed 10%. ROP = (capacity of wellbore at nozzle in ft/bbl) x (bbl/min
return rate) x 10%
Expect losses as perforations are approached.
Friction reducers can be used to lower pump pressure.
It is important to know the loss rate in the well. High pump rates may be necessary
to get the required rate of return in the coil to lift fill. For example, if losses to the
formation are 3 bbls/min and the rate required to lift solids is 1.5bpm, then a surface
discharge rate of 4.5 bbls/min would be required.
47
sleeves and inflow control valves in intelligent completions where the hydraulic controls
have failed. To minimise the risk of getting the reel stuck.
48
Figure 48: Gun deployment pressure control equipment and gun connector (right).
49
Operation of all coiled tubing pressure control equipment, including the well control
panel if used.
All senior coiled tubing staff should have an accredited cased hole and intervention
well control certificate.
2. Establish good communications between the coiled tubing control cabin and other
operational personnel.
Shell representative.
Facilities operators.
Injector
50
14. When working at height ensure that the Shell Drops standards are implemented and
fully adhered to.
15. Ensure all crews are conversant and in adherence with the Shell temporary pipework
standard.
16. Ensure deck loading limits are not compromised ensuring that calculations consider full
containment of fluids in use (Coil contents for example).
7. Rigging up.
Rig ups vary, depending on the location. However, the probability of operational problems is
reduced by adhering to a few basic principles.
1. Pre-rig up preparations.
Function test all of the coiled tubing unit major components (reel, injector,
BOPs) before shipping.
Pickle and flush the coiled tubing reel to remove debris before transporting
Place a length of the coil to be used for the job across the BOP and close the pipe
and slip ram. Open the ram, remove the pipe and inspect for damage.
Use the shear seal BOP to cut a sample of the coil that will be used during the
job.
Before rigging up, cut a small length of coiled tubing from the reel for later
analysis.
For some interventions it is preferable to use slickline to drift the well to confirm
access before coiled tubing is mobilised.
2. Isolate the automatic shut-down functions on the xmas tree (hydraulic UMV and
SCSSSV) from the host facility shut down system and connect them to a remote well
control panel see Wireline, Chapter 7. Section 7.7.6.
3. BOPs (shear seal and primary) must be fully function tested
4. Always use new ring gaskets for all flanges.
5. If a pump in tee is being used, a flange type is more resistant to accidental damage.
Figure 49: Flanged side outlet valve (left). The hammer union (middle) is prone to damage (left)
51
Position vent lines from pressure relief valves to discharge in a safe area and away from
people. Ensure they are tied down sufficiently.Injector head preparation and use:
Properly support and secure the injector head throughout the operation.
Remove transport clamps and confirm proper function of the weight indicator.
Check that the centreline is in alignment with the centreline of the BOP.
Figure 50: Properly support and secure the injector head throughout the operation!
52
Fig 51 shows one example of an equipment configuration that might be used on an offshore
platform well. High pressure lines enable fluid to be pumped through the coiled tubing. Fluid
returns could be taken back through the kill wing and routed to the rig choke or test
separator.
The positioning of lo-torque valves in the lines also enable fluid to be pumped in to the well
below the shear rams and above the slip rams on the quad BOP. This would enable the well
to be killed through the coil if it had been cut in the BOP and the end removed through the
stripper. A line has also been connected to the kill wing.
This example is by no means the only method of arranging the pipe-work for a coiled tubing
operation. A fracturing operation where fluid was being simultaneously pumped into the
coiled tubing and the production tubing would require two fluid pumps and two high
pressure lines. One lined up to pump into the coil and the second to pump into the tubing.
53
Strippers.
All components will be tested in excess of the maximum anticipated pump pressure, or the
maximum closed in wellhead pressure; whichever is greater. The exact test pressure should
be stipulated in the work programme.
All tests on critical pressure control equipment must be witnessed by a Shell representative.
A record (electronic or paper chart) must be kept of all tests on pressure control equipment.
Any components that fail the pressure test must be repaired or replaced and the test
repeated.
Water is normally used for pressure testing. If there is a risk of hydrates, then a 50/50
glycol/water mixture should be used. Remember to agitate the glycol water mixture before
use (see chapter 2 section 7).
54
Where possible ensure that all the air is purged from the lines. This is easily
managed by flushing from the fluid pump to the highest point or points on the rig up.
For example, in the drawing below (fig 46) fluid would be flushed through the kill
wing until returns were seen at the (open) BOP. Fluid would also be flushed through
the reel until returns were seen at the injector end.
Pressure relief valves are tested off-line and isolated from the surface lines during
surface pressure tests.
55
Wing valve.
56
Wing valve
At the ends of the test, pressure should be bled back to the pump.
57
58
Swab valve
Test the lower stripper first. At the end of the test, bleed off. Un-pack the
lower stripper and flush until fluid is seen overflowing the upper stripper.
Pack off the upper stripper and carry out the pressure test.
59
Figure 57: Testing the check valves by bleeding back through the coil - careful now!
60
61
1. If the injector head is supported by a crane, the crane engine must be run
continuously while the load is suspended.
2. Lubricate the coil while running in to protect the stripper elements.
3. Zero the depth counters and weight indicator(s) before opening the well.
4. Maintain the lowest possible hydraulic pressure on the stripper that creates an
effective seal around the CT in order to minimize wear on the stripper elements.
5. To avoid buckling the pipe on unexpected obstructions when running in, use the
minimum possible hydraulic pressure to drive the injector.
6. Maintain positive pressure in the CT reel at all times. Agree a maximum allowable
collapse pressure for the operation (normally 500 psi).
7. Do not use the slip rams during normal operations. If they are used, pick up and
inspect the surface of the CT contacted by the rams for signs of damage before
continuing. Do not run damaged CT below the BOPs.
8. Mark the CT with paint at known depths for visual reference. Do not scratch, dent, or
otherwise mark the surface of the CT.
9. Agree a maximum allowable sit down weight before running into the well. (normally
>2,000 lbs and should be agreed in programme).
10. If in use, data acquisition should run continuously while pipe is in the hole.
11. Monitor the VME (Von Mises Equivalent) stress in the CT wall relative to the working
limit prescribed by the work programme.
12. Monitor pick-up RIH weight for comparison with predicted values.
Agree a maximum pick up weight before running in to the well. 14 If the expected
parameters are incorrect stop. Consult the coil tubing vendor and the onshore support
group before continuaing.
62
Operation
Running
in
Pulling
out,
Maximum speed.
m/min
ft/min
15
15
25
Uninterrupted running in
20
75
15
15
15
30
100
After running in to about 500ft (150m) to verify that all of the equipment is working
properly.
More frequent checks are made if pick up weight is getting close to the maximum
allowable tension, or if well conditions are giving cause for concern.
Note: Do not perform the pull test at the same point on every run i.e at exactly 1000 ft,
2000 ft and so on. Change the point at which the pull test is taken to reduce bending
fatigue in the reel.
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Depth
Stripper pressure
Wellhead pressure
64
65
If shear seal rams are fitted above the tree, cut using these then close in
tree valves. The coil may or may not clear the SCSSSV depending on
where in the well the reel end was when the pipe was stopped (during
initial production shut down). In all probability well control panel pressure
be dumped irrespective of the position of the tubing in the well.
the
the
the
will
If no shear/seal rams are fitted the pipe will be cut with the shear rams in the
quad BOP. If the pipe had been picked up clear of bottom before the injector
was stopped then it should fall clear of the tree and the tree can be closed in.
If the pipe was stuck on bottom when the emergency began, or there was no
time to pull back then the pipe will have to be cut, pulled out of the BOP and
the blind ram closed.
Some xmas trees are fitted with hydraulically assisted master valve actuators
that are capable of cutting coil. These are the exception rather that the rule.
If a well is equipped with such valves, they would activate during a platform
abandonment.
Figure 59: Hydraulic actuator - capable of cutting coiled tubing with hydraulic assist.
1. If the injector head has stopped moving and the CT is stationary, then apply the
injector brake (if it has not activated automatically with the reduction in hydraulic
pressure).
2. If the coil was moving when the failure occurred, take action to prevent the tubing
from running away (see below 10:10)
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66
3. Close the BOP slip rams, then close the pipe rams. Engage the manual locks on the
rams.
4. Set the reel brake.
5. Repair or replace the power pack.
6. Equalize pressure across the BOP pipe rams.
7. Pick up and inspect the pipe at the point where the slip rams had contacted.
8. If the pipe is OK, continue with the operation, if not, pull out of the hole and repair
or replace the reel.
If the power pack fails during scale milling, fill removal of drilling operations,
continue to circulate at the planned pump rate to reduce the possibility of getting stuck.
Warning:
If it is not possible to run the tubing further into the well, and it is not possible to spool the
tubing in the well back onto the reel, (no surplus capacity on reel) then it will be necessary
to cut the tubing. Cutting the tubing will also be necessary if the reel is damaged beyond
repair. In either case proceed as follows:
1. Confirm check valve integrity by bleeding off reel pressure if it is safe to do so do
not risk collapsing the reel if there is a high external differential pressure. Pumping
water into the reel might be necessary. Flowing the well can also help reduce
external reel pressure.
2. If it is safe to do so, cut the pipe above the goose-neck and remove the damaged
reel.
3. Replace the reel and connect the end of the pipe protruding from the injector to the
pipe on the new reel make sure there is enough reel capacity before continuing.
4. Open the pipe and slip rams and POOH.
67
68
Check the injector, pressure control equipment, tree and wellhead for damage. close and
manually lock the BOP slip and pipe rams whilst repairs are made.
Equalise across the pipe rams. Unlock and open the pipe and slip rams and continue
operations.
1. Pull out of hole to position the leak on the lower part of the reel (be prepared to deal
with containment of any hazardous fluid).
2. If hazardous chemicals were in the reel, e.g. acid, flush through thr eel with water.
Wash down and neutralize any spillage.
3. If there are concerns about reel collapse, flowing the well and (or) pumping through
the reel will reduce the risk.
4. Pull out of hole and replace coiled tubing reel.
If valves are not holding or have not been included in bottom hole assembly:
1. Observe severity of leak and decide whether it is safe to pull out of hole. Factors
such as fluid type and area of dispersion will influence decision.
2. If leak is too severe to continue pulling out of hole Close slip and pipe rams
3. Operate shear rams to cut pipe.
4. Remove cut pipe from the surface stack.
5. Circulate well to kill fluid through coiled tubing left in well through the side outlet
port between the shear ram and slip ram.
6. Recover the remainder of the pipe from the well.
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If difficulties are experienced calculating the depth of the leak, or if the leak is severe and
getting worse, killing the well may be the best option. Continued pumping, necessary to
keep hydrocarbon out of the reel, risks washing out and parting the pipe. If wellhead
pressure is low, and the leak rate manageable, proceed as follows:
1. Continue pulling out of hole while circulating. Establish a minimum pump rate just
high enough to keep hydrocarbon out of the pipe. Watch for signs of the leak
passing the stuffing box. As long as the fluid escaping is the same as that being
pumped (i.e. water or brine) and it should be safe to pull the leak back on to the reel
2. Once the leak is seen at surface, pull it back on to the reel. It is best to put the leak
on the low side of the reel so it drains when pumping stops.
3. If well pressure is low (below the collapse rating of the pipe) it may be possible to
stop pumping at this point and confirm the integrity of the check valves.
4. If the leak is too severe then run back into the well, set the slips, close the pipe
rams, shear the pipe and close the blind rams.
If internal reel pressure is lower than well pressure, then the first indication of a failed check
valve or pipe leak will be increasing circulating pressure.
70
5. If the leak is too severe then run back into the well, set the slips, close the pipe
rams, shear the pipe and close the blind rams.
10.7.1. Tubing pulled out of the stuffing box.
When pulling back to surface with leaking tubing, there is always a risk of the tubing parting
and pulling out of the stuffing box there is no BHA to stop it. If this happens, try to stop
the pipe before it leaves the top of the injector chains. Close the BOP.
Note: Reel pressure will bleed rapidly as soon as the fractured end exits the stripper. In
high pressure wells the loose end can be blown up and out of the injector and will flail
about. It is important to ensure everyone is clear of the area before the pipe exits the well.
When the pipe is deep in the well and pulling back to surface would expose people and plant
to too much risk:
1. Pull sufficient coiled tubing out of hole to ensure that the string will drop below the
Xmas Tree master valve when the shear rams (or shear/seal BOPs) are activated.
2. Close shear rams (or shear/seal BOPs) to cut coiled tubing.
3. Close Xmas Tree swab and master valves.
4. Repair leak in riser and pressure test all broken connections.
5. Commence fishing operations.
Note: If the leak is small, then pulling out of the hole can be attempted. This will be at the
discretion of the Shell supervisory staff on site. Pulling out of the hole should only be
attempted if:
71
The facility to pump into the tubing (coiled tubing/production tubing annulus) is already in place
and can be used without delay.
If increasing the packer pressure does not stop the leak the stripper rubber will have to be
changed.
72
12. If the CT is damaged, POOH and make permanent repairs or substitute a different
reel of tubing.
10.9.1. Replacement of Elements In Conventional Top Entry Stuffing Box
1. Unscrew the split cap or remove the pins and lift out
2. Remove the old stripper elements
3. Inspect the upper bushings for wear. Replace if required.
4. Insert new stripper elements.
5. Replace the split cap and energize the stuffing box assembly.
10.9.2. Replacement of Elements in the Side Door Stuffing Box
1. Open the side doors.
2. Apply 100 200 psi (700 - 1,400 kPa) hydraulic pressure to the packer cylinder to
open the sleeve upward.
3. Remove the stripper element halves. Be aware that the upper brass bushings may
fall down into the window once the stripper elements have been removed.
4. Remove the split Teflon non-extrusion ring.
5. Remove and inspect the brass bushings above and below, replace if required.
6. Insert the bushings and the split Teflon non-extrusion ring.
7. Insert new stripper elements
8. Release the packer cylinder hydraulic pressure, allowing the sleeve to close.
9. Close the side doors and manually lock.
73
4. If these actions fail to make any difference, reduce the injector hydraulic pressure to
zero. This should cause the safety brake in the motors to actuate and the counter
balance valves to close, stopping the injector. Under certain circumstances, if the
runaway tubing is at a speed above the critical speed, the back pressure created by
the circulating hydraulic fluid may prevent the injector motor brakes from actuating.
If this situation occurs, select the pull mode for the injector and increase system
hydraulic pressure until the tubing comes to a standstill.
5. If the tubing is not too far off bottom it may be practical to let it fall to bottom then
investigate the causes and repair. This can only be done if there is sufficient tubing
on the reel to reach bottom.
Note: Tubing may helix when hitting bottom making it difficult to pull into tail pipe.
6. As a last option close the slip rams. This will probably lead to pipe breakage but it
might be the only safe option. If the pipe is still intact, proceed as follows.
7. Shut down the power pack and tag the control valves before any person climbs onto
or works on the injector head.
8. Open the injector chains and clean or repair the gripper blocks.
9. Ensure that all personnel are safely clear of the injector.
10. Close the injector chains, remove the tags from the injector controls, and reinstate
hydraulic power to the injector head.
11. Adjust the chain gripper pressure.
12. Energize the stripper.
13. Equalize pressure across the pipe rams. Open the pipe and then the slip rams and
inspect the surface of the CT contacted by the rams for signs of damage.
14. If the CT is undamaged, continue CT operations.
15. If the CT is damaged, POOH and make permanent repairs or change out the reel.
1.
2.
3.
4.
Attempt to match the speed of the injector with the CT's rate of ascent.
Increase the inside chain tension to increase friction on the CT.
Increase stripper pressure to increase friction on the CT.
If the BOP slip rams are bi-directional these can be closed, but it risks parting the
pipe.
If the run away is hydraulic, manually set the injector brake or reduce the injector hydraulic
pressure to zero to set the injector brake.
1. Increase the reel rotational speed to pace the CT coming out of the well.
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2. Prepare to close the hydraulic master valve if the CT comes out of the stripper.
3. Reduce WHP as much as possible by flowing the well.
4. If the preceding actions do not stop the tubing runaway, close the slip rams on the
CT.
You are unlikely to be able to pull squashed pipe through the back-up bushings in
the stripper.
If the tubing is being pulled out of the hole and a collapse is pulled up to the stripper,
causing a leak at surface:
1. Immediately run the tubing back in the well a sufficient distance to make sure that round pipe is
in contact with the stuffing box and across the BOP.
2. Immediately reduce the wellhead pressure by all safe means possible. Either flow the well
through a choke at a higher rate or stop the annular fluid injection if reverse circulating.
3. Increase the coiled tubing internal pressure by attempting to circulate.
4. Once pressure conditions inside and outside the coiled tubing have been optimized the well will
need to be killed.
If it is not possible to run down to place undamaged pipe across the stripper and there is a
leak at the stripper:
1. Close the pipe rams. This might reduce or even stop the leak.
2. Clear all non essential personnel from the vicinity.
3. If the leak is small and the escaping fluids are not hazardous, it might be possible to kill the well
without cutting the tubing. This will be at the discretion of the Shell supervisory staff.
If is not possible to control the well then the tubing must be cut and dropped and the blind
rams closed followed by the tree valves.
Once the well has been killed:
1. Arrange for clamps to be fitted to the coiled tubing above the injector head.
2. Release the pressure from the stuffing box and open the pipe rams.
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3. Cut the tubing at the gooseneck and use the rig or a crane to pull the tubing through the
injector.
4. Re-clamp the tubing above the injector head and cut off in 30 ft (10 m) sections (or as
appropriate to the crane or rig).
5. Continue pulling and cutting tubing until the tubing pulled to surface can be pulled by the
injector head.
6. Once undamaged (not collapsed) tubing is above the injector chains (plus some excess) close
the slips and pipe rams. Remove the clamps.
7. Using a dual roll-on connector, join the end of the pipe protruding from above the injector to
the end on the reel. Take up any slack.
8. Open the pipe and slip rams.
9. Continue to pull out of the hole.
An increase in pump pressure as fluid or gas is now being pushed through an additional
restriction created by a hinge.
A decrease in pump pressure indicating the tubing has parted.
A loss of string weight parted tubing.
An increase in string weight when pulling caused by deformed pipe dragging on the tubing wall.
10.12.2. Tubing kinked above the stuffing box and below the injector chain.
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Run undamaged tubing down through the injector until it protrudes below the stuffing box.
Lower the injector down over the pipe sticking out of the BOP.
Attach the pipe in the injector to the pipe held in the BOP using the inline connector.
Slack off the inside chain tension. Rotate the chains slowly in the out-hole direction whilst
simultaneously lowering the injector head until the quick union connection below the stuffing
box can be made.
Increase inside chain tension. Pick up until tension is equal to the weight of the tubing
suspended below the slips + 2000 lbs (900 daN) for friction.
Equalize the pressure across the tubing rams.
Unlock the tubing and slip rams.
Open the slip and tubing rams and pull out of the hole, repairing or replacing the tubing on the
power reel.
If the downhole check will not hold then the tubing will have to be cut.
It has to be assumed that the pipe has parted downhole. Recover the remaining pipe to surface
as per the procedure for parted pipe (10.14).
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Solids settling and packing off around pipe. This will happen if the fluid pump fails
during a well clean out, or if fluid velocity in the annulus is lower than the settling
velocity of the lifted solids.
Unexpected increase in friction or drag where regular pull tests are not performed.
Mechanical obstructions in the well.
Inability to recover or set mechanical intervention tools coupled with a failure of the
release mechanism.
Differential sticking.
Guns stuck during underbalanced perforating operation in unconsolidated formation.
In some situations, the only way of getting the pipe out of the well will be to cut it above
the stuck point. However, before taking drastic measured, it is worth trying to pull free of
the obstruction.
Work the pipe. Shell policy is to limit over-pull to 80% of the pipe yield. Keep a close
record of fatigue cycles. Do not risk parting the pipe. Although pumping whist
working the pipe will accelerate fatigue, it may be necessary if the nozzle is buried in
fill.
Circulate a friction reducer.
Rapidly bleed off annulus pressure (if possible) while pulling on the pipe. This may
cause sufficient backflow to dislodge debris.
Try to increase buoyancy by pumping heavier fluid into the annulus and displacing
the coiled tubing to nitrogen, but watch collapse pressure.
Release the BHA by using ball operated shear sub if circulation is possible.
If none of this works the next step will be to try to cut the pipe above the free point.
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1. From neutral weight, slowly pick up to the agreed limit of coiled tubing tension. A
normally accepted tension is 70% of the yield of the pipe. 70% of the pipe yield can
be calculated if the wall thickness is known and the yield of the pipe material is
known. With 70% of pipe yield (F1) applied, note the depth (L1).
WARNING: Be careful to avoid collapsing the pipe. tension lowers collapse
resistance.
2. Slack off until the pipe is at 20% of yield (F2) and record the depth (L2).
3. Calculate the distance from the injector to the free point from the following equation:
=
( )
Where E is the modulus of elasticity of steel (27 x 106)psi for carbon steel.
For a not vertical well or where a tapered string is being used, a CT simulator should be
used to determine the free point.
Having established the free pont, the next stop will be to cut the pipe above the free point
(as estimated above) and recover the pipe above the cut. Cutting the pipe means losing
the integrity provided by the check valves.
1. Pull the coiled tubing into tension so that it is as straight a conduit as possible. Tension in the
string will also help when the pipe is cut.
2. Close the pipe and slip rams hydraulically and set the manual locks. Energize the stuffing box
and increase the injector head inside chain tensions, ensuring that the coiled tubing is secure.
Set the reel brake.
3. Monitor for pressure build-up across the pipe rams.
4. Bleed off the pressure from the coiled tubing.
5. Monitor for pressure build-up at the reel to confirm downhole check valve and coiled tubing
integrity.
6. If the integrity of the barriers is proven, build a scaffold tower around the injector head. This will
allow safe working above the injector head.
Note: If the check valves fail to hold, an attempt will have to be made to kill the well.
Problematic if there is no circulation path.
7. Remove the gooseneck latch down rollers and cut the coiled tubing approximately 5 ft (1.5 m)
above the injector head. Ensure that the coiled tubing is supported on both sides prior to
cutting.
8. Spool the reel end of the tubing back onto the reel and secure.
9. If required for access, remove the gooseneck.
10. Straighten the tubing above the gooseneck to allow the passage of wireline.
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11. Fit a compression (swage) connection with a cross-over to a hammer of quick union connection.
12. Install two plug (lo-torq) valves, large enough OD to allow cutter to pass through onto the top of
the cross-over.
13. Rig up a pump in tee and wireline BOP.
14. Rig-up the wireline lubricator long enough to accommodate the cutter.
15. Run in the hole with the cutter and a free point tool on wireline. When at depth with the
wireline, cycle the wire a few times to release all torque, then cut tubing.
16. Pull out of well with the wireline and observe the well. If required, circulate kill fluid through
the coiled tubing via the temporary pump-in connection.
17. Rig down the wireline BOP and lubricator, remove the 'T' and plug valves. Cut off the swage
connection. Dress the pipe.
18. Open the BOPs and attempt to pick up on the pipe.
Note: Sometimes it is necessary to work the coiled tubing a few times to get the explosive or
chemically weakened tubing to break and come free.
19. If successful, pull out of the hole until there is enough tubing to joint the end to the reel.
Connect the two ends using a dual roll-on connector.
1. When the reel parts the check valves will be lost. Continue to circulate fluid to keep
hydrocarbon out of the coil.
2. Estimate the length of the remaining pipe left in the hole from pick up weight.
3. Slowly pull the broken end of the pipe back towards surface. When it is calculated
that the end of the pipe is close to the stripper, try to close the swab valve. Count
the number of turns. If it will not close, re-open the valve and pick up a distance
less than that measured between the swab valve and the stripper. Try again to close
the swab valve. Repeat until the swab valve can be closed.
Note: The aim here is to pull the pipe back in to the riser, but not out of the stripper.
There is no BHA, so nothing to stop the pipe exiting the stripper and allowing the
release of hydrocarbons except care and patience.
4. Close the hydraulic master valve.
5. Prepare to fish the CT left in well.
It may be that the first indication of parted tubing is the release of well fluids as the tubing
stub is pulled out of the stripper. In this event, closing the blind rams or the hydraulic
master valve will regain control of the well.
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1. Immediately stop the injector to stop the end of the coil leaving the top of the
chains.
2. Close the blind rams. If you are sure there is no pipe across the tree the UMV should
be closed as well. Closing the UMV may be a quicker means of securing the well if it
is fitted with an actuated valve operated from a well control panel.
3. Depressurise the reel and riser.
4. Plan to fish the lost pipe from the well.
1. If circulation is lost during a well cleaning operation, immediately pick up off bottom
or away from any point where debris might accumulate.
2. Once clear of possible obstructions, reciprocate the pipe do not reciprocate
between the same two depths, change the fatigue points on the pipe.
3. Activate the circulation sub or bypass if fitted, or release the BHA to try to regain
circulation.
4. If it is not possible to restore circulation, POOH.
5. Monitor pressure while pulling out to avoid bursting or collapsing the pipe.
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