SPE 54482

Full-Scale Coiled Tubing Fatigue Tests With Tubing Pressures to 15,000 psi
D.C. Headrick and R.S. Rosine, SPE, Halliburton Energy Services, Inc.

Copyright 1999, Society of Petroleum Engineers, Inc.

This paper was prepared for presentation at the 1999 SPE/ICoTA Coiled Tubing Roundtable
held in Houston, Texas, May 25-26.
This paper was selected for presentation by an SPE Program Committee following review of
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presented, have not been reviewed by the Society of Petroleum Engineers and are subject to
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Abstract
In recent years, the performance envelope of coiled tubing (CT)
has expanded because of improvements in tubing manufacture
and the prediction of low-cycle fatigue life. More accurate life
predictions have been achieved with data from laboratory-scale
and full-scale CT fatigue tests. To date, most testing has evaluated only tubing pressures below 10,000 psi. Fatigue models at
higher pressures remain unvalidated.
This paper presents results from new, full-scale fatigue tests
performed at 7,500 to 15,000 psi. CT with 90,000-psi minimum
yield strength was cycled to failure at internal pressures of 7,500,
10,000, 12,500, and 15,000 psi. The measured fatigue-life
values helped validate the fatigue model used for CT job design,
and allowed the models further refinement.
Additional data are presented for full-scale fatigue tests
performed with extended tubing-stroke lengths. This testing
verifies the correlation between the tubing life observed in
controlled, full-scale, short-stroke fatigue tests and the fatigue
life observed in field applications with significantly longer
stroke lengths. Measurements and analyses of tubing-diameter
growth during high-pressure cycling are included.
Introduction
For many years, the coiled tubing service industry considered
5,000-psi internal pressure and 3,000-psi wellhead pressure to
be the limits for routine CT operations. Recent technological
advances have allowed applications with internal and wellhead
pressures as high as 10,000 psi. This paper focuses on the
technical issues of fatigue damage and diameter growth that can
occur when CT internal pressures exceed 10,000 psi.
References at the end of the paper.

Although coiled tubing encounters a variety of loading

conditions during normal operation, most of the fatigue damage
and diameter growth results from plastic bending, caused by
internal pressure. This plastic bending occurs when tubing is run
on and off the reel and guide arch. Because the reliability of CT
operations depends on predictable fatigue damage and diameter
growth, the mathematical models for CT fatigue and diametergrowth predictions are continually refined. Data from laboratory-scale and full-scale CT fatigue tests have significantly
improved the accuracy of these predictions.
To date, almost all published CT fatigue-test data reflect
tubing pressures below 10,000 psi.1,2 Fatigue models at higher
pressures remain unvalidated. However, this paper presents the
results of new, full-scale fatigue tests with internal pressures of
7,500 to 15,000 psi. In addition to helping validate and enhance
models that measure diameter growth and fatigue, these tests
provide valuable experience with equipment and procedures for
high-pressure CT operations.
Laboratory-Scale vs. Full-Scale Tests
CT fatigue data are collected from three primary sources:
actual field operations
controlled tests that use full-scale CT equipment and simulate field conditions on CT specimens of 100 ft and longer
(Fig. 1, Page 3)
laboratory-scale machines that duplicate the loads observed
in field operations on 4- to 8-ft long CT specimens
(Fig. 2, Page 4)
Fatigue data from field operations are preferable. However,
safety and reliability requirements in field operations prevent
operators from intentionally allowing tubing to fatigue to failure.
Assessing the dependence of fatigue life on a specific paramater
can be difficult in many field operations, because of the spectrum of operating conditions.
Full-scale fatigue tests use the same equipment that is used
in field operations, but loading conditions are scientifically
controlled, and test personnel can cycle the tubing until failure
occurs.
CT testing with laboratory-scale machines is faster and more
economical. Loads can be applied with greater precision than is
possible in field operations or full-scale test conditions.

FULL-SCALE COILED TUBING FATIGUE TESTS WITH TUBING PRESSURES TO 15,000 PSI

However, laboratory-scale machines usually provide a simplified loading, which may not accurately duplicate the fatigue
damage observed with full-scale equipment.
To understand CT limitations and develop an accurate
mathematical model of fatigue and diameter growth, operators
should consider data from all three sources. Although this paper
presents results from full-scale tests only, efforts are underway
to obtain similar data from field operations and laboratory-scale
fatigue machines.
Fatigue Test Procedures
The following fatigue tests were performed on 1.5-in. CT with a
90,000-psi nominal-yield strength. Most of the tests used a
conventional CT service unit, rated for 60,000 lb. Fig. 1 shows
the setup used for full-scale fatigue tests. Fig. 3 (Page 4) shows
the actual test arrangement.
In the first set of tests, 1.50-in. OD 0.188-in. wall tubing
was cycled to failure at internal pressures of 7,500, 10,000,
12,500, and 15,000 psi. Ten individual tests were run: one at
7,500 psi, three at 10,000 psi, three at 12,500 psi, and three at
15,000 psi. The tubing was run into a water-filled test well,
containing 4.0-in. ID casing open to the atmosphere (wellhead
pressure = 0 psi). The CT was sealed off at the tip, and pressurized with water through the reel to the required test pressure. A
tubing stroke length was selected on the basis of providing a
25-ft CT section that would encounter all bending events and run
into the well with each stroke.
In the second set of tests, 1.50-in. OD 0.156-in. wall tubing
was cycled to failure at various stroke lengths. The longer stroke
lengths more closely simulated actual field conditions. The
internal pressure was maintained at 10,000 psi for all tests in this
series. The CT was run into 2 7/8-in. tubing, rather than the 4.0in. ID casing used on previous tests.
Results of Tubing-Pressure Variations
Table 1 (Page 3) contains results of the full-scale fatigue testing
on 1.50-in. OD 0.188-in. wall tubing at various internal
pressures. A single fatigue test was performed with 7,500-psi
tubing pressure for evaluating equipment, procedures, and safety
issues. Then, testing proceeded with tubing pressures of 10,000
psi and higher.
Nearly all failures occurred while the tubing was coming off
or going onto the reel. A pinhole developed during the 7,500-psi
tests (Fig. 4, Page 5). Tests at higher pressures resulted in a
blowout of the tubings underside (Fig. 5, Page 5). In almost
every case, the tubing remained in one piece.
Results of Stroke-Length Variations
Table 2 (Page 3) presents results of the full-scale fatigue testing
on 0.156-in. wall tubing at 10,000-psi internal pressure. The
varied stroke length produced the test specimen lengths shown.
Because of the amount of tubing required for the tests and time
limitations, only one test was performed at each of the stroke
lengths greater than 100 ft.

SPE 54482

Updated Fatigue-Damage Model

The parameters and results of these fatigue tests, combined with
previous test data, provided a basis for refining the fatigue
model used for predicting tubing life in field operations.
Fig. 6 (Page 6) shows tubing life predicted by the model vs.
measured life values.
Fig. 7 (Page 6) compares measured fatigue life to predicted
fatigue life as the cycle length is varied. The model is used for
prejob planning and for determining real-time fatigue damage
accumulation. The plot in Fig. 8 (Page 7), generated with the
fatigue model and real-time data acquisition software, relates
tubing life to the tubings position along a typical CT string.
Diameter Growth During Cycling
As expected, diameter growth during cycling at high internal
pressures is dramatic (Table 3, Page 3, and Fig. 9, Page 7).
In most applications, diameter growth (not fatigue life) will
determine the service life of a CT string exposed to continuous
cycling at internal pressures of 10,000 psi or higher. Careful
tubing management and handling can help reduce and control
problems caused by diameter growth.
Conclusions
Full-scale testing and comparative data analysis resulted in the
following conclusions:
CT operations at internal tubing pressures of 10,000 to
15,000 psi can be safe and reliable when proper procedures,
tubing, equipment, and analytical tools are selected and
used.
The enhanced fatigue model can handle tubing pressures as
high as 15,000 psi.
In high tubing-pressure applications, diameter growth may
have more effect than fatigue does on the service life of
coiled tubing.
Acknowledgments
The authors thank Halliburton Energy Services, Inc., for permission to publish this paper; Halliburtons Gulf Coast operations
for providing testing equipment and personnel; and Quality
Tubing, Inc., for general support. Special thanks goes to
Dr. Vladimir A. Avakov for his assistance with planning and
analysis.
References
1.
2.

Avakov, V.A. and Martin, J.: Large Coiled Tubing Fatigue Life,
paper SPE 38407 presented at the 1997 SPE/ICoTA North American Coiled Tubing Round Table, Montgomery, TX, Apr. 1-3.
Avakov, V.A., Foster, J.C., and Smith, E.J.: Coiled Tubing Life
Prediction, paper OTC 7325 presented at the 1993 SPE Offshore
Technology Conference, Richardson, TX, May 3-6.

SPE 54482

D.C. HEADRICK, R.S. ROSINE

Table 1Strokes to Failure (1.50- 0.188-in. tubing)

Strokes
Internal Tubing
Pressure (psi)
Test 1 Test 2 Test 3 Average
7,500
10,000
12,500
15,000

165
117
69
39

112
66
40

105
71
33

165
111
69
37

Table 2Strokes to Failure (1.50- 0.156-in. tubing)

Strokes
CT Length Exposed
To All Events (ft)
Test 1 Test 2 Test 3 Average
25
500
1,000
1,950

60
49
46
34

55

54

56
49
46
34

Table 3Diameter Growth

During Cycling at High Internal Pressures
Tubing Size
(in.)
1.50 0.188

Tubing Pressure
(psi)

Diameter Growth
Per Stroke (in.)

7,500
10,000
12,500
15,000
10,000

0.0006
0.0018
0.0037
0.0045
0.0034

1.50 0.156

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Fig. 1Typical full-scale fatigue test rigup.

FULL-SCALE COILED TUBING FATIGUE TESTS WITH TUBING PRESSURES TO 15,000 PSI

om000253

Fig. 2Typical laboratory-scale fatigue test machine.

Fig. 360K rigup used for testing CT fatigue at tubing pressures as high as 15,000 psi.

SPE 54482

SPE 54482

D.C. HEADRICK, R.S. ROSINE

Fig. 4A crack in tubing during a fatigue test with 7,500-psi tubing pressure.

Fig. 5Blowout in underside of tubing, typically observed at tubing pressures of 10,000 to

15,000 psi.

FULL-SCALE COILED TUBING FATIGUE TESTS WITH TUBING PRESSURES TO 15,000 PSI

SPE 54482

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Fig. 6Measured fatigue life vs. fatigue life predicted by a fatigue model for QT-900 coiled tubing.

om000305

Fig. 7Fatigue life variation with length of fully cycled tubing.

SPE 54482

D.C. HEADRICK, R.S. ROSINE

Fig. 8Typical display showing percentage of fatigue life used vs. position along the CT string.

om000388

Fig. 9OD growth of 1.50- 0.188-in. CT during cycling while internal pressure is varied.