10 Coil Tubing 31-10-11

Section 10: Coiled Tubing.
Section 10.
Coil Tubing.
Prepared by
Howard Crumpton
Date: 28/10/11
Proof reading
Anita Lee
30/10/11
Reviewed
Final Approval.
Advanced Completion and Intervention Well Control Manual.

Draft: Version 2
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

Draft: Version 2
ii
4.2. Check Valves. ................................................................................................ 36

4.3. Back Pressure Valve. ...................................................................................... 37
4.4. Disconnect Sub. ............................................................................................. 37
4.5. Circulating Sub. ............................................................................................. 38
4.6. Straight bar. ................................................................................................. 38
4.7. Multi Purpose Tool Head. ................................................................................ 38
5. Coiled tubing operations. ....................................................................................... 39
5.1. Nitrogen lift. .................................................................................................. 39
5.2. Well bore clean out operations. ........................................................................ 40
5.3. Acid treatments. ............................................................................................ 41
5.4. Hydraulic removal of scale. ............................................................................. 42
5.5. Mechanical removal of scale. ........................................................................... 43
5.6. Reverse circulation clean out. .......................................................................... 44
5.6.1. Reverse circulation BHA selection. .............................................................. 46
5.6.2. Pumping Operations. ................................................................................ 47
5.7. Mechanical Interventions with coiled tubing. ...................................................... 47
5.8. Perforating with coiled tubing. ......................................................................... 48
6. General coiled tubing safety guidelines. ................................................................... 50
7. Rigging up. .......................................................................................................... 51
8. Well-site pressure testing. ..................................................................................... 54
8.1. Testing the surface lines. ................................................................................ 55
8.2. Shear Seal BOP test. ...................................................................................... 56
8.3. Riser Quad BOP test. ...................................................................................... 57
8.4. Coiled tubing reel test. ................................................................................... 58
8.5. Testing the stripper rubber. ............................................................................. 59
8.6. Testing the check valves. ................................................................................ 60
8.7. BOP pipe rams. .............................................................................................. 61
9. General operating guidelines. ................................................................................. 62
9.1. Recommended running speeds. ....................................................................... 63
9.2. Pull tests....................................................................................................... 63
10. Coiled Tubing Operational Procedures. ................................................................... 65
10.1. Emergency procedures. ................................................................................ 65
10.1.1. Production shut-down. ............................................................................ 65
10.1.2. Muster alarm. ........................................................................................ 65
10.1.3. Platform abandonment. ........................................................................... 66
Draft: Version 2
iii
10.2. Power pack failure ........................................................................................ 66

10.3. Failure of reel hydraulic motor. ...................................................................... 67
10.4. Injector replacement. .................................................................................. 68
10.5. Hoist failure with pipe in the hole. .................................................................. 69
10.6. Leaking coil tubing at surface (above BOP). ..................................................... 69
10.6.1. Downhole check valves holding pressure. .................................................. 69
10.7. Leak in the reel below the stripper. ................................................................ 70
10.7.1. Tubing pulled out of the stuffing box. ........................................................ 71
10.8. Riser leak .................................................................................................... 71
10.9. Leaking stripper rubber. ................................................................................ 72
10.9.1. Replacement of Elements In Conventional Top Entry Stuffing Box ................ 73
10.9.2. Replacement of Elements in the Side Door Stuffing Box .............................. 73
10.10. Coiled tubing runaway. ............................................................................... 73
10.10.1. Running in: .......................................................................................... 73
10.10.2. Pulling out. .......................................................................................... 74
10.11. Collapsed pipe. .......................................................................................... 75
10.12. Tubing kinked. ........................................................................................... 76
10.12.1. Tubing kinked below the stuffing box. ..................................................... 76
10.12.2. Tubing kinked above the stuffing box and below the injector chain. ............ 76
10.12.3. Increase in pump pressure or increase in string weight. ............................ 77
10.12.4. Decrease in pump pressure and loss of string weight. ............................... 77
10.13. Tubing Parts at Surface. .............................................................................. 77
10.14. Stuck pipe ................................................................................................. 78
10.14.1. Finding the free point. ........................................................................... 78
10.14.2. Releasing stuck coiled tubing using a chemical or explosive cutter. ............. 79
10.15. Tubing Parted Downhole.............................................................................. 80
10.15.1. Tubing pulls out of stripper. ................................................................... 80
10.16. High frictional drag. .................................................................................... 81
10.17. Unable to circulate...................................................................................... 81
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
Draft: Version 2
iv
Figure 5: The UTIM. Universal Tubing Integrity Monitor. ................................................. 8

Figure 6: Coiled tubing Pressure Control Equipment. ...................................................... 9
Figure 7: Inline stripper............................................................................................ 11
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 non-extrusion rig. ................................................................... 12
Figure 9: The stripper is normally flanged to the base of the injector frame. ................... 13
Figure 10: The gap between the injector chain and the stripper. .................................... 13
Figure 11: TIW type radial stripper. ........................................................................... 14
Figure 12: Quad BOP ............................................................................................... 15
Figure 13: After the cut. This reel was run with internal e-line (Smart coil). .................... 16
Figure 14: Slip rams. ............................................................................................... 16
Figure 15: Valve closure sequence for cutting and removing cut pipe from the well.......... 17
Figure 16: Combi BOP. Shear/Seal upper ram and Pipe/Slip lower ram. ......................... 18
Figure 18: Shear seal BOP ........................................................................................ 19
Figure 17: Shear seal BOP in use. Flanged directly on to the tree .................................. 19
Figure 19: The right and wrong way to hook up the hydraulic hoses. The one on the right
does happen! .................................................................................................... 20
Figure 20: A Coil Tubing Injector Head with goose neck attached. ................................. 21
Figure 21: Chain tensioning devices. .......................................................................... 22
Figure 22: Injector chain and blocks. ......................................................................... 23
Figure 23: Guide arch (Gooseneck) ............................................................................ 25
Figure 24: Coil Tubing weight indicator. ..................................................................... 26
Figure 25: Single pivot point injector head.................................................................. 27
Figure 26: Coil Tubing depth measuring equipment. ................................................... 28
Figure 27: Pipe connections at the centre of the reel. ................................................... 29
Figure 28: High pressure swivel with 'Chiksan' hammer union. ...................................... 29
Figure 29: Tension must be maintained between the reel and the goose neck. ................ 30
Figure 30: CT reel level wind..................................................................................... 30
Figure 31 Coil tubing controls. ................................................................................... 33
Figure 32: Coil Tubing Lift frame. .............................................................................. 34
Figure 33: Roll on connector ..................................................................................... 35
Figure 34: Making up a dimple connector. .................................................................. 35
Figure 35: Grapple - slip on connector. ...................................................................... 36
Figure 36: Dart check valve (top) and ball check valve (bottom) - single valve. ............... 36
Figure 37: Double check valves: Dart/Ball (top) Double flapper (bottom). ...................... 36
Figure 38: BPV ........................................................................................................ 37
Figure 39: Shear disconnect (top) and hydraulic disconnect (bottom) ............................ 37
Draft: Version 2
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

Draft: Version 2
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 continuous length of tubing that could be spooled in to a well (the coil

tubing string).
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:
Traditional Coil tubing operations.
Growth applications.
Well unloading (Nitrogen lift)
Coil Tubing drilling
Well Cleanout
Fracturing
Acid wash/Stimulation.
Subsea interventions.
Velocity string.
Deeper wells (External taper strings)
Fishing.
Pipelines/Flowlines.
Cement squeeze.
Well Logging.
Setting recovering plugs.
Table 1: Coil tubing applications.
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.

Draft: Version 2
2. Coiled Tubing Equipment.

As Coiled tubing is used to carry out a range of different services no standard equipment
configuration is common to all applications. However, some components that are common
to most operations. These are shown in the illustration here fig 1 & 2.

Draft: Version 2
Section 10:
10 Coiled Tubing.
Figure 1:: Main coiled tubing equipment components: A typical offshore platform rig up for fluid
pumping.
Figure 2: A typical land based coil tubing rig up.
2.1. Coiled Tubing The Pipe.

2.1.1. CT Manufacturing.
Coiled tubing manufacturers weld together cut strips of suitable material using bias welds to
form a continuous strip of steel of the required length and
a
wall thickness. Joining strips of
varying wall thickness form a tapered string. A coiled tubing mill then forms the continuous
strip into a tube. The edges are welded together with a continuous longitudinal
longitudi
seam. In
most reels
ls the internal seam is left in place and is seen on the ID of the pipe. Nearly all
coiled tubing is manufactured from low-alloy
low alloy carbon steel. The mills are able to adjust the
yield of the steel over the range 55 120 Kpsi with heat treatment. Coiled tubing is
commercially available in the size range 1 to 4 OD. Most intervention work is carried
out using coiled tubing at the smaller end of the range (1 , 1 ).

Draft: Version 2
Table 2: Coil Tubing steel properties.
2.1.2. Coiled tubing performance.

The mechanical performance of coiled tubing differs from standard oilfield tubular
(production tubing, casing or drillpipe) in one important respect. Normally, we go to great
lengths to avoid bending jointed pipe beyond the elastic limits of the steel. Not so with
coiled tubing. This is repeatedly plastically deformed during routine use. Deformation of the
coiled tubing is caused by the bending and unbending of the steel as it is run into and pulled
out of the well.
Figure 3: Bending cycles during coiled tubing use.

Draft: Version 2
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.

Draft: Version 2
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.

Draft: Version 2
2.1.4. Repairing and Splicing Coiled Tubing.

If CT is damaged or corroded, the only reliable repair is removal of the damaged section
and re-connection of the reel using a temporary or permanent splice.
At the wellsite, a temporary splice can be made using an internal (external flush) or
external (internal flush) slip roll-on or dimple type connector. These connectors sometimes
give problems when running through pressure control equipment because of their rigidity,
although some designs do have a degree of flexibility.
Additional problems arise because of the restrictions to flow through the reel if external
flush connectors are used. Similarly, the increased OD of internal flush connectors
sometimes make running through wellbore restrictions and upsets more difficult. These
types of connectors are only intended for temporary use, to enable operations to continue in
the short term and to enable damaged coil to be retrieved from the well. For a more lasting
repair, welding is required.
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.
2.1.5. Corrosion resistance.

Until recently, many coiled tubing operations were limited by the corrosion resistance of the
pipe. Low allow carbon steel is particularly susceptible to CO2 corrosion. The recent
introduction of 16% chrome coiled tubing by Quality Tubing will alleviate some of these
problems. Erosion resistance (to abrasive slurry) will be improved. There are still concerns
about fatigue resistance, although the manufacturers claim that the high chrome coil has a
better resistance to fatigue than equivalent yield material in carbon steel.1 To date most
16Cr coiled tubing has been used for long term installations velocity strings and CT
completions.
A limited amount of titanium Coiled Tubing has been manufactured, but the cost of this
material is prohibitive. To date, titanium has only been used for permanent installations.
2.1.6. Inspection tools.
Many CT vendors will inspect the pipe as it is being run into and pulled out of the well.
There are three techniques currently available.
NOV Quality Tubing. Product Data Sheet. QT-16Cr Special Coiled Tubing Product.
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.
Figure 5: The UTIM. Universal Tubing Integrity Monitor.

Image courtesy of Schlumberger
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.

Draft: Version 2
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:
Shear seal BOPs made up directly above the xmas tree
High pressure riser. A pump in tee can be included.
Quad (or dual ram combi) BOP with a pump in facility between the slip and shear
rams
Single or tandem stripper. and tandem strippers.
The use of flanged connections is increasingly common and mandatory in some locations.
Figure 6: Coiled tubing Pressure Control Equipment.

A simple low pressure or sub-hydrostatic rig up (left) and a high pressure system (right).

Draft: Version 2
3.2. Coiled Tubing Barriers.

It is worth reminding ourselves what barriers are in use when coil tubing is used on a live well (from
section *** Barriers and well integrity envelopes).
3.2.1. External Pressure control.
Primary Barrier.
Stripper rubbers and riser.
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.
Gate valves if a tool-sting deployment system is being used.
Secondary Barriers.
BOP rams.
SCSSSV or Lubricator valve if the coil tubing BHA is above.
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.
3.2.2. Internal Pressure control.

Primary Barrier.
Check valves (non return valves) in the BHA.
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.

Draft: Version 2
10
3.3. Stripper or pack-off.

The stripper (packoff or stuffing box) is the primary well control device in the coil tubing rig
up. Its a dynamic seal when the pipe is moving and a static seal when the pipe is
stationary. The stripper is located immediately below the injector head.
As pipe is run into and out of the well, friction wears away the elastomer seal. To counter
the effect of pipe wear a hydraulic piston is used to squeeze the packing enabling well
control to be maintained. Stripper packing elements should be resilient, with a low
coefficient of friction, good chemical and abrasion resistance.
3.3.1. Inline stripper.
Inline strippers are rarely used today, now replaced
by the more functional side-door stripper. The
drawback with the inline stripper was no inability to
change the main seal whilst pipe was in the well.
Figure 7: Inline stripper
3.3.2. Side door strippers.

Side door strippers (fig 8) allow the seal element to be replaced while pipe is in the well.
The seal element is a similar design to the inline stripper. Wellhead pressure can be enough
to energise the seal by forcing a piston against the bottom end of the elastomer
compressing it until it seals. The coiled tubing operator is able to apply additional sealing
force by applying hydraulic pressure to a piston. However, the application of too much
pressure will result in increased frictional drag and will alter weight indicator readings. In
extreme cases, too high a stripper rubber pressure can buckle the pipe between the bottom
of the injector chains and the top of the stripper.
Draft: Version 2
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.

Draft: Version 2
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.
3.3.3. Radial strippers.

In a radial stripper, as the name suggests, a radial force is applied directly to the stripper
element. Hydraulic fluid forces opposing pistons together squeezing the stripper elements
and creating a seal.

Draft: Version 2
13
Figure 11: TIW type radial stripper.
3.4. Coiled Tubing BOPs

A CT BOP is a pressure control devise that retains well pressure. Coiled tubing BOPs are
designed specifically for coiled tubing operations. The most common type of BOP is the
quad (four ram) BOP. The different ram functions (top to bottom) are:
Blind ram. Pressure is contained below the ram when the pipe has been removed
from the well.
Shear ram cuts the pipe.
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.
Pipe rams designed to seal around the pipe.

Draft: Version 2
14
Quad BOP
Ram configuration:
Blind Ram
Shear ram
Slip ram
Pipe ram.
Figure 12: Quad BOP
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.

Draft: Version 2
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.
Figure 14: Slip rams.

Draft: Version 2
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.
Equalising and side outlet.

In a standard configuration the BOP will be fitted with two equalising ports. One across each
of the sealing rams (blind and pipe). Most BOPs will also be fitted with a side outlet port
located above the slip rams and below the shear rams. Side outlets are normally fitted with
a 1502 Chiksan hammer union, but for high pressure applications a flange fitting is used.
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.

Draft: Version 2
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.

Draft: Version 2
18
Shear Seal BOP.

As the name suggests, shear seal BOPs (fig 12) are
designed to cut pipe and seal the well below the rams.
Shear seal BOPs are normally rigged up directly above
the xmas tree during live well interventions (fig 5).
There are two main reasons for including shear seal
BOPs in a coiled tubing pressure control rig up.
Shear seals act as a back up to the quad (or

combi) BOP.
Shear seal BOPs are used to ensure that if the

pipe is stuck in the well and subsequently has to
be cut it will drop below the xmas tree valves
enabling them to be closed. This is of particular
importance when a long riser is being used and
the quad BOP is a significant height above the
tree, for example on an offshore platform where
the injector head is on the rig floor and may be
30 40 meters above the tree.
Figure 17: Shear seal BOP in

use. Flanged directly on to the
tree
Figure 18: Shear seal BOP

Draft: Version 2
19
Section 10:
10 Coiled Tubing.
3.4.1. BOP operations.

A BOP normally operates with approximately 1500 psi (10,350
(
kPa)) hydraulic pressure. Two
hoses must be connected
onnected to each cylinder for operation of a BOP. One hose is used to close
the ram, the other to open it. Correct hook
hook up of the hoses is confirmed by functioning all of
the rams.
Figure 19:: The right and wrong way to hook up the

the hydraulic hoses. The one on the right does
happen!
Closing and Locking the Rams.

Rams
Rams are operated using control levers on the consul in the control cabin. Rams are
operated individually, each one having its own leaver. To close any ram:
Move the control lever to the desired position.

Push the BOP activate button supplying pressure to the circuit.
Observe the pressure drop in the hydraulic circuit and subsequent pressuring back up to system
pressure as ram opens or closes completely.
Observe the ram
m indicator pins to verify the operation of the ram.
Open or close in the manual locks. (Flag system to indicate position of rams.) Closing the manual
lock will keep the ram in the closed poition should system hydraulic pressure be lost.
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.

Draft: Version 2
20
3.5. Injector head.

The injector head is the prime mover for coiled tubing. Injector heads come in a range of
sizes, weight and performance capability. Of interest to the well site supervisor will be the
pulling power and snubbing capacity of the injector head.
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.

Draft: Version 2
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.
Figure 21: Chain tensioning devices.
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.

Draft: Version 2
22
Figure 22: Injector chain and blocks.
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
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
= air weight of tube
Pf
= density of fluid in well
Ps
= density of steel = 489.5 lb/ft3 or 65.4 lb/gall
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
Snubbing therefore would stop at

10,835
= 7739
1.4/
In most cases, the tubing is filled as it is run to reduce collapse loading on the string. Therefore steel
buoyancy needs to be considered. Using the same example 1.5 coil with an ID of 1.291 in 9ppg fluid.
1.291
[ ](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.

Draft: Version 2
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.
Net weight 1.4lb/ft + 1.2 lb/ft = 2.52 lb/ft
Force increase = (5385) (2.52 lb/ft)

-10,835 = 2,735 lbs.
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.
Figure 23: Guide arch (Gooseneck)
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).

Draft: Version 2
25
Coil Tubing OD Reel Core Radius Goose Neck Radius.

(in)
(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
Table 6: Recommended Gooseneck radius.
3.7. Weight Indicator

The coiled tubing weight indicator is an integral part of the injector frame. The frame is hinged on one
side and on the opposite is a hydraulic load cell. This sends a signal, calibrated to read tension or
compression in lbs or Kg. Forces exerted by the action of the drive system and the tubing weight are
applied along the centerline of the tubing and cause the sub-frame to pivot; the resulting
deflection measures direct force or load acting on hydraulic load cell bladder. Individual
hydraulic load cells will measure either pipe-heavy (positive weight) or pipe light (negative
weight snubbing). fig 16.
Figure 24: Coil Tubing weight indicator.

Front weight sensor (left/yellow) and rear load sensor (right/red) One load cell is used to measure
positive weight, the other negative weight.

Draft: Version 2
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.
Figure 25: Single pivot point injector head.
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.
3.8. Depth Measurement Equipment.

Coil tubing depth is measured electronically, mechanically, or more commonly using both
methods. Depth counters are usually mounted on the injector head an electronic encoder
assembly on the injector head drive chain and friction wheel counter between the chain and
the stripper. Friction wheel counters can also be mounted by the level wind on the reel.
Note: accurate depth determination with coil can be difficult. Friction wheel slippage,
encoder calibration errors and pipe stretch can combine to give significant errors.

Draft: Version 2
27
Figure 26: Coil Tubing depth measuring equipment.

Draft: Version 2
28
3.9. The reel.

Fluid reaches the coil tubing through the centre of the reel via a pressure tight rotating axle
(fig 27).
Figure 27: Pipe connections at the centre of the reel.

The photo on the right shows the extra fittings used to allow a ball or wiper plug to be pumped
through the reel.
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.
Figure 28: High pressure swivel with 'Chiksan' hammer union.
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

Draft: Version 2
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.
Figure 30: CT reel level wind.
3.10. The Power Pack.

Coiled tubing power packs are normally powered by a diesel engine or an electric motor. The power
pack supplies pressurised hydraulic fluid to the motors that operate the injector, reel motor and BOPs.
Draft: Version 2
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.

Draft: Version 2
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).
3.11. Control Cabin

The operating controls the coil tubing specialist needs to deploy and retrieve the coil are in the control
cabin. From here the operator controls and monitors:
Injector head chain tension.

BOP rams open and close functions.
Pack-off/stripper rubber pressure.
Reel weight.
Wellhead pressure (coil tubing/completion tubing annulus)
Pressure in the reel (at surface)
Depth.
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.

Draft: Version 2
32
Figure 31 Coil tubing controls.

The three large gauges are Wellhead Pressure (left) Reel tension (centre) and Reel pressure (right). In
this cabin, parameters are electronically recorded for post job analysis.
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.
3.12. Coil Tubing Lift Frame.

Rigging up coil tubing on a floating rig (semi-submersible or drill ship) requires an additional item of
equipment the coil tubing lift frame.
The lift frame is picked up using the compensated rig floor blocks. A hydraulic connection is made up to
the riser (usually above a surface tree). The injector head is then lifted on and off using a winch built
into the top of the lift frame. With this set-up, the injector head does not move relative to the riser
when it is being stabbed/unstabbed. Without the lift frame rigging up coil tubing equipment would put
personnel at very real risk of injury unless sea conditions were flat calm no heave.

Draft: Version 2
33
Figure 32: Coil Tubing Lift frame.

Draft: Version 2
34
4. Downhole tools and the Coiled Tubing BHA.

Coiled tubing is used for a wide range of applications, each with its own special tools. In
this section of the manual we will describe the tools that are common to most operations or
that can have a direct bearing on pressure control and well integrity.
4.1. Coiled Tubing Connectors.

Different methods of attaching the Bottom Hole Assembly (BHA) to the coil are available.
The most widely used are the roll on connector, the dimple connector and the grapple
connector.
Figure 33: Roll on connector
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.
Figure 34: Making up a dimple connector.

Draft: Version 2
35
Figure 35: Grapple - slip on connector.
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.
4.2. Check Valves.

Every coiled tubing BHA should be fitted with a check valve, or more commonly a dual
check valve.. The only exception is where reverse circulation is used for cleaning a wellbore. The check valve prevents well-bore fluid entering the coil and is the primary barrier
against internal pressure in the reel.
There are three types of check valve in common use; dart, ball and seat or flapper. It is
standard practice to run two check valves with the BHA (fig 29 & 30)
Figure 36: Dart check valve (top) and ball check valve (bottom) - single valve.
Figure 37: Double check valves: Dart/Ball (top) Double flapper (bottom).

Draft: Version 2
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.
Pressure build up as a result of shutting in a flowing well.
During pressure test.
4.3. Back Pressure Valve.

A back pressure valve is used when the hydrostatic pressure in the coil CT will be higher than external
pressure, e.g. during a cement job. The valve opening pressure can be set at the well location.
Figure 38: BPV
4.4. Disconnect Sub.

Disconnects are run below the coil tubing connector when there are concerns that the BHA
could get stuck milling and reaming operations for example. Two types of disconnect are
in widespread use. Firstly, the shear release, activated a straight pull on the tubing
(shearing pins). The risk with this design is an inability to get enough tension to the
disconnect to shear it.
An alternative to the shear release is a hydraulic disconnect. This is operated by
pumping/dropping a ball through the coil until it seats in the disconnect sub. Pressure is
then used to shear pins or a disk to release the tool.
Figure 39: Shear disconnect (top) and hydraulic disconnect (bottom)

Draft: Version 2
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.
4.5. Circulating Sub.

Circulation subs are used to open a circulation path above the BHA, or to regain circulation
if it is lost due to a blockage in the BHA. There are three options;a simple burst disk, a
shear out ball drop, or a combination of the two. In the latter case, if circulation is lost,
pressure is increased to rupture the burst disk. This gives enough circulation rate to enable
a ball to be dropped, this shears the ball seat, uncovering ports that allow circulation at the
maximum possible rate.
Figure 40: Circulation sub: Burst disk (top) and Dual Circulating and Burst disk sub (bottom)
4.6. Straight bar.

Coil tubing is naturally curved as it comes off the reel and over the goose neck. Use of a
straight bar offsets the worst effects of the bending in the coil and helps limit the tendency
to hang up at upsets in the tubing. The assistance of centalisers can also be used to limit
hang-ups.
Figure 41: Straight bar.
4.7. Multi Purpose Tool Head.

The MP tool head combines a coil tubing connector, emergency release and a double check valve
(flapper) in a single assembly.

Draft: Version 2
38
Figure 42: MP Head Tool.
5. Coiled tubing operations.

The nature of the coiled tubing operation will influence how pressure control is dealt with.
For example during a nitrogen lift there is a risk of collapsing the coiled tubing if pressure is
not maintained in the reel. Recovering collapsed coil from a well complicates pressure
control because flattened pipe cannot be pulled back through the stripper. To give another
example; if during a coiled tubing sand lifting operation, fluid velocity in the annulus (coil to
production tubing) is too low or not maintained, stuck pipe will be the result. It might be
necessary to cut the pipe to recover it from the well. Again, pressure control is
compromised.
5.1. Nitrogen lift.

One of the simplest operations that is routinely performed with coil tubing is the gas lifting
of wells. It is used to kick off overbalance wells following a completion or workover, or to
kick off lazy wells following a production shut down. Coil tubing is run in to the well.
During the run in and once at depth, nitrogen is circulated, reducing fluid density above the
point of injection and enabling the well to flow, once the well is flowing the coil is recovered
from the well. Gas lifting requires additional equipment.
Nitrogen liquid nitrogen , usually in 1500 gallon tanks.

Nitrogen convertor to convert liquid nitrogen to gas.
Figure 43: Liquid nitrogen storage.

Draft: Version 2
39
Although nitrogen lifting is generally thought of a relatively straightforward operation, there

are still some risks that could create pressure control problems.
If internal reel pressure is too low, the pipe will collapse. Collapsed coil cannot be pulled
back through the stripper. To prevent this happening:
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.
5.2. Well bore clean out operations.

About half of all coil tubing interventions are carried out to remove formation sand,
fracturing proppant, hard scale and other unwanted solids from wells. These materials
restrict production and prevent access to the reservoir for logging tools. Conventional coil
tubing clean out operations involve running coil to the top of the fill then circulating fluid to
lift the unwanted material out of the well. Rig site supervisors need to be aware of the main
problem areas when performing clean out operations.
For clean out operations to succeed
velocity of the solids being removed.
because the frictional pressure drop
velocity. The following methods can
pump rate.
the flow rate needs to be higher than the settling

In large completion tubing this may not be possible
through the coil limits pump rate to below critical
help reduce frictional pressure losses and increase
Selecting the largest ID string available

Reducing the length of the CT string as much as possible
Use of hydraulic friction reducers
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.

Draft: Version 2
40
Single Particle Settling Rates

10/20 Mesh Sand
Fluid
ft/min
m/min
20 lb/1000 gal gel
7.5
2.3
40 lb/1000 gal gel
2.0
0.6
60 lb/1000 gal gel
0.5
0.15
22
6.7
Diesel
Water
22
6.7
20/40 Mesh Sand

ft/min
m/min
2.2
0.67
0.5
0.15
0.1
0.03
10.2
3.1
12.6
3.8
10/20 Mesh Bauxite

ft/min
m/min
14.4
4.4
4.1
1.2
1
0.3
33.7
10.3
33.7
10.3
20/40 Mesh Bauxite

ft/min
m/min
4.1
1.2
1
0.3
0.24
0.07
16.9
5.2
20
6.1
Fluid
20 lb/1000 gal gel
20 lb/1000 gal gel
60 lb/1000 gal gel
Diesel
Water
Table 7: Single Particle Settling Rates Courtesy of George King.
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.
5.3. Acid treatments.

Acid treatment of wells is used in three situations; to remove carbonate scale deposits from
casing and tubing, . to stimulate the producing zone and in the fracturing ofcarbonate
reservoirs to improve inflow performance.
Since fracture treatments are normally carried out at very high pressure and require large a
large volume of treating fluid, they are not normally performed with coil. In recent years,
the introduction of new techniques such as Halliburtons Surgifrac has meant a place for
coiled tubing in well fracturing. Matrix treatments, where acid is pumped at below fracture
pressure to remove formation damage, are commonly applied to both sandstone and
carbonate formations. Coiled tubing matrix treatment is very common as it normally gives
good results.:
The CT pressure control equipment configuration allows the treatment to be

performed on a live well. This avoids additional formation damage associated with
well killing operations.

Draft: Version 2
41
Associated operations can be performed as part of an integrated service, e.g.

wellbore fill can be removed prior to the matrix treatment and nitrogen or artificial
lift services may be applied to restore production following the treatment if required.
Performing the treatment through CT avoids exposing the wellhead or completion

tubular to direct contact with corrosive treatment fluids.
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
How to reduce risk when performing acid pumping operations:
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.
Figure 44: Corrosion caused by an acid puddle in the bottom of a wrap.
Photo courtesy of Precision Tubes.
5.4. Hydraulic removal of scale.

Jetting is an effective way of removing scale from the well. Jetting operations are
categorised as high pressure jetting (pump pressure above 5,000 psi) and low pressure
Draft: Version 2
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.
Selecting the largest ID string available

Reducing the length of the CT string as much as possible
Use of hydraulic friction reducers
Including a bypass valve in the BHA
Increasing the pump pressure to the maximum value that will allow completion of
the jetting operation without exceeding the fatigue limit for the string
Low-pressure jetting is only effective for removing soft scale.

High-pressure jetting can
provide the hydraulic impact or cutting action to remove hard scale. However, high-pressure
jetting has several disadvantages. The high circulating pressure and constant movement of
the BHA is detrimental to the working life of the CT string. Accurate data acquisition and
real-time fatigue monitoring are essential for preventing premature failure of the CT string.
Controlling the cutting action of a high-pressure jet is nearly impossible. If held stationary
too long, the jet can damage the host completion tubular beneath the scale. High-pressure
jetting can produce large cuttings that can be difficult to remove from the wellbore with the
relatively low flow rate possible with this scale removal method.
5.5. Mechanical removal of scale.

Hard scale (barium sulphate) is normally removed from the wellbore by milling or underreaming. Scale mills and underreamers often produce large cuttings so obtaining a high
enough annular velocity to keep the hole clean might is difficult. Failure to keep the
wellbore clean will increase the risk of getting the pipe stuck.
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.

Draft: Version 2
43
5.6. Reverse circulation clean out.

Under some circumstances reverse circulation is a more efficient method of removing fill
from the well bore. It is generally a more effective way of lifting solids in larger tubing and
casing sizes. Fluid is pumped down the backside at a high enough pressure and high enough
rate to lift the solids in the coil. It is the preferred option when:
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.

Draft: Version 2
44
Section 10:
10 Coiled Tubing.
Figure 45:: Coil tubing layout for a reverse circulation operation.
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.
Figure 46: Four way manifold

Draft: Version 2
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:
Multi-zone well that are known to cross-flow.

Well that are not killed by a column of clean-out fluid (additional circulating pressure
has to be held to prevent hydrocarbon entering the well).
Wells that produce but have low or no injectivity.
Deep deviated wells where the reel would be at maximum yield on pick-up.
Abrasive wells where the tubing is worn.
HPHT wells no reversing experience.
General additional precautions all reversing operations.
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
Draft: Version 2
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.
5.7. Mechanical Interventions with coiled tubing.

Coiled tubing is frequently used for the setting and retrieving of mechanical intervention
tools such as packers, bridge plugs and straddles. They are also used to manipulate sliding

Draft: Version 2
47
sleeves and inflow control valves in intelligent completions where the hydraulic controls
have failed. To minimise the risk of getting the reel stuck.
Include a release mechanism (shear or hydraulic) in the BHA.

Pulling tools for mechanical plugs must have a secondary release mechanism. This is
normally operated by setting off weight and increasing circulating pressure.
Before running large OD mechanical tools (bridge plugs, straddles and packers) it is
advisable to run a full bore drift. The drift run can be carried out on wireline before
rigging up the CT unit.
5.8. Perforating with coiled tubing.

The main advantages of perforating on coiled tubing are the ability to perforate with more
underbalance than would be the case if wireline were used. Also, the coil in the well can be
used to circulate in an underbalanced cushion when the guns are at depth. In most
circumstances, coiled tubing allows longer guns to be run. Gun deployment BOPs allow very
long guns to be run in to live wells. Pressure control and operation considerations::
When perforating unconsolidated formation with underbalance there is a risk of

sticking the gun if sand enters the wellbore.
When using gun deployment systems, the deployment BOP (locator and connector
ram) must be function tested before it is rigged up. It is good practice to have
double the amount of connectors in the string. i.e. there will be two connectors
between the stripper and the locator ram. If a connector will not release when the
guns are being deployed out of the well, the second connector can be used.
When a pressure activated firing head is used, confirm there is no pressure trapped
in the reel before the guns are pulled out of the well. A gun was recently detonated
at surface after being pulled back to surface with pressure trapped in the reel.
Bleeding of reel pressure activated the time delay in the firing head, firing the guns
in the pressure control riser.

Draft: Version 2
48
Figure 48: Gun deployment pressure control equipment and gun connector (right).

Draft: Version 2
49
6. General coiled tubing safety guidelines.

1: All members of the coiled tubing crew should be competent and trained in the following
Operation of all coiled tubing pressure control equipment, including the well control
panel if used.
Operation of ancillary equipment; nitrogen converters, tanks and transfer hoses,

fluid pumps and mixing equipment.
Safe handling of any chemicals required for the operation.
All senior coiled tubing staff should have an accredited cased hole and intervention
well control certificate.
Use of H2S breathing apparatus where relevant see chapter 2 Fundamentals.
2. Establish good communications between the coiled tubing control cabin and other
operational personnel.
Shell representative.
Equipment operators (nitrogen converter, fluid pump, mixing equipment etc).
Facilities operators.
3. Erect barriers to prevent non-essential personnel from accessing hazardous areas.
High pressure lines.
Wellhead, riser and BOP
Injector
Mixing and pumping equipment particularly if hazardous chemicals (e.g.acid) is

being mixed.
4. Hazard data sheets available for all chemicals.

5. If acid is being used, neutralising agents must be available.
6. If nitrogen is being used on offshore platforms, fire hoses should be positioned to wash
away spills liquid nitrogen can crack metal decks.
7. Ensure access and escape routes are properly marked and the crew briefed on their
use.
8. Only Shell supervisory staff, or a competent person nominated by a Shell supervisor will
operate the tree and wellhead valves and associated wellhead equipment.
9. Confirm that all of the pumping equipment is accompanied by up to date test pressure
test certification and that the test rating as high enough for the job.
10. Confirm that pressure relief valves (if required) are properly calibrated and function at
the set pressure.
11. Confirm that all of the lifting equipment is accompanied by up to date load certification.
12. Hold a safety briefing before work begins.
13. If well is tied into a production facility ensure the integrity of isolating valves has been
proven and that the isolations in place have been secured formally and recorded as part
of the operational permit to work.
Draft: Version 2
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)

Draft: Version 2
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!
6. Make sure there is an up to date well schematic in the control cabin.

7. If drag modelling was carried out as part of the pre-job preparation have a copy of
the predicted pick up weight vs depth available in the control cabin.
8. Check that all of the sensors and displays are functioning before opening up the well.
9. If there are any ball operated components in the BHA, the reel must be drifted with a
wiper plug at least as large as the ball OD. This need to be done before pressure
testing.
10. Prepare a fishing diagram of the BHA.
11. If a crane is being used to support the injector head, its engine should be left
running while the load is suspended.
12. For nitrogen operations over steel decking, all the liquid nitrogen containers and
cryogenic hoses must be lifted clear of the deck with canvas, tarpaulin or rubber
matting supported wooden beams.

Draft: Version 2
52
Figure 51: Coiled tubing rig up.
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.

Draft: Version 2
53
8. Well-site pressure testing.

Well-site pressure testing is used to confirm the integrity of
the pressure control
components before they are exposed to wellhead pressure. This includes:
All the surface treating iron.
Coiled tubing reel.
Body test of the BOP(s),
Riser and riser connections.
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).

Draft: Version 2
54
8.1. Testing the surface lines.

The sequence for testing the surface lines will vary depending on the layout and the
requirement to confirm the integrity of in line isolation valves.
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.
Figure 52: Pressure testing the surface lines.

Draft: Version 2
55
8.2. Shear Seal BOP test.

Shear seal BOPs are closed and tested from below. If they are rigged up immediately above
the tree, the test will be conducted through the open kill wing and swab valve (fig 47).
Shear seal BOPs are normally pressure tested before the riser and quad BOP are rigged up.
Test pressure is applied against:
Wing valve.
Upper Mater Valve
Shear seal BOP ram.
At the end of the test bleed back to the pump.
Figure 53: Pressure testing the shear seal BOP ram.

Draft: Version 2
56
8.3. Riser Quad BOP test.

After rigging up the riser and quad BOP, flush through the kill wing until returns are seen at
the top of the BOP.
Close the blind ram and pressure test. The test will be against:
Wing valve
Lower Master Valve
Closed blind ram.
At the ends of the test, pressure should be bled back to the pump.
Figure 54: Testing the blind ram and riser.

Draft: Version 2
57
8.4. Coiled tubing reel test.

It is standard practice to flush through the coiled tubing reel before attaching a blank cap.
The reel is tested against the cap to the reel test pressure. This test can be carried out
before rigging up, or once the pipe has been fed through the injector head (fig 49).
Figure 55: Testing the reel.

Draft: Version 2
58
8.5. Testing the stripper rubber.

1. After inserting the coiled tubing through the injector and stripper, make up the BHA.
2. Check all of the BOP rams are fully retracted.
3. Lower the injector head and stripper on to the BOP and make up the final connection
(flange or quick-union).
4. Pick up on the reel until the BHA tags the lower wear bushing in the stripper.
5. Line up to pump via the reel. Slowly flush the lines and riser until fluid is seen
escaping from the stripper. Stop pumping.
6. Pack off the stripper.
7. Pressure up through the reel to test against:
Stripper rubber (packed off)
Swab valve
BOP side outlet (2 x lo torque).
8. If tandem strippers are used, they must be tested individually.
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.
Figure 56: Stripper test.

Draft: Version 2
59
8.6. Testing the check valves.

Once the stripper has been tested, pressure can be bled back through the reel to confirm
the integrity of the check valve(s) in the BHA. Take care when performing this test. There
is a risk of collapsing the reel if differential pressure between the riser and the pipe is too
high. More than one reel has been collapsed this way.
To prevent pipe collapse, limit the amount of pressure that is bled off through the reel, or
reduce the riser pressure by bleeding down through the kill wing valve first.
Figure 57: Testing the check valves by bleeding back through the coil - careful now!

Draft: Version 2
60
8.7. BOP pipe rams.

1. With the stripper fully retracted, lower the BHA until it is at least 1ft (30 cm) below
the quad BOP pipe rams it is good practice to have a riser vent open before
running in. If fluid does not leak past the stripper, reel volume displacement could
raise the pressure in the riser above the collapse pressure of the coiled tubing.
2. Increase injector chain gripper force to prevent piston forces pushing the pipe out of
the stripper as test pressure is applied.
3. Close and lock the BOP pipe ram.
4. Confirm the vent line from the BOP port is open.
5. Apply test pressure through the coil.
6. At the end of the test, bleed off through the kill wing.
Figure 58: BOP blind ram test.

Draft: Version 2
61
9. General operating guidelines.

During a coiled tubing intervention, the pressure control equipment may be exposed to
pressurised hydrocarbon and corrosive chemicals for a long time. The following measures
will reduce the risk of loss of containment.
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.

Draft: Version 2
62
9.1. Recommended running speeds.

The running speeds listed here are widely regarded as being reasonable for most operation
and should be used if nothing is specified in the work instructions.
Operation
Running
in
Pulling
out,
Maximum speed.
m/min
ft/min
Passing restrictions in the well
15
When the BHA is leaving the riser and passing through

the tree.
15
Within 500 ft (150m) of tagging bottom or a known

obstruction
25
Uninterrupted running in
20
75
Uncertainly about depth close to surface
15
Passing restrictions in the well
15
BHA passing the wellhead entering riser.
15
Uninterrupted pulling out
30
100
Table 8: CT running speed
9.2. Pull tests.

Pull tests must be carried out to ensure that pick-up weight is not exceeding agreed tension
limits. Pick up weight are compared to modelled predictions..
If pull test frequency or location is not specified in the programme, the following is
recommended:
After running in to about 500ft (150m) to verify that all of the equipment is working
properly.
Every 300m/1000ft where the wellbore inclination is less than 60 degrees.
Every 150m/500 ft if the inclination is in excess of 60 degrees.
After passing any restriction.
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.
Draft: Version 2
63
At each pull test record the following:
Depth
RIH, hanging and POOH weight
Stripper pressure
Pump rate and pressure
Wellhead pressure

Draft: Version 2
64
10. Coiled Tubing Operational Procedures.

10.1. Emergency procedures.
When coiled tubing is used on an offshore platform, all members of the crew must know
how to react if there is an emergency on the platform. Whilst procedures will vary between
instillations, action to make a well safe isuniversal.
There must be communication with the installation radio room at all times and a channel
kept clear for the ongoing operation.
10.1.1. Production shut-down.
This procedure assumes that the well is equipped with a SCSSSV and that the master valve
and SCSSSV are connected to a well control panel operated by the coiled tubing crew or
Shell supervisor. This scenario will be discussed and agreed with platform, rig or location
supervisors before work begins. The controls agreed should be documented and signed off
by all relevant supervisors. A copy of the agreement will accompany the permit to work.
1. Stop fluid pump (or nitrogen converter). If the well has an actuated wing valve, this
will normally close in response to the shut down. Automated wing valves are not
normally under the control of the well intervention crew although there are
exceptions. If the valve has been isolated and is under the control of the Well
Interventions Supervisor it must be closed. and the facilities operators informed. If
the well is equipped withj a manual wing valve, it should be closed and the facilities
operators informed.
2. If scale milling or sand washing operations are under way, pick up to get the nozzle
clear of open perforations and above any fill that could settle and stick the pipe when
circulation stops.
If there is time, pull back the distance equivalent to the space between the cutting
rams in the pressure control equipment and the SCSSSV. If the situation deteriorates
and a platform abandonment is imminent then the coiled tubing will be cut and
dropped. It should fall far enough to clear the SCSSSV which can then be closed as
will the remaining open tree valves and the coiled tubing blind rams
3. If the reel end is above the SCSSSV, close the SCSSSVIf the end of the reel is blow
the SCSSSV, stop the pipe and apply the injector break. Close and lock the pipe
rams. If not already closed, close the wing valve.
If the BOP is connected to an accumulator, and you are sure there is enough pressure in the
accumulator bottles to shut the BOP, then shut down the power pack. If the power pack is
needed to function the BOP leave it running. Inform the platform control room/management
of the well status and await instruction.
10.1.2. Muster alarm.
As per the procedure for a production shut down. Non essential members of the crew report
to their muster station. The Shell supervisor and essential members of the crew remain in
the coiled tubing unit, ready to cut and drop the pipe if situation deteriorates. The definition
of who is essential must be clear from the offset of the job. Pass the details of those
remaining at the wellsite to the muster point coordinator.

Draft: Version 2
65
10.1.3. Platform abandonment.

Follow the procedure for a production shut down, then:
4. Cut the coiled tubing and secure the well.
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.
5. Shut down the power pack and go to muster station.
10.2. Power pack failure

In the event of a power pack failure:
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)
Draft: Version 2
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:
10.3. Failure of reel hydraulic motor.

If drive is lost to the coiled tubing reel, it will not be possible to maintain tension between
the injector head and reel. A loss of power will cause some of the pipe on the drum to
slacken off (un-spool) un-spool. There is a risk of loops of pipe falling off the side of the
drum and striking anyone alongside. In this situation:
1. Immediately stop the injector.
2. Inform all relevant personnel of the situation and warn them to keep away from the
reel until the situation has been assessed.
3. Slowly pick up a few feet to put some pipe slack between the guide arch and the
reel.
4. Close the BOP slip and then the pipe rams and apply the manual locks.
5. Apply the reel break (if fitted)
6. Repair the reel drive and inspect the pipe for damage.
7. If the pipe is damaged, make a temporary splice. Open the pipe and slip rams and
POOH.
8. If the pipe is undamaged, open the pipe and slip rams and RIH as far as necessary to
correct the wraps on the reel. Do not run any kinked tubing into the well.
9. Once all the unwrapped tubing has been removed from the reel, pull out of the hole
spooling the pipe correctly.
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.

Draft: Version 2
67
10.4. Injector replacement.

If the injector fails and it cannot be repaired whilst remaining rigged up:
Close the tubing and slip rams, manually lock.

Ensure that the slips are holding the tubing.
Back off the power reel pressure enough to get a little slack in the tubing at the goose neck.
Install a safety clamp on the tubing above the injector 4 ft (1.2 m). Secure the tubing above the
gooseneck on either side of the area of tubing to be cut.
Ensure that the pressure is bled off of the coiled tubing and that the double check valve is
holding pressure downhole.
Cut the tubing above the injector. Always use a hack saw initially, until a small hole has been
cut. This will release any trapped pressure without the tubing breaking in two. Once all pressure
has been removed, complete the cut with tubing cutters.
With the tubing cut, spool the tubing back onto the power reel.
Bleed the pressure from above the tubing rams.
Slack off inside chain tension and rotate the chains slowly in hole, if able to.
Break the union below the injector and lift the injector slowly with the crane until it is possible
to install a safety clamp on the tubing below the injector and above the BOP.
Remove the safety clamp from above the injector and lift the injector off of the tubing standing
above the BOP.
Lift the replacement injector into position.
Reduce inside chain tension and rotate the chains out-hole slowly while lowering the injector to
just above safety clamp. Tubing should be picked up through the injector as it is slowly lowered.
Place the safety clamp above the injector and remove the safety clamp from below the injector.
Continue to lower the injector until able to reconnect the union below the injector.
Pump up the inside chain tension and apply pull to the tubing equal to the weight of the tubing
suspended in the slips.
Open the manual locks on the tubing and slip rams.
Equalize pressure across the tubing rams
Open the tubing and slip rams.
Pull out of the hole until enough coiled tubing is on the catwalk to allow joining of the tubing on
the reel with dual roll-on and pull out of the hole Note: Do not run inline connector back into
well.

Draft: Version 2
68
10.5. Hoist failure with pipe in the hole.

If the hoist supporting the injector and BOP fails with the pipe in the hole:
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.
10.6. Leaking coil tubing at surface (above BOP).

A visible leak in the coiled tubing normally means an area of weakness that could easily lead
to pipe failure (parted tubing) if cycling of the pipe over the gooseneck continues. Action
must be taken to recover the damaged pipe from the well.
Monitor coiled tubing pressure and observe leak to ensure check valves are holding. If the
valves are holding, internal reel pressure will begin to drop and the leak should get visibly
smaller.
10.6.1. Downhole check valves holding pressure.
WARNING: Do not let wellhead pressure exceed the pipe collapse pressure. Flowing the
well will reduce wellhead pressure. It may be necessary to pump fluid (water) through the
reel to prevent collapse. In wells where there is a hydrate risk, the water should be
pumped with 50% glycol.
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.
Draft: Version 2
69
10.7. Leak in the reel below the stripper.

If reel pressure is higher than well pressure, then a leak from the reel will be seen as a drop
in circulation pressure. When this is observed proceed as follows:
1. Stop reel movement.

2. Stop pumping for long enough for reel pressure to stabilise. It may be possible to
estimate the depth of the leak from hydrostatic calculations. beware of reel
collapse.
3. If acid, nitrogen, cement or abrasive slurry is being pumped it is advisable to
displace the reel to water or brine. Pump at a rate/pressure high enough to prevent
hydrocarbons from entering the reel.
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.
1. Stop pipe movement.

2. Stop circulation for long enough to allow reel pressure to stabilise. Hydrostatic
calculations can be used to try to establish where the leak is the BHA in the pipe
itself.
3. Circulate water or brine in to the reel to flush out hydrocarbons if gas has entered
the reel the pump rate will been to be higher than the gas migration rate to remove
gas from the pipe.
If the leak is in the tubing, too high a pump rate risks washout and a parting of the pipe.
4. With a safe non hydrocarbon fluid in the well, pull out slowly until the leak is
above the stripper. It may be necessary to continue pumping to prevent collapsing
the reel once the leak is at surface.

Draft: Version 2
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.
10.8. Riser leak

Major riser leaks are rare, and much less likely if flanged connections are used to make up
the pressure control equipment. Leaks are more likely if the rig up is not properly
supported. If the riser between the Xmas tree and the BOP begins to leak take the
following action:
When only a short section of pipe is in the hole:
1. If it is thought safe to do so (as judged by the Shell supervisor on location), pull out
of the hole to above the Xmas Tree (and shear/seal BOP if used).
2. Close the swab valve on the Xmas Tree.
3. Close hydraulic or manual master valve on the Xmas Tree.
4. Bleed off pressure in riser and repair leak.
5. Pressure test all broken connections and re-commence operations.
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:
There is no H2S in the leaking hydrocarbon.

There is a shear seal BOP in the rig up and the leak is above the shear seal BOP.

Draft: Version 2
71
The facility to pump into the tubing (coiled tubing/production tubing annulus) is already in place
and can be used without delay.
If these conditions are met then proceed as flows:

1. Pump water (or water glycol mix if there is a risk of hydrates)slowly down the tubing
ensuring collapse pressure is not reached.
2. Pull out of the hole. Monitor the leak continuously. Be prepared to cut the pipe and
close in the well if it worsens.
3. As soon as the pipe is back in the riser, close in the well and bleed off.
4. Repair the leak.
10.9. Leaking stripper rubber.

Stripper rubber wear is worse if packing pressure is too high, the surface of the pipe is
rough (rust) and corrosive fluids are present. That said, even during routine interventions,
the seal element in the stripper can wear enough to leak.
If the stripper rubber begins to leak.

1. Stop pipe movement. If the coil is being used to remove scale or fill from the well
continue pumping (circulating) fluid at the planned maximum rate to reduce the
possibility of the pipe sticking. If a small volume of none hazardous fluid (water) or
gas (nitrogen) is leaking past the stripper, the coil should be pulled off bottom, clear
of scale or fill, before movement is stopped this will be at the discretion of the
Shell supervisor.
2. Increase packing pressure to the stripper to stop the leak.
If increasing the packer pressure does not stop the leak the stripper rubber will have to be
changed.
1. Close and manually lock the BOP pipe rams.

2. Ensure the injector is in neutral and the brake engaged.
3. Remove any pressure trapped above the pipe rams.
4. If tandem strippers are in use, pack off the lower stripper this assumes the upper
stripper was the operational stripper and is the one leaking.
5. Replace the sealing elements in the stripper see notes below.
6. Energize the stripper.
7. Equalize pressure across the BOP pipe rams.
8. Unlock and open the pipe rams.
9. Unpack the lower stripper
10. Pick up a few feet and inspect the surface of the CT contacted by the rams.
11. If the CT is undamaged, resume CT operations.
Draft: Version 2
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.
10.10. Coiled tubing runaway.

A coiled tubing runaway can happen when running into or pulling out of the well and is
caused by a lack of grip between the contra-rotating drive chain and the pipe. Poor grip in
the pipe is normally caused by insufficient hydraulic pressure on the gripper rams, or under
gauge pipe.
10.10.1. Running in:

A runaway is most likely to occur when running in to a deep, low pressure gas well.
Snubbing force at the stripper is low and there is little buoyancy to offset the weight of pipe
in the well, so the axial load (tension) supported by the injector is high. Once a runaway
has started it may be difficult to control. The following may enable control to be regained:
1. Attempt to speed up the injector to match the speed of the pipe.

2. Increase inside chain tension to grip the pipe. If chains begin to grip, the injector can
be slowed and brought to a stop. If grip is not improving continue with the
procedure.
3. Increase stripper pressure to a maximum in an attempt to slow down rate of
runaway.

Draft: Version 2
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.
10.10.2. Pulling out.

A runaway when pulling out of the well is most likely where wellhead pressure is high. The
injector chains might completely lose their grip on the CT (traction runaway) or, less
common, the injector motors spin freely (hydraulic runaway). This mode of runaway is
unusual as the counter balance valves on the injector motor hydraulic circuit are designed
to stop it happening. If pipe is being blown out of the well it needs to be stopped quickly. If
not the pipe can buckle below the stripper with catastrophic results, parting above the
injector. If the BHA reaches the stripper it is likely to shear and drop into the well.
If pipe is being blown out through the stuffing box the following may help control be
regained:
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.
Draft: Version 2
74
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.
10.11. Collapsed pipe.

Coil tubing will collapse if the external pressure is too high. Ovality will reduce collapse
pressure significantly and collapse can occur at quite low external pressure monitoring
pipe condition is important.
Pipe collapse is normally associated with a sudden and unexpected rise in circulating
pressure, or an inability to pull the flattened pipe through the stripper. A collapse close to
surface will be problematic:
The stripper will not seal around collapsed pipe.
You are unlikely to be able to pull squashed pipe through the back-up bushings in
the stripper.
The BOP pipe rams will not seal of flattened pipe.
The injector chains will not grip
Collapsed pipe is more likely to part.
Circulation will be limited or impossible.
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.
Draft: Version 2
75
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.
10.12. Tubing kinked.

Running into a downhole obstruction with injector pressure set too high or at speed will
buckle the pipe. Coiled tubing being run through small ID BOPs, riser and tubing, normally
fails (buckles) between the top of the stuffing box and the bottom of the injector chains.
Failure is more likely where there is a large gap between the bottom of the chains and the
top of the stripper.
Coiled tubing being run through casing or open-hole will normally fail below the BOP,
usually where the ID largest. The pipe will normally kink several times forming plastic
hinges. This type of failure is a little more difficult to detect.
10.12.1. Tubing kinked below the stuffing box.
Sudden weight loss when running into a large ID well is a good indiction that the tubing has
kinked. Indications are:
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.
Stop the injector as quickly as possible.

Close the slip and tubing rams and manually lock them.
If the downhole check valves are holding, bleed the pressure in the tubing down and cut the
tubing. Use a hacksaw to start the cut until you are sure there is no trapped pressure in the
tubing. Remove as much of the kinked tubing as possible leaving any undamaged tubing
showing above stuffing box intact so that it may be rejoined later.
Bleed the pressure from above the tubing rams and undo the connection below the injector
Slowly raise the injector until it is clear of the damaged tubing.
Cut away any damaged tubing, dress the tubing and install an inline connector.
Draft: Version 2
76
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.
10.12.3. Increase in pump pressure or increase in string weight.
Stop the pumps and pick up slowly.

Pull out of hole slowly, 10 - 20 feet/min (3 - 6 m/min) watching the weight indicator carefully.
If the tubing is kinked close to surface, the kinked tubing will pull into the bottom of the stuffing
box and stop.
Close and lock the slip and tubing rams.
NOTE: If the ram indicators show that they are not completely closed (there may be more than
one piece of tubing inside the BOP) open the rams and try to put good tubing across the tubing
and slip rams.
Make arrangements to kill the well and fish the remaining tubing from the well.
10.12.4. Decrease in pump pressure and loss of string weight.
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).
10.13. Tubing Parts at Surface.

When tubing parts at surface the results can be dramatic and potentially lethal. The end of
the pipe will flail about until reel pressure dissipates or can be contained. A good reason for
keeping non essential people away from the reel and injector, especially when pumping high
energy fluids. Nitrogen being the best example.
In the event that the coiled tubing parts at surface:

1. Attempt to spool as much coiled tubing back on to the reel to avoid whiplash. Equally
important attempt to run excess coiled tubing through the gooseneck
Draft: Version 2
77
2. Stop injector, close slip and pipe rams

3. If personnel are in danger from fluid release and/or the check valves are not holding,
operate the shear/seal rams and commence well kill operations.
If the check valve holds and the leak is contained:
1. Monitor WHP while contingency plans are reviewed
2. Kill well and make necessary repairs to coiled tubing
3. Remove injector and feed coiled tubing back through injector chains
4. Install fishing spear. (Depending on the tubing stick-up, other methods of
attachment may be more appropriate for example a pipe to pipe connector)
5. Rig up injector and stab into top of fish, pull test spear then release slips and pull out
of hole.
10.14. Stuck pipe

The most likely causes of coiled tubing getting stuck in the well are:
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.
10.14.1. Finding the free point.

In a vertical well and where the coiled tubing has uniform wall thickness (not a tapered reel
the free point can be determined by measuring the amount of stretch at surface.
Draft: Version 2
78
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.
10.14.2. Releasing stuck coiled tubing using a chemical or explosive cutter.
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.
Draft: Version 2
79
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.
10.15. Tubing Parted Downhole.

A sudden loss of weight and a decrease in circulating pressure normally means the pipe has
parted downhole. Care must be taken when pulling out of the hole after the tubing has
parted. Proceed as follows:
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.
10.15.1. Tubing pulls out of stripper.

If the tubing is accidentally pulled clear of the stripper:

Draft: Version 2
80
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.
10.16. High frictional drag.

Caution: Excessive working of stuck pipe causes fatigue and will rapidly fail the
tubing.
If the pipe is stuck, use the response of the weight indicator to determine where the
problem is the deeper the sticking point the more stretch or buckling there will be.
Responses to high frictional drag or a tight spot:
Increase buoyancy in the reel by displacing to a lower density fluid or nitrogen if

available.
Circulate friction reducing chemicals in to the well.
Reciprocate the CT (caution).
If it is thought that the BHA is causing the problem it should be released.
10.17. Unable to circulate.

If circulation there is an obstruction or blockage down-hole:
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.

Draft: Version 2
81

10 Coil Tubing 31-10-11

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

10 Coil Tubing 31-10-11

Enviado por

Direitos autorais:

Formatos disponíveis

Section 10: Coiled Tubing.

Advanced Completion and Intervention Well Control Manual.

Section 10: Coiled Tubing.

Advanced Completion and Intervention Well Control Manual.

Section 10: Coiled Tubing.

4.2. Check Valves. ................................................................................................ 36

Section 10: Coiled Tubing.

10.2. Power pack failure ........................................................................................ 66

Section 10: Coiled Tubing.

Figure 5: The UTIM. Universal Tubing Integrity Monitor. ................................................. 8

Section 10: Coiled Tubing.

Advanced Completion and Intervention Well Control Manual.

Section 10: Coiled Tubing.

A continuous length of tubing that could be spooled in to a well (the coil

Traditional Coil tubing operations.

Well unloading (Nitrogen lift)

Coil Tubing drilling

Deeper wells (External taper strings)

Table 1: Coil tubing applications.

Advanced Completion and Intervention Well Control Manual.

Section 10: Coiled Tubing.

2. Coiled Tubing Equipment.

Advanced Completion and Intervention Well Control Manual.

Figure 2: A typical land based coil tubing rig up.

2.1. Coiled Tubing The Pipe.

Advanced Completion and Intervention Well Control Manual.

Section 10: Coiled Tubing.

Table 2: Coil Tubing steel properties.

2.1.2. Coiled tubing performance.

Figure 3: Bending cycles during coiled tubing use.

Advanced Completion and Intervention Well Control Manual.

Section 10: Coiled Tubing.

Advanced Completion and Intervention Well Control Manual.

Section 10: Coiled Tubing.

Advanced Completion and Intervention Well Control Manual.

Section 10: Coiled Tubing.

2.1.4. Repairing and Splicing Coiled Tubing.

2.1.5. Corrosion resistance.

Section 10: Coiled Tubing.

Figure 5: The UTIM. Universal Tubing Integrity Monitor.

Advanced Completion and Intervention Well Control Manual.

Section 10: Coiled Tubing.

Shear seal BOPs made up directly above the xmas tree

High pressure riser. A pump in tee can be included.

Single or tandem stripper. and tandem strippers.

Figure 6: Coiled tubing Pressure Control Equipment.

Advanced Completion and Intervention Well Control Manual.

Section 10: Coiled Tubing.

3.2. Coiled Tubing Barriers.

Stripper rubbers and riser.

Gate valves if a tool-sting deployment system is being used.

SCSSSV or Lubricator valve if the coil tubing BHA is above.

3.2.2. Internal Pressure control.

Check valves (non return valves) in the BHA.

Advanced Completion and Intervention Well Control Manual.

Section 10: Coiled Tubing.

3.3. Stripper or pack-off.

Figure 7: Inline stripper

3.3.2. Side door strippers.

Section 10: Coiled Tubing.

Advanced Completion and Intervention Well Control Manual.

Section 10: Coiled Tubing.

3.3.3. Radial strippers.