Coiled Tubing Equipment

Coiled Tubing Equipment

Objective:
Provide general knowledge of CT operations, CT equipment and it’s
functional requirements, operational parameters and well control
requirements.
 What is the Coiled unit?

Coiled Tubing Unit is a portable, hydraulically powered service system which is

designed to inject and retrieve a continuous string of tubing
 Coiled Tubing History

Prior to the Allied invasion of Europe in 1944, engineers developed and produced very
long, continuous pipelines for transporting fuel from England to the European Continent
to supply the Allied armies.
The project was named operation PLUTO, an acronym for “Pipe Lines Under The
Ocean”, and involved the fabrication and laying of several pipelines across the English
Channel.

be displayed. This image cannot currently

The Pluto (Pipe Line Under the Ocean) project

 Coiled Tubing History

Seven 3-in. ID pipelines from England to France during World War II

 Coiled Tubing- General

In the oil and gas industries, Coiled Tubing refers to metal piping,
normally from 1" to 3.25" in diameter, used for interventions in Oil and
Gas wells which comes spooled on a large reel up to length of
to 28,000 ft.

Coiled Tubing is often used to carry out operations similar to Wireline

operations.

The main benefits over wireline are the ability to pump chemicals
through the coil and the ability to push it into the hole rather than
relying on gravity.

However, for offshore operations, the footprint for a Coiled Tubing

operation is generally larger than a wireline spread, which can limit the
number of installations where coiled tubing can be performed and make
the operation more costly.
 Coiled Tubing Description
• Coiled Tubing is an electric-welded pipe manufactured with one longitudinal
seam formed by high frequency induction welding without the addition of
filler metal.

• The first step in the typical coiled tubing manufacturing process involves the
acquisition of steel stock supplied in 48” wide sheets which are wrapped in
approximately 3,500’ rolls.

• When the diameter of the coiled tubing to be manufactured is

selected, the sheet steel is slit into a continuous strip of a specific
width to form the circumference of the specified tube.

• The flat strip steel is then bias welded to another segment of strip to
form a continuous roll of sheet steel.

• The welded area is dressed-off smooth, cleaned, and then X-ray

inspected to ensure that the weld is free from defects.

• Once a sufficient length of the continuous strip steel is rolled onto the
master coil, the tube milling process can begin.
 Coiled Tubing Uses

• Sand and Solids Washing

• Paraffin and Asphaltene Cleanouts
• Unloading Wells and Initiating Production
• Formation Stimulation - Acidizing
• Remedial Cementing
• Sand Consolidation
• Thru-Tubing Milling Services
• TCP Perforations
• Underbalanced Drilling
• Circulating well with Kill Weight Fluids
• Conveying Logging and Perforating Tools
• Fishing and Running Tools
• Chemical Injection Strings
• Production Tubing
• Siphon/Velocity Strings For Secondary Production
• Gas lift
 Advantages of Coiled Tubing
• Coiled Tubing can be deployed and retrieved while continuously
circulating fluids.
• Ability to work with surface pressure present. No need to kill the
well.
• The body of the Coiled Tubing has no connections to make or
break.
• The body of the Coiled Tubing has no connections to make or
break.
• Reduced service time as compared to jointed tubing rigs.
• Units are highly mobile and compact. Smaller crews are needed.
• Formation damage is minimized when workover is performed
without killing well.
• Lack of tubing connections or couplings provide greater clearance
in the annulus and afford larger sizes of CT to be run as compared
to jointed tubing.
• Existing completion tubulars remain in place, minimizing
replacement expense for tubing and components.
• Ability to perform continuous well control operations, especially
with pipe in motion.
 Disadvantages of Coiled Tubing
• Coiled Tubing is subjected to bend cycling, which causes the tubing to
fatigue (wear out) and requires frequent pipe replacement.
• Coiled Tubing will typically have a thinner wall thickness as compared to jointed
tubing (with the exception of “macaroni” or small tubing). This will limit the tensile
load strength of the tubing.
• Due to the effects of bend-cycle fatigue, the specified yield strength of the Coiled
Tubing material will be reduced. This adversely affects the burst and collapse
resistance of the tubing.
• Due to reel transport concerns (height and weight), there is a limited
length of Coiled Tubing which may be spooled onto a reel.
• Sizes of Coiled Tubing available for services are limited, however 2 ”3/8
and 2 7/8” are common.
• Due to small diameters and long string lengths, pressure losses are typically very
high when pumping fluids through coiled tubing. Circulation rates
through Coiled Tubing are typically low when compared to similar sizes of
jointed tubing.
• The biggest disadvantages of not being able to rotate the pipe has been
partly overcome by the development of downhole rotating tools that can be used
for light drilling or milling. However, coiled tubing cannot be rotated at surface.
The working life of the Coiled Tubing is affected by a
lot of factors such as:

• Bend Cycles - Fatigue

• Internal Pressure Loading
• Applied Axial Loading
• Corrosion - internal and external
• Mechanical Damage
• Reel Radius
• Goose neck Radius
• Goose neck Rollers
• Reel Alignment
• Storage and atmosphere conditions
• Spooling
• Job design
• Number of runs
• Pressures differentials
 Coiled Tubing Operational Life limits

Life Limits
When being run on and off the reel and over the gooseneck, often
with internal pressure on the pipe
Tension Limits
Which vary with depth and weight of coiled tubing.
Pressure Limits
Burst and collapse pressure vary with tension and compression.
Diameter and Ovality Limits
• Real time monitoring of the pipe is required to ensure that the pipe is not
ballooned, ovaled, or mechanically damaged.
• It is important that all these limits are considered together. For example the
life limits allow 1.25” OD coiled tubing with a 0.087” wall thickness, made of
70,000 psi yield material, with 5,000 psi internal pressure, to be cycled in
and out of the hole about 40 times before reaching the limit.
• This means that the pipe will not fail due to fatigue before this point.
However, when the pipe reaches this limit, it will have grown from 1.25” OD
to 1.5” OD, which is far beyond the acceptable diameter limit.
 CT Fatigue

Fatigue is defined as progressive and localized structural damage that occurs when a
material is subjected to cyclic loading

Factors effecting’ fatigue life

Increase reel/guide arch diameter increases fatigue life
Bend Geometry
or longer CT operational life
Increase internal pump pressure. During CT operation
Internal Pressure decreases fatigue life or shorter CT operational life
Increase CT outside diameter decreases fatigue life.
CT Size – OD The bigger the CT size, the more difficult it is to bend.
Increase CT wall thickness increases fatigue life because
CT Wall Thickness
the overall hoop stress is reduced.
Reciprocating the CT will decrease the fatigue life as it is
repeatedly plastically deformed during routine use. Example
Reciprocation
of frequent CT reciprocating is performing jarring action, and
cleaning out an obstruction downhole.
 Description of Fatigue

Several Factors affect the operational limits of Coiled Tubing

Fatigue
• It is generally considered the single major factor in determining the working
life of Coiled Tubing.
• The deployment and retrieval of the continuous-length tubing string require
that the pipe be subjected to repeated bending and straightening events,
commonly referred to as bend-cycling.
• The amount of strain imposed upon the tube body during the bend-
cycling process is considered enormous, in many cases on the order of 2 to
.3%
• When subjecting the Coiled Tubing to this type of fatigue cycling, the stress
and/or strain fluctuations to failure may be adequately calculated using
conventional multi-axial fatigue life prediction approaches.
 Bending Events Occuring during Coiled Tubing Operations

• However, when the bend-cycling process is coupled with internal tube

pressure loading, the prediction of fatigue life becomes very difficult to
calculate accurately.

• Numerous tests performed have confirmed the fact that bend cycling Coiled
Tubing with internal pressure loading dramatically reduces the fatigue life of
the pipe when compared to the cycle-life of un-pressurized tubing.
 Coiled Tubing Stresses
• Normally maintained in an
elastic stress state, but is
subjected to plastic stress
state each time it is rolled
on or off the reel and over
6x Bending events the gooseneck
3 x Plastic cycles
• Plastic stress states causes
the CT to be permanently
deformed

• This cycling fatigue causes

the CT to weaken and burst.
In the hole leaks are
common occurrence

• Usually, CT fails on the

underside when on the
gooseneck while POOH
 The Minimum Bending Radius

Bending Cycles

Coiled tubing OD Minimum bending radius (ft)

0.75 13
1.00 18
1.25 22
1.50 27
1.75 31
2.00 36 Available Coiled Tubing.
2.375 42

Load capacity - Yield minimum calculated on minimum wall. Tested:

Test pressure value - 80% of internal yield pressure rating. Maximum
working pressure is a function of tube condition and is determined by
user.
All data is for new tubing at minimum strength
 Geometric change to the tube diameter as a result of ovality

• When subjected to plastic deformation due to bend-cycling with

internal pressure loading, the diameter of coiled tubing tends to grow or balloon.
• Even when internal pressure loading is well below the yield stress of the
material, the tube body is subjected to hoop and radial stress which cause
material to distort in the phenomenon described as diametric growth.
• Primary factors influencing diametric growth are the material properties, bend
radius, internal pressure loading and coiled tubing geometry (outside diameter
and wall thickness.)
 Observations of bend-cycle fatigue testing directly relating to diametric
growth in Coiled Tubing follow:
• The growth rate of the Coiled Tubing outside diameter increases with
increasing internal pressure loading.
• The diametric growth of larger diameter Coiled Tubing as a percentage of
it specified diameter tends to be greater than that of smaller diameter Coiled
Tubing.
• Coiled Tubing specimens with higher material yield strength have less diametric
growth than lower yield strength specimens.
• Mechanical limitat•ions of surface equipment tolerances for allowable
diametric growth restricts the effective working life of Coiled Tubing in high
pressure service to only a fraction of the projected fatigue life.

Examples of Geometric change to tube diameter as a result of ovality

 Coiled Tubing Buckling

Contact forces will increase Friction

Force and can eventually lead to Helical
Buckling and ultimately to ‘Lock-Up’

Sinusoidal buckling We must consider:

• Weight that can be applied on the

tool within deviated/horizontal
Helical buckling section

• Predict when CT being snubbed into

the well is likely to buckle/bend
Lock-up
• Stay within CT operation limits for
the well configuration and job
requirement
 Coiled Tubing Integrity Check
Integrity check usually done with a
Magnetic Flux Leakage System

This provides 360° coverage of the pipe,

including outer diameter, inner diameter
and wall thickness, detects corrosion, as
well as pitting and other defects

Approx. 60% of CT manufactured is 2-in. diameter or greater, with 130,000

psi or greater yield strength and Injectors have gone to some 140,000 lbs
hookload capacity up from 70,000 psi yield strength and 35,000 lb
hookload capability respectively
The Magnetic Flux Leakage Systems use powerful magnets to magnetize
the steel.
At areas where there is corrosion or pitting, the magnetic field ‘leaks’ from
the steel.
A magnetic detector is placed between poles of the magnet to detect the
leakage field.
 Typical CT equipment configurations
Land based rig-up
Typically for land based coiled tubing operations the BOPs can be rigged up the Xmas
directly onto Tree with no need for a riser. However if the tool string is complex and
configuration hence long in length a riser can be installed below
the BOPs.

Offshore Platform Rig Up

A typical rig up for an offshore platform is where the injector head and BOPs are
positioned on a higher deck (probably the drill floor) than the wellhead. A riser connects
the BOPs and the Xmas Tree which acts as a lubricator for long tool strings. In order to be
able to secure the well in an emergency and have the ability to de pressurize the riser a
shear/seal BOP is usually included in the rig up, directly above the Xmas Tree.

Sub-sea Rig Up
Sub-sea coiled tubing operations from a floating rig require the injector head and BOPs
etc. To be compensated to allow for rig movement. The injector head, BOPs and stripper
are housed In a lift frame which is suspended from the drilling blocks. The riser and sub-
sea BOPs are in turn suspended from beneath the lift frame, commonly through a
hydraulic connector for ease of rig up, and are kept in constant tension when attached to
the sub-sea Xmas Tree to avoid buckling of the riser joints.
 CT Equipment

Regardless of working environment CT unit will include the following

main components: 4

1. Control Cabin
5
1
2. Power Pack
6
3. CT Reel
3 2
4. Goose Neck
7
5. Injector Head
8
6. Strippers
7. BOP
8. Kill Line
9. BHA XMAS TREE

WELLHEAD
 CTU Control Cabin
Various configuration and design:
• Independent or truck mounted unit
• Elevated Location - to provide full view of all activities.

Instrument and Control System:

• Primary control: Weight Indicator, Counter, Circulating and Wellhead Pressure
• Secondary control: Depth/Speed, Stripper Pressure and Chain Tensioner
• Support control: Engine RPM, Drive System, Air and BOP Pressures

Standby pumps as back-up to operate PCE in maintaining maximum well security in

the event of major equipment failure.
Gauges are located at operator’s eye level.
CTU Control Panel
 CTU Power Pack
Prime mover usually diesel engine that provides power to hydraulic circuits in CT Unit.
• Driving an array of hydraulic pumps supplying each system or circuit with the
required pressure and flow rate.
• Operate independently of exterior power or air supplies once started.
• Includes accumulators providing backup hydraulic energy to key components in
the event of an emergency
Power Pack Main Components:
• Engine
• Hydraulic Pumps
• Pressure Control Valves
• Hydraulic Reservoir
• Accumulators
• Filters and Strainers
• Heat Exchangers
• Hydraulic Fluid
• Safety Devices.
 Hydraulic hoses
There are a lot of hydraulic hoses with different pressure ratings and sizes in the
coiled tubing hydraulic operating systems.

The hoses are exposed to environments, that can cause physical damage or
conditions , which cause deterioration over time causing leaks.

A physically damaged or leaking hose or connection should be replaced to maintain

the operating integrity of the hydraulic systems.

The hydraulic operating systems have different operating pressures. If a 1/2 ” 3000
psi hose has to be replaced, it cannot be replaced with a ½” 1500 psi hose although
the hydraulic connections may be the same.

In an emergency, If no alternative is available, a lower pressure hose can be

replaced with a hose with higher pressure rating.

However, since the higher pressure hose can have smaller ID, which may effect the
hydraulic performance of the system negatively ,it should replaced as soon as
possible.
 CT Reel
Primary function is store and protect CT. (25k ft of 1”, 1¼”, 1½”, 1¾”, 2” & 2⅜” CT)
Component: (RIH and POOH Speed: 250 ft/min
• Reel motor Maintain proper tension, Reel and IH.
• Level wind assembly Ensures close, even and efficient spooling onto reel.
• Reel swivel Allows fluid to pumped while CT rotating.
• Lubrication system Application of inhibitor or protective coating.
• Mechanical counter Back-up depth measurement system,
• Crash frame Protect CT during handling & transporting.
RIGHT ANGLE DRIVE (Floor Mounted Motor) DIRECT DRIVE (Axle Mounted Motor)

Supplementary Hydraulic System

Crash Frame

Chain Drive

Reel Motor
Service reel
Service reel
 CT Goose Neck
• It guides CT from horizontal to vertical position as it leaves the reel to enter
the top of IH. Profiled rollers the Goose Neck support the CT as it is bent over
the Goose Neck arc.

• The gooseneck can have a radius as small as 48” or as large as 120” depending
upon the size of the CT.

• Larger gooseneck sizes (radii) are used to minimize the fatigue of the CT
string. The recommended gooseneck radii and their relative sizes are shown
below.
API RECOMMENDATIONS
CT Size Radius
”¼1
”72 – ”48
”½1
Profiled Rollers
”¾1
”96 – ”72
”2
”⅜2
”120 – ”90
⅞2 CT GOOSE NECK
”½3 ”120 – ”96
 Injector Head
• The Injector Head essentially consists of
hydraulic motors connected to chains ,
that move the CT. The motors actually turn
the chains through a set of timing gears to
synchronize the movement of both chains.

• The IH basically consists of two separate

frames.

• Inner frame attached to base with a hinge

and an electronic load cell

• Outer frame consists of crash frame

attached to the same base by rigid
connections.

• The gooseneck is attached to the outer

frame to avoid interference with the load
cell readings.
Inside and outside chain tensioner configuration ("S" system.)
 CT Auxiliary Surface Equipment

Weight indicator Mechanical

Mechanical - oad cell Weight Indicator
Electronic strain gauge] one side hinged
2 –load cells]
Depth Measurement – Counter Mechanical
Mechanical [at reel or inj. head] counter
Electronic at injector head Friction wheel
between injection
Hydraulic quick connector Head and stripper]
standard connections Stripper Hydraulic quick
Can stab with 10° offset connector -HQC
Mechanical latch w/ locking dogs below stripper
HQC and above BOPs
 Coiled Tubing External Barriers

Primary Barrier
Stripper rigged up above BOPs to create the primary barrier envelope.
Sometimes called CT stuffing box.
Usually a tandem stripper to ensure back-up is readily available

Secondary Barrier
Quad/Combi or Triple BOPs along with riser/other equipment, like
Shear/Seal BOP close to the top of the Xmas tree to create a
secondary barrier envelope consisting of blind rams, cutter rams, slip
rams and tubing rams

Tertiary Barrier
Shear/Seal BOP - Safety head], mounted close to or flanged to the
Xmas tree and capable of cutting the tubing, but not the tool string,
like mud motor and check valves

.
 Coiled Tubing External Barriers

Injector head

Stripper Primary barrier

Quad BOPs Secondary barrier

Shear/Seal BOP Tertiary barrier

Adapter flange

Xmas tree
 Coiled Tubing External Barrier Envelope

Pressure control equipment in the envelope includes:

• Stripper sealing devices - single or tandem

• Annular BOP if available for BHAs
• Riser/Lubricator/Flanges/Hydraulic Quick Unions
• BOPs including the Shear/Seal - Remote controlled
• Kill Line, Choke Line and associated valves

To prevent the accidental release of a sudden failure of a barrier, at

least two barriers should be available at all stages of an operation.

All connections between wellhead and the nearest barrier device

must be capable of forming a reliable seal and should therefore be API
flanges with ring gaskets
 Typical Coiled tubing PCE low and high pressure rig-ups

Primary Barrier
Primary barrier

Primary Barrier

Secondary barrier barrier

Secondary Barrier

Secondary Barrier
Tertiary barrier Secondary Barrier
Secondary Barrier
Tertiary Barrier

High
Low pressure
pressure
 CT Strippers

Pressure containment devices:

• Installed above BOP and below Injector Head
• Dual assembly used for extreme well conditions.
• Hydraulic activation from Control Cabin.
• Can be redressed during operation with pressure isolated
 Conventional Stripper
 Tandem Stripper
 Side Door Stripper
 Radial Stripper
 Dual Strippers
 Conventional Stripper
• Hydraulic pressure applied through Pack Port
moves Piston and Lower Bushing and
energize stripping element against Non
Upper Brass
Extrusion Ring. De-energize is achieved Locking Pin Bushing
through Retract Port.
• Wellhead pressure will further energize Non-
Extrusion
stripper element. RETRACT PORT Ring

• Stripper components are split into two and

Stripping
make possible to be redressed during Element
operation from top of Stripper within IH
frame provided the well pressure is isolated.
• Redressing period 45 min – 1 hr. Energizer

Lower
PACK PORT
Brass
Bushing

Piston

Conventional stripper
 Side Door Stripper
• Specifically designed to facilitate easy access
Coiled Tubing
to the Packer Insert, primary seal and Upper Brass
bushing with CT still in the well. Bushing

• Easy and safer access for seals inspection.

• Extended Upper Bushing improve guides and PACK PORT
minimizing seals wear. Piston
• Hydraulic pressure applied through Pack Port
moves Piston, Upper Brass Bushing and Non-
Extrusion Ring ▼ thus energize the element. Non-
Extrusion
• Well pressure does not help to energize the Ring
element. Element
• 10 – 5min redressing period. Retractable
Door
• Most Side Door Strippers are run in Tandem
• A Tandem Stripper is actually similar to the
Single Stripper, with the exception, that it has Lower
a top threaded connection for a Tandem Brass
Bushing
Stripper make up
 Tandem Stripper

• Used in conjunction with fixed Stripper.

• Similar in principle with Side Door Stripper

• Back up Stripper system.

• Allow operation to continue without delay.

• Primary Stripper should be redressed at the

earliest practical opportunity.
 Radial Stripper

• Similar to conventional Pipe Ram, with

pressure applied from side pistons
• It provides a lower stack-up height , 50%], less
space from Injector Head
• Can change Stripper Packing with coil in the well
• Well pressure will not assist. Used for high
pressure gas wells
• Commonly used for large sized CT, such as -2
”7/8to 3-1/2” OD
• 45min period redress
 Stripper Elements

• The different types of stripper elements are

governed by their Durometer Hardness.
• Typically the low pressure type are 75 Durometer is
New Worn out colored yellow while the high pressure seals rated
90 Durometer is colored orange.
• The efficiency of the stripper elements rests on
external condition of CT, lubrication used, Stripper
Pack-off Pressure and Wellhead Pressure.

Materials used for CT Stripper:

• Polyurethane
• Viton for High Temperatures

Maximum Wellhead Pressure for Standard Stripper

Packing under dynamic conditions, is 3,500 psi
Interlocking
 Replacing Stripper Elements

Example: Side Door Stripper

Can be replaced with the CT still in the well, simply

Side door
and quickly, and with BOP under pressure stripper

Procedures: Hydr.
connect

• Stop CT movement and circulation Choke/kill

line
• Engage Injector Brake
• Close pipe rams. Bleed off above and inflow test Annular
• Close Annular BOP - if available preventer
• Bleed off pressure above and inflow test.
• Open Stripper. Replace stripper elements
• Re-test stripper using choke/kill line
• Open Annular BOP/Pipe Rams in sequence after
full pressure equalization
• Release injector brake and resume operations
Quad BOPs BOPs
 Return Line Adjustable Choke
• Return flow of the CT from the well will usually go to an Adjustable
Choke, located at the fluid exit of the Coiled Tubing/Completion
Annulus.
• Before the Adjustable Choke, we install two choke line valves, with
the outside valve operated hydraulically and inside one operated
manually
• The upstream pressure is controlled by a choke manifold through fixed
or adjustable choke, so that the collapse differential pressure ,
between the inside and outside of the coiled tubing is not exceeded
• During well killing operations the choke controls the flow maintains
the CT annulus bottom hole pressure to prevent any formation influx.
 Return Line Remotely Operated Choke
• Hydraulic and remotely operated choke and Choke/Kill line valves form an
integral part of the control system and are often controlled from the
control cabin.
• Enables Choke Operator to communicate easily with other parties
• Enables Choke Operator to monitor Coiled Tubing and Annulus pressures
and other critical parameters related to a forward circulation or to a well
kill
• Choke panel also has a hand pump that can be used to operate the choke
if the hydraulic supply from the BOP control unit fails
HCR - Hydraulic Control Remote Valve.

Coiled Tubing Circulating Rig Up With Option To Rig Choke

 Damage of CT Pressure Control Equipment
Damage to and within the pressure containment system BOPs ,
Lubricator, Riser, etc. could affect the function of the equipment parts.

Preventive measures:
• Sealing Elements-:
• Must be checked visually prior any installation or use
• Change Pipe Ram Elements when 80% of rubber remains
• Closing BOP around tools with sharp edges should be
avoided/minimized

Metallurgy and Working Pressure:

• Equipment parts including seals must be OEM - Original Equipment

Manufacturer
• Test certificates must originate from independent QA/QC Inspector
• Rated WPs must fulfil the well program pressure requirements, and
able to give adequate protection against potential corrosive
environment
 Damage of CT Pressure Control Equipment
Identifying Wear or Damage:

• If any doubt exists about the extent of damage or wear on

replaceable parts either whole or part of should be replaced and
the BOP equipment re-tested to the MASP

• If the wear is on the PCE body itself and this is an integral part of
the pressure control equipment, then no ‘on-site’ repair is
permitted.

• Operations have to be suspended until certified replacement is

made available

• Monitor effects of explosive decompression on elastomer seals.

• When high pressure gas migrates into an elastomer and if this

elastomer is decompressed, it may result in explosive
decompression causing tears, holes, blisters, or cracks
 Blowout Preventer – BOP – Secondary Barrier

Always perform a Body Pressure Test before any deployment

This test is to verify material strength of the equipment before use,

without inducing fractures in the material carried out by the
manufacturer as per API guidelines:

• 2times working pressure up to and including 5k Equipment

• 1.5times working pressure for 10k and 15k Equipment
• 1.25times working pressure for 20k Equipment

 Ram type BOPs are located below Strippers and may be a Double,
Triple or Quadruple , Quad, BOPs
 Ram Preventer are designed to hold pressure from below
 Ram Preventer assembly is fitted with equalizing valves so as to allow
pressure equalization across a closed ram before it is opened
 A ram preventer is also fitted with a Kill Port
 CT Combi, Triple and Quad BOPs
Solid block BOPs
Ram Configuration from top down:

1 Combi BOP
• Shear / Blind Ram
• Pipe /slip Ram
2 Triple BOP
• Blind Ram
• Shear or Slip
• Pipe Ram
3 Quad BOP
• Blind Ram
• Shear Ram
• Slip Ram
• Pipe Ram
 Quad BOP Configuration

1. Blind Rams – Top Set of rams. Serves to

seal off well pressure when no CT is across

2. Shear Rams - Second set of rams that 1

serve to shear the tubing. Large bore
2
3. Slip Rams - Third set of rams. Serves to
hold CT in place while shearing, or for 3
other applications
4
4. Pipe Rams - Bottom set of rams. Serves
to seal around CT, thus isolating wellbore
pressure below rams

There are equalization ports and a kill port

 Combi BOP Configurations

.1Blind/Shear Rams - Upper set of rams that Back

can shear CT, and seal off well pressure.

.2Slip/Pipe Rams - Lower set of rams serving

to hold CT in place while shearing or for
other applications and also seal around CT,
thus isolating wellbore pressure below the
rams Front

Advantages Combi BOP over Quad BOP

• Less Height
• Minimizes steps during an Emergency
• Easier to Operate
 Closing Quad in case of Emergency

• Close Slip Ram

• Close Pipe Ram Press. port
• Close Shear Ram to cut CT Equalizing Blind ram
• Pull CT above Blind Ram valve
• Close Blind Ram Shear ram

• Connect Kill Line to Kill Port

Kill Slip ram
port
Equalizing Pipe ram
valve
 Sequence of Cutting and Removing CT with Quad

All rams open Close slip rams Cut pipe with

and pipe rams shear rams

Pull out cut CT Close blind rams

 Triple BOP
• The triple BOP has three rams, where the upper ram is shear/seal , the middle ram
is slip ram and the bottom is the pipe rams.
• This BOP makes for a shorter rig-up as an alternative to rigging up with the Quad
and Shear/seal BOP.
• The triple ram is often combined with a single ram and spacer or riser spool for
running tools

Triple BOP
Blind Ram Assembly
Slip Ram Assembly
Pipe Ram Assembly
Pipe Ram Assembly
Shear Ram Assembly
 Combi Rams

Shear/Blind
rams

Slip/Pipe
rams
 CT BOPs Hydraulic Control System

1,000psi 3,000psi 1,200psi

The accumulator System for
BOP Operational Control has
a number of bottles, which
permit fluid under pressure
to function the various BOP
Rams and hydraulic valves.

volume
usable
Precharged
The bottle is pre-charged with Nitrogene
1,000 psi
with N2 to 1,000 psi
The maximum hydraulic
pressure in the bottle is
3,000psi Fluid can be
used to
The minimum hydraulic operate BOP
functions to
Piusmp with
pressure in the bottleelectric/air min. press.
of 1, 200 psi
1,200psi pump to 3,000 psi
 CT Quad BOPs and Annular Preventer Hydraulic
Accumulator Capacity
Volume Calculation and Number of Bottles Requirement
Example:
Company Policy is to provide sufficient volume to close, open and
close again all rams and annular preventer, using information below:

Item Open Vol. Close Vol.

Annular BOP 7 8
Slip Ram BOP 3 4
Pipe Ram BOP 3 4
Blind Ram BOP 4 5
Shear Ram BOP 4 5
Annular = 1 x (8 + 7 + = )8 23gals
Other Rams = 2 x (4 + 3 + = )4 22gals
Other Rams = 2 x (5 + 4 + = )5 28

Total Volume Required = 73 gallons (in accumulator bottles)

 Shear/Seal BOP - Safety Head
• Purpose is to provide additional shear capacity in set-up. It is mainly installed in
high pressure wells when Shear ram on Combi or Quad BOP
can not successfully cut Coiled Tubing and drop down hole
• The shear/seal BOP must be flanged directly to the wellhead during well-
intervention operations on live wells for the least possible leak paths in a well
control situation
• The shear-seal BOP is a ram-type preventer that performs the dual functions of
shearing or cutting the tubing string and then fully closing to provide isolation or
sealing of the wellbore.
• Shear-seal BOPs are most commonly used in offshore or high-pressure applications
where an additional contingency pressure barrier is required. In a situation where
the coiled tubing has to be cut, it should be picked up sufficient distance to ensure,
that it falls below the Xmas tree after the cut is made.
• The latest type of the Shear/Seal BOPs are capable of shearing and sealing after
cutting CT , Slickline, Braided Line, Sinker bar, even Drill Pipe, but BHAs may not be
cut successfully

Note: This BOP will only cut coiled tubing and not larger OD intervention equipment
like tubing conveyed perforating, TCP, guns.
Shear/Seal BOP - Safety Head

Shear/Seal Actuator

Shear/Seal BOP
 Shear/Seal Ram Operation

Note: There must be sufficient riser/lubricator above the shear/seal BOP to

accommodate non-sharable intervention equipment when running in or pulling out.
The CT shear/seal BOP is only designed to cut coiled tubing.
Components that cannot be Sheared in the CT BHA

COIL

Cannot be Sheared Can be Sheared

Note: If not sure about shear capability, then do not attempt to shear
anything else, but the coil.
 Cutting CT with Shear/blind and Shear/seal

Kill line
Clean cut Crimped cut

• The design of shear cutters should be such

that they will not completely crimp the CT
when cut.
• This allows monitoring and most
importantly ,it permits fluid to be pumped
through the coil, which may be critical for
killing the well.
 Summary of CT BOPs Design and Ability
Blind Rams
Designed to close and seal on open hole

Shear Rams
Designed to shear or cut CT in the hole

Shear/Seal Rams- Safety Head

Designed to cut CT and then seal the well but will not cut the BHA

Slip Rams
With Slip Inserts not sealing pressure.
Used to hang off CT, prevent it from rotating and stripping down due
to CT weight. Designed to grip only in one direction

Pipe Rams
Designed to shut off well pressure when replacing of stripper
elements are required. Also called Safety Ram
 Annular Preventer – “Hydril”

• If we need to shut in the well around

various sizes, dimensions , shape of pipe
and or BHA, the annular preventer is
needed to perform this operation
• Annular preventer will provide an extra
secondary barrier and this will be useful
when stripper elements have to be
changed
• It is normally installed above the
Shear/Seal BOP or Safety Head and
alternatively above the Quad BOPs
• Annular Packing Element cannot be
changed with CT in the hole.
• Therefore must be changed prior to start
operating
 Annular Preventer – “Hydril”
The Annular Preventer is also used to
permit stripping of CT and/or other
components.

If we strip, then we must pay attention to:

• Annular Preventer Operating Pressure Annular BOPs have a donut

• Weight Indicator, if string has various shaped rubber packing; it allows
ODs stripping of tapered strings
• Info on Fishing Necks of Tool String maintaining a seal.
Pre-charge

Annular BOP closing line

400psi

connected to a one gallon

Annular accumulator bottle, facilitating
Open Oreventer the stripping of taper strings
because bottle functions as a
Close dampener and thereby avoids
Surge Bottle/ damage to the packing
Accumulator element.
API Flanges and Ring Gaskets for CT BOPs and other PCE

Flange Description :
7-1/16”, 10,000 psi
Flange, means this
flange has a 10,000
psi working pressure
and has a 7-1/16”
through bore ID
 API Flanges and Ring Gaskets for Wellhead Adapters
API 6B flanges have a gap between the flanges after make-up; will
therefore need periodic re-tightening of bolts/nuts

API 6BX flanges are ‘face- to-face’ flanges; gaskets are slightly larger
than groove, but when compressed, gaskets are deformed and create
initial seal
RX and BX are pressure self-energizing gaskets; this means that
pressure from the well bore will act upon the inoner face of the ring and
assist in the flange sealing feature
 BOP external leaking and malfunctioning
Body The actuator body O-ring (often referred to as a bonnet or door seal) is
leaking and needs to be replaced.
Hydraulic oil leaking around the indicator stem extension The indicator stem seal is
damaged and needs to be replaced.
Shear rams will not cut - Must be addressed prior to job start up
• Sufficient hydraulic pressure may not be available.
• Try to close shear rams several times.
• If the situation allows, check the shear blades to see if they are sharp or
damaged.
• Make sure they are the correct size for the particular application.
Slip rams are not holding - Must be addressed prior to job start up)
• Sufficient hydraulic pressure may not be available.
• Check the condition of the slip rams. If they are dull, flattened or filled with well
deposits, they may not hold. The slip wickers must be sharp. If dull, replace, if
gummed up, clean.
• Make sure they are the correct size for the particular application.
Rams damage tubing , which must be addressed prior to job start up
• Make sure they are the correct size for the particular application. If the ram bore size is
larger than the pipe, the corner of the inner seal retainer plate extending beyond the face
of the ram guide may pinch or mark the tubing.
• Check the guide rod slot and guide rod for wear. If either is severely worn, the ram may
become cocked in the ram bore causing the ram to engage the pipe improperly.
 Fluid Leaking out of Weep Hole
• If wellbore fluid is leaking from the weep hole, the O ring stem seal is probably
leaking and needs to be replaced.

• If hydraulic fluid is leaking from the weep hole, the outer stem seal O-ring is
leaking and needs to be replaced.

Note: If there is a fluid leak through the weep hole, the leak can temporarily be
stopped or reduced by injecting a sealant through the injection port

Sealant injection port

BOP Actuator Piston

BOP Ram

Seals

Weep hole
 General maintenance of preventers

• BOPs that are H2S service rated are composed of alloys that are relatively soft. This
means that care must be exercised to prevent unnecessary damage to the BOP.
• If the BOP must be worked on in the field, rest any part removed on a soft cloth
and make sure that it is clean before reinstalling. Hose ends or couplings should be
kept clean, free of dirt or grit when not in use.
• If they should become dirty, damage and improper sealing may result. Use
hydraulic oil or an approved cleaning solvent to clean a dirty part.
• Ensure that no air is trapped in actuators, hydraulic lines and equipment by
bleeding or purging lines. Air pockets or bubbles may lead to sluggish responses of
equipment.
• Never apply pressure to any tubing ram without having the proper OD test rod or
test tool in the ram.

• Remember: some residuals from hazardous material may be in the BOP.

Always wear proper safety clothing and take all precautions when rigging
down or working on stack.
• Before rigging the stack down, remember that pressure may be trapped.
 BOP test procedures

• Before starting a job, the BOP stack must be tested to insure that it will hold up
to the maximum anticipated pressures from the job.
• Most BOPs are checked out and tested at the maintenance facility
of the contractor prior to shipment to the job site.
• Keep in mind that this inspection/testing may not be recent and that
damage may have occurred in transit or rig up.
• Both safety and peace of mind dictate testing of this equipment before
the job begins.
• The onsite test includes function, low and high pressure tests.
• The results of each individual test must be recorded.
• The low pressure test must be performed first and should be
conducted at pressures between 200 to 300 psi.
• The high pressure test should be the lesser of the maximum expected
surface pressure, minimum burst pressure of the well’s tubing, or Before
starting a job, the BOP stack must be tested to insure that it will hold
up to the maximum anticipated pressures from the job.
 BOP test procedures contd.

• Test all components that will be exposed to pressure. When conducting these
tests use a fluid (i.e. water) that will not cause pollution, or harm personnel if a
leak develops.

• Other fluids may be used , if pollution or operator restrictions allow.

• Test intelligently within all equipment ratings, and remember that pressure may
become trapped, especially between valves, and then vent off at an
inopportune moment.

• Bleed off any pressure before repairing leaks.

• Have only necessary personnel in the test area.

High Pressure CT Stacks
1

1. Goose Neck
2
2. Injector Head
3. Dual Stripper System
3

4. Hydraulic Connector
4
5. Quad BOP System
5
6. Flow line
6
7. Annular BOP
7
8. Shear/Seal BOP
8
.9 Xmas Tree

9
Low Pressure CT Stacks

1. Goose Neck 1

2. Injector Head
2
3. Stripper
4. Hydraulic Connector
3

5. Flow line 4

5
6. Combi BOP System
6

7. Annular BOP
7
8. Xmas Tree
x
 CT BHA, Bottom-hole Assembly

1
CT BHA configuration:

1. Coiled Tubing
2
2. Connector

3. Check Valve 1
Standard BHA 3

4. Check Valve 2
4
5. Hydraulic disconnect

6. Optional - such as Circulating sub

5

6
 Check Valves - Internal Primary Barrier

• Installed at the end of CT but above the [rest of the

BHA, with main purpose to control and/or to maintain
pressure when CT fails at surface
• Dual Flapper Type Valve are most frequently used
Flapper Type Valves allows Plugs and Balls to be
pumped through, such as to operate special
equipment in the BHA
• Reverse Circulation is not possible If Reverse
Circulation is required for optimal cleaning efficiency,
then an extra circulating sub
• It must be installed above check valves
• However, once the ball for this circulation sub has
been dropped no mechanical barriers remain to stop
Dual flow inside the CT
flapper
valve
 Pump-out Check Valve
• Used for CT velocity string applications. this application involves
hanging off a CT string in a well permanently as part of the
completion. When installed, the string must be fully open to the
flow of wellbore fluids
• A single pump-out check valve works as a standard ball check
valve, thus assuring well control during normal CT operation, until
a circulating ball is pumped to eject the sleeve containing the ball
check valves procedure:
• The pump out check valve is attached to the bottom of the CT.
Before running the CT in, pressure required to pump it out is
adjusted by varying the number/type of shear screws.
• Upon reaching final depth, a circulating ball is pumped down to a
seat in the check valve.
• Pressure is applied to shear the screws, pushing the check valve
cartridge out of the housing.

Flow to
pump out
check valve
 Check Valves - Internal Primary Barrier

Ball Dome Dart Flapper

valve valve valve valve
Removable
cartridge
flapper
valve
flow in
Circulation sub with Dual flapper valve
 Dual Flapper Check Valves

Double Flapper Check

Valves recommended
and used for all CT
operations.

Features

The flapper type check

valve allows for pumping
through the string of
coiled tubing but
disallows back flow
Double Flapper
Check Valves
 CT Release Mechanisms

There are three basic types of Release Joints:

Ball operated shear sub - BOSS -Hydraulic Disconnect and Tension

Disconnect.
• This equipment is particularly important because it guarantees the
possibility to release the coiled tubing hydraulically from the tool
string, if it is stuck downhole.

Hydraulic Disconnect
• It is similar in design to the BOSS, but operated by differential
pressure inside the CT.
• The activating mechanism depends on depth and fluids in the well
Tension Disconnect
• These are simply two components pinned together such that they will
separate upon application of a straight pull on the coiled tubing,
leaving a standard fishing neck looking up.
• It is not generally recommended to use the tension disconnect as
part of the down hole tools because of the lack of control over down
hole tension forces and the possibility of premature release.
 BOSS Release Operation
Fluid Fluid
Ball Pick-up
pressure pressure
• The release is carried out by
inserting a ball , that is pumped
down the CT.
• The pumping pressure is kept
constant until the ball reaches Upper
body
the seat of the releasing tool.

Pin sheared
• Adequate over-pressure of the Piston
Shear
CT causes the separation of the pin
two tool components allowing
Dogs
the coiled tubing to be
retrieved.
• One or a double flapper check Lower
valve must be used so the ball body
can pass freely to the releasing
tool.
Dogs held in Apply press. Shear pin –Separation
position to shear pin release dogs complete
Circulating Sub

• The circulating sub is a hydraulically

operated tool by pumping a ball which
allows the opening of a wide passage for
circulation after reaming or packer release
operations.

• The circulating sub must be positioned just

below the check valves and hydraulic
disconnect.

• The shifting ball is pumped down the CT

and when the ball reaches the seat in the
circulating sub , an additional
predetermined pressure on the ball will
shift the circulating sub open.

• This ball is smaller than the hydraulic

release ball and will also pass freely
through flapper type check valves.
 CT Mud Motor BHA
CT connector

Check
valves

From Top to Bottom: Release

tool

X-over
Coiled Tubing Connector
Tandem Check Valves
Release Joint/Safety Joint* Drill
collars
Drill Collars
Coiled Tubing Motor
Stabilizer - Optional
Mud
Bit Rotor motor
Stator

*Release Joint is usually run w/ a By-Pass/Circulating Valve Drill bit

 Coiled Tubing End Connectors

The choice of Tubing End Connector depends on the type of duty to be

performed and is also a critical item.

Dimple External Roll-on/

-set screw- grapple crimping
connector connector connector

For most Does not For light

restrict ID duty
‘general’
operation of tubing operation
 CT Deployment Systems – Option 1

• In normal circumstances, we will only have a

quick union between Injector Head and BOPs.

• However, this makes it impossible to run

Bottom Hole Assemblies.

-•: If a BHA is run in the space between Injector

Head and BOP will make use of a Deployment
System and Bar, which could be accompanied Annular
BOP
by an annular BOP.

• The annular BOP will be either above CT

BOPs, and below Strippers or below CT BOPs,
but above Shear/Seal BOP
 CT Deployment Systems – Option 1
Procedure for Deployment
Bar

• Use wire line system, and

run long BHA inside the Wireline
wire lubricator
• line lubricator with the
BOP shearing blind rams, Deployment
SBR, closed, install bar
lubricator onto the BOP
stack
Tool
• Equalize pressure and
string
open SBR and run BHA
with wireline into the well
and close pipe/slip rams
using the deployment bar
• Bleed off and remove
lubricator
• Connect injector head
and coiled tubing
 CT Equipment Pressure Testing

Overview:
The on site testing include Function test and Low
Pressure test at 250-350 psi
The High Pressure test is test up to maximum
anticipated surface pressure and by some Operators
, %10 +but importantly less than burst pressure of
CT

• Test Blind Ram and Shear/Seal by pumping

through Kill Port of BOP

• Test Strippers and Pipe Ram by pumping through

CT

• Test Check Valves is to invert a Check Valve and

pump down through CT or inflow test after
testing Pipe Ram
 CT Equipment Pressure Testing

Pressure Test Shear/Seal

• Close UMV and LMV. Then fill up Riser up to above

Blind Rams via test line on Xmas Tree or pumping
tee
• Close Shear/Seal ram Kill
• Apply test pressure via test line on Xmas Tree or port
pumping tee

Pressure Test Blind Ram and Riser

As above
Kill line Choke line
Mud cross

Note: Although there is a Kill Port on a Quad/Combi

BOP and Shear/Seal BOP, most companies prefer a
Mud-cross as well and do not like to pump through or
have returns through Xmas Tree valves
 Pressure Testing Surface Line and Separator
Before any pressure test flush and then test surface systems.

Surface line
pressure test

During Test, Separator- closed

drain or choke manifold
Pressure Testing CT Reel against Test Cap

Reel test
against test cap

During Test, Separator

closed
drain or choke manifold
 Pressure Testing CT Shear Seal Rams

Note: Blind Rams of Quad or Combi will be done in a similar way

Test below shear/seal

ram - via Kill Wing valve

During Test, Separator

closed drain or choke
manifold
 CT Equipment Pressure Testing with CT in place

Pressure Test Strippers

• Ensure Swab Valve and Upper Master Valve are closed
• Using a straight bar to avoid CT being crushed if too much pressure
applied and ran this bar across Stripper
• Fill up via reel until water overflows from Stripper
• Energize Stripper Packer by applying hydraulic pressure
• Apply test pressure from the reel , pressure up from below, and repeat if
we have Tandem Strippers

Note: Only OEM straight bars must be used when testing CT Strippers.
The incorrect bar may blow out of the stripper and cause equipment damage
or personnel injury

Pressure Test Pipe Ram or Annular Preventer

• With pressure still maintained from the Stripper test, close the Pipe Ram
or Annular Preventer
• Bleed off pressure from above
Pressure Test Check Valves
With pressure still maintained from the above test, release pressure from
reel and perform inflow test on check valves
Pressure Testing CT Pipe Rams-Annular Preventer
Strippers and Check Valve by Inflow Test
Avoid CT collapse when Inflow Testing the Check Valves

Test stripper, pipe

ram through CT reel

During Test, Separator,

closed drain or
choke manifold
Coiled Tubing Operations
 CT Mechanical Operations

Pumping’ Jobs
Conveying Fluids or Gases

Circulating like HCl hydrochloric

acid] , N2 Nitrogen gas or Cement,
and do so often on a live well

Conveying Mechanical Tools

Performing mechanical tasks like

pulling/running plugs, packers,
fishing, removing scale, sand, drilling,
re-entry and sidetracking
 Coiled Tubing Logging
• Most conventional electric Wireline work depends on gravity to pull
the tool down. At high deviation angles - greater than 65 degrees - and
horizontal wells, gravity alone cannot pull tools to the desired depth.

• If the Wireline and tools are conveyed using conventional tubing, the pipe will
cease to slide due to its weight at inclinations over 26 degrees Coiled Tubing is
then used to convey the electric tools

• The Wireline must be inserted into the tubing.

Circulating

• One of the big advantages of a Coiled Tubing unit is its ability to circulate
as the tubing is run into or out of the well.
• Additionally, it can run pack-off tools to isolate a zone and then perform a
remedial operation, and retrieve the isolation packer in one trip.
• Coiled Tubing may also be used for well kill operations. This is very useful,
especially when a hole develops in the primary drill pipe or tubing string.
 CT Reverse Circulation

• Although not a common practice, the

advantage of using CT for Reverse
Circulation is that the flow can lift
Coiled solids within the CT more easily than
Tubing the CT to Compl. Tubing Annulus or CT
to Casing Annulus.
• However, Reverse Circulation can only
Reverse sand
be done when Check Valves are
Clean-out
bypassed.
• If using a Circulation Valve, we must
Jet
open this Valve with a ball.
Sand Pump
• Once dropped to open the Circulation
Suction Valve, no Mechanical Barrier left inside
Intake CT string
Ports
Note: If the well is not dead, then the well
must be killed first before POH
 CT Reverse Circulation
• The return flow from the well is routed to an adjustable choke
downstream of the CT/Completion Annulus
• This set-up is most suitable for flow returns with hydrocarbons
and solids, which will require effective separation
 Cementing and squeezing
Due to economics, speed, and relatively precise measurement of footage run and
precise tubing capacities, coiled tubing has been gaining popularity for doing many
routine cement operations.
Spotting cement, squeeze cement and many other operations are now routinely
performed using coiled tubing operations.
Always evaluate string limitations prior to operations requiring high pump
pressure.
Gravel packing/sand consolidation
Due to speed, efficiency and economics, many gravel pack and sand
consolidations are performed with coiled tubing units. Remember that pump high
pressures coupled with hazardous chemicals are potentially lethal. non-essential Keep
personnel out of the area.
Fishing
The biggest advantage of fishing with Coiled Tubing over conventional wireline is the
ability to circulate while the fishing operation is going on with the addition of pulling
capability.
With circulation capabilities, sand deposits and debris can be washed off
the fishing neck. In some instances the tools can be run/pulled faster than
wireline.
 Gas Lift

Installing coiled tubing strings

• It has been well documented that when a well does not have sufficient pressure
to produce from standard production tubing sizes, that running a siphon or
velocity string can allow the formation to produce on its own.

• An installed Coiled Tubing string may also be used as a treatment and a gas lift
line, where treating chemicals or gas can be pumped down the Coiled Tubing to
achieve the desired results.
 Treating a well
Chemical treating of the tubing or formation can be performed by Coiled Tubing, often
without killing the producing zone, or minimizing the shut in time. This provides the
benefits of less lost production and more importantly, less possible formation damage
than bull heading treatment methods.

Acidizing
Coiled Tubing units are used for acidizing and/or selective zone chemical treatments. It
should be noted that due to its nature, acids and some chemicals shorten the life of a
coiled tubing string and can lead to holes in the pipe and premature failure of the string.

Unloading a well
In this process coiled tubing is run to a desired depth and nitrogen or lightweight foam is
injected down the coiled tubing and back through the annular space of the production
tubing. This results in a reduction of hydrostatic pressure imposed on the formation to be
produced, which should allow the well to come in.
 Sand Cleanout with Coiled Tubing

Mostly this type of operation is performed to establish communication

with an open completion interval.
It is therefore important to balance the fluid pressure used to that of
reservoir pressure to avoid fluid loss or formation damage.

There are a number of factors to be considered:

• Fluid type - to control solids carrying ability

• Fluid density - to control hydrostatic pressure.

 Sand Cleanout with Coiled Tubing

Example: Sand clean-out

Circulation often takes place in a narrow annulus
between completion tubing and ct. this effects
lLong narrow annulus

the annular pressure loss:

• Annular pressure loss will increase

• Circulating/pump pressure will increase
• Dynamic BHP will increase

Effect: Because perforations are open/clean, the

exposed formation may experience losses
Clean
Perforations
Coiled Tubing Emergency Operations
General Muster Alarm while running CT - Contingency
Procedure:

• If pumping is in progress, stop/shut down pumping

unit. Close valves to isolate the flow return line

• However, if washing or milling the CT should be lifted

above the worked interval or above perforations to
prevent differential sticking or solids settling prior to
shutting down CT Unit

• If the CT end is above the SCSSV then it should be

closed

• However, if the CT end is below the SCSSV close the Muster Alarm
Slip and Pipe Rams and lock them manually.

• Apply the Injector and Reel Brake

• Standby for further instructions

 Shut-in Procedures

In an Emergency Situation and if there is a need to immediately

shut in well to return the well to safe conditions, the following shut-
in procedures apply:

• Stop the coiled tubing run

• Stop pumping fluids

• Close slip rams

• Close pipe rams

• Await for further instruction

• A decision should be made to close the shear/seal BOP

 Recording Shut-in Pressures

How to calculate Shut-in Coiled Tubing Pressure - SICTP

how to calculate differential pressure between CT and annulus
Example:
Well Depth –TVD 10,000ft
SICTP 3,500psi
Annular Fluid: 0.15psi/ft
Coiled Tubing Fluid: 0.45psi/ft

Question: What is the ‘anticipated SICTP?

BHP is (10,000ft x 0.15 psi/ft ) + 3,500 psi = 5, 000 psi

SICTP-Anticipated] is = 5,000 psi – (10,000 ft x 0.45 psi/ft ) = 500 psi
Differential at surface between Annulus and CT is = 3,500 psi –500 psi
3,000=psi

Note: By slowing down the pump rate through the check valves we will be
able to record and thereby confirming the SICTP
 Contingency Operations –General Measures
• For every and any emergency, priority must be to make the well
safe
• Inform and alert company representative and clear all personnel
from immediate area of the CT
• Following a pump failure or any surface pin hole leak or parting,
confirm that the check valves are holding pressure
• If pulling out because of pin hole or parting downhole, continue
pumping with water] and reduced pulling speed to 15 ft/min, as
this will stop migration of hydrocarbons up inside CT and reduce
the risk of CT collapse
• If hazardous chemicals are in the reel, e.g. acid, flush through the
reel with water. Wash down and neutralize any spillage
• If the check valves are not holding pressure and backflow is
severe, do not hesitate to shear the CT to make the well safe.
• The Shear/Seal BOP, close or on top of the Xmas Tree, will then
ensure CT will drop below Xmas Tree valves
• All possible risks must be discussed in detail. Following a safety
analysis contingency measures must be agreed, drills held and
competent staff put in charge of operations
 Power Pack Failure - Contingency
In case of power pack failure, then Injector Head, and the CT Power pack failure
reel and Control System will not function, but all functions on
the unit are fail safe and/or there are manual locks as well

Note: The BOPs remain active as they are controlled from the
accumulator system

Procedure:

• Engage Injector Brake

• Set Reel Brake.
• Close Slip Ram and Pipe Ram and lock manually
• Repair/Replace Power Pack.
• Maintain circulation as mud pump has independent power
source. This is to avoid solids settling
• Disengage Brakes.
• Check weight and condition of CT
 Pump Failure - Contingency
In case of pump failure, and a spare pump is
or is not available:
Procedure:
• Pull CT some distance to a trouble-free
position to avoid solids settling
• Close slip rams/pipe rams. Apply lock
Spare
stems pump??
• If CT check valves hold pressure, close
reel isolation valve, -Lo-torque manual
valve, adjacent to the Power Reel Switch
to spare pump
• If no spare pump is available, consider Pump Fluid
pulling out to surface, secure well, and failure tank

awaiting pump replacement

Note: A pump shut down during CT clean-

up may cause CT to get stuck in the well.
Be aware!!!
 Common solutions to problems – kicks
Kicks with pipe to bottom
• If the well should kick during operations while on bottom, standard well control
techniques will work.
• Shut in pressures must be recorded, then control of the well regained by using
constant bottom-hole pressure circulating techniques.
• Often the fluid does not have to be weighted up as in the Wait and Weight method
cause the fluid in the well should be of a sufficient density. If this is the case, then the
Driller’s method should be used.

Well kicks with pipe off bottom

• The Coiled Tubing unit’s ability to circulate while moving its tubing is ideally suited to
handle unforeseen kicks before either out, or in the hole at the work depth. Options
on what to do when a well kicks with the pipe off bottom are based on how much
tubing is in the well and what the shut-in pressures are.
• The Volumetric method techniques may be used while circulating. In this method,
backpressure with corrections for gas migration based on fluid displaced over pipe
displacement provides adequate control of the well. Once back to bottom, normal kill
procedures can be employed.
• If the pipe is nearly out of the well options include stripping to bottom, or pulling out
of the well. If the decision is made to pull out of the well, the blind rams must be
closed as soon as the lowermost tool is pulled above it.
 Well Kicks while CT Out of the Hole
• In the case where no pipe is in the hole, if the tubing can be snubbed and
stripped back into the well and to bottom using the volumetric method, then the
well may be killed using a standard kill technique.

• If the maximum expected pressures exceed the tubing’s collapse, or if the tubing
weight limitations exceed tensile strength, then either a Volumetric kill technique
must be used, or a snubbing unit will need to be used.
 CT Pin hole Leak – Contingency
between Gooseneck and Reel Level Wind.
Leak due to pin hole in the CT between Gooseneck and Reel Level Wind.
Confirm if Check Valves are holding - CT pressure should drop quickly

Procedure:
Option 1 whereby we have a leak, but does not worsen and acid is not
pumped
• Stop pump and confirm, that check valves are holding pressure
• POOH with CT until pinhole is located back on CT reel.
• Close Slip Rams/Pipe Rams and lock manually
• Decision to be made to pull out further or kill the well
• In some cases, operators may temporarily repair CT with tube-to-tube
connector.

Then establish circulation again , open BOPs and pull out BHA and replace CT
reel

CT tube-to-tube Connector
 CT Pin hole Leak – Contingency
between Gooseneck and Reel Level Wind.

From the previous slide it will become clear that the ultimate decision will
depend on a number of variables, which may even change over time.
But well integrity must be retained and a CT fish can usually be retrieved.

PIN HOLE
FAILURE

PIN HOLE
FAILURE
 CT Pin Hole Leak At Surface-Contingency

• Clear area - especially around reel and injector)

Minor leak – pinhole

• Pull slowly on to reel while displacing to water -minimize reel

pressure

Major leak - large or hazardous material

• Set slip and pipe rams then check set

• Cut pipe with shear rams, pull up to close blind rams
• Purge reel , remove failure, fish CT in BOPs
Pinhole Leak -1
 CT Severe Pin Hole Leak – Contingency
between Gooseneck and Reel Level Wind.
If there is a severe leak due to pin hole in
the CT between Gooseneck and Reel Level Severe pin
Wind, confirm if that the Check Valves are Hole leak
holding - CT pressure should drop quickly

Procedure:
Option 2 whereby leak is moderate or severe
and is getting worse or when Check Valves
are not holding pressure:

• Close Slip Rams and Pipe Rams

• Close Shear Rams. Pull CT above Blind
Rams.
• Close Blind Rams and manually lock all
rams
• Prepare for killing the well through the Kill
Port
• Replace reel or repair leak
• Retrieve remaining CT from well
 CT Severe Pin Hole Leak – Contingency
between Gooseneck and Reel Level Wind.

If there is a severe leak due to pin hole in the

CT between Gooseneck and Reel Level Wind,
confirm if that the Check Valves are holding -
CT pressure should drop quickly

Procedure:
Option 2 whereby leak is moderate or severe
and is getting worse or when Check Valves
are not holding pressure:

• Close Slip Rams and Pipe Rams

• Close Shear Rams. Pull CT above Blind
Rams. Severe pin
• Close Blind Rams and manually lock all Hole leak
rams
• Prepare for killing the well through the Kill
Port
• Replace reel or repair leak
• Retrieve remaining CT from well
Pin Hole Leak between Surface and Check Valves - Contingency

Leak due to pin hole in the CT, somewhere below surface

and above Check Valves. The most likely cause will be a
defect or area of weakness.
The pin hole will allow well fluids to enter the CT and
therefore will make it impossible to depressurize the CT
until the leakage point is out of the well.

Procedure:

• Stop all CT movement

• Stop circulation and allow pressures to stabilize
• Perform calculations to estimate the leak point
• If the leak point is severe and the wellhead pressure is
high, then it is advisable to kill the well, before an Pin hole
attempt is made to pull out below
surface

Note: If the Check Valves are leaking instead, the effect,

and also the immediate action will be similar
 CT Leak Below Surface-Contingency

Loss of pump pressure or string weight

• Hole or parted CT may come through stuffing box

• Clear area and displace to water
• Pull out at max. 20 ft/min, pumping slowly
• Evaluate leak when exits stripper

Minor
• Pull on to reel carefully or the CT may break

Major or parted coil

• Follow Emergency BOP sequence
 Stripper Leak- Contingency

• Stop coil and close Slip and Pipe rams to isolate annulus. Set
manual locks.
• Place injector in neutral and engage brake.
• Bleed off pressure above pipe rams to inflow test
• Bleed off stripper hydraulic pressure and replace elements.
Pressurize.
• Pressure test stripper through kill line (avoid collapsing CT)
• Equalize pressure across BOP rams and release manual locks.
• Open pipe and slip rams.
Stripper Failure 1
Stripper Failure-2
 Major RISER Assembly Leak between Xmas Tree
and Quad/Combi BOPs with the Coiled Tubing ‘well
below’ the SCSSV – Contingency

Procedure:
Major
• Pull sufficient CT out of the hole to ensure CT will riser leak
drop below Xmas Tree Master Gate Valves when
Shear Rams are activated

• Close Shear Rams of Quad/Combi BOPs or the

Shear/Seal BOP, if available, and if Riser Length is
substantial
Pull up coil and close blind rams.

• Close Xmas Tree Swab valve counting turns and

Upper Master Gate Valve as a second barrier Bleed CT ’long’
therefore
off pressure and repair leak. sheared
and
Pressure Test. Start fishing the dropped CT dropped
Riser Assembly Leak With Long String Of Coiled Tubing In Hole
 Major riser assembly leak between Xmas tree
and Quad/Combi BOPs but with the coiled tubing
just below surface and above SCSSV- Contingency

Major
riser leak
Procedure:

Pull out of hole to above Xmas Tree and above

Shear/Seal BOP, if used

Close Xmas Tree Swab valve counting turns and

Upper Master Gate Valve as a second barrier
Bleed off pressure and repair leak.
Pressure Test PCE
CT ‘short’
o and can
therefore
pulled
above
Xmas tree
Riser Assembly Leak With Short String Of Coiled Tubing In Hole
 Tubing Parts and Pulls Out of the Stripper -
Contingency

If BHA is lost, there is no external upset to tag on the stripper brass

inserts.

• Stop the injector to keep the coil in the chains.

• Close the blind rams to isolate the well.
• Plan fishing operations for BHA.
 CT Parts Downhole - Contingency

Parting of CT downhole will show by a sudden reduction in

weight and circulating pressure

Procedure:

• Continue pumping water to prevent migration of well

fluids up the tubing and circulate with minimum rate
• Determine approximate length of CT remaining from
pick up and hanging weight
• Pull out of hole slowly until CT clears the Xmas Tree.
• Make absolutely sure, that the CT is above the Xmas
tree valves POOH CT
• Close Xmas Tree Swab and Upper Master Valves slowly
pumping
counting the turns water
• Depressurize the PCE and continue pull out the rest of
the CT CT parting
• Kill the well by Bull Heading and perform fishing downhole
operations
Tubing Parted Downhole
 CT Parts at Surface -Contingency

CT parting
at surface
• Stop CT movement and stop pumping
• Monitor CT returns to confirm that the
check valves are holding pressure
• Attempt to spool as much CT back onto
the reel to avoid whiplash.
• Run excess CT through Gooseneck
• Set Injector and Reel Brake.
• Close Slip and Pipe Rams and lock
them manually Spool back CT
• Monitor WHP. Discuss contingency onto reel and
Excess CT thru
plans gooseneck
• If check valves are not holding pressure
, then use the shear/ seal rams to
cut/drop the CT.
• Kill the well and repair CT.
• Perform fishing operation
 Coiled Tubing Collapse-Contingency
When check valves are fitted a risk exist that the coil may be
exposed to high collapse loads like external pressure much
higher than internal pressure, which may exceed the collapse
pressure of the coil.

These possible collapse loads occur:

• During gas lifting operations where nitrogen is in the reel

and fluid is in the completion tubing, in particular, if the gas
pressure in the reel is bled off
• While running into a closed system like un-perforated casing
or liner.
• Steel displacement will cause an increase in pressure,
which must be bled off in a timely manner
• If pressure around the CT builds up rapidly when a flowing
well would be shut in, for operational reasons or during
pressure testing of BOP surface equipment
Coiled Tubing Collapse
 Failure of Check Valve
• If failure of a check valve is indicated and if it is possible to pull out of the well,
replace or repair the BPV. If it is not possible to pull out, the well should be killed.

• Once the string can be removed from the well the check valve must be repaired or
replaced.

Case History Coiled Tubing Rig Up

 Leak at Rotating Joint – Contingency

Procedure:

• Stop Injector Head and Service Reel

and set the brakes on both

• Close the reel isolation valve, Lo-

torque and manual valve inside reel

• Repair or replace the Rotating Joint

• Re-test and resume operation

Rotating
Swivel
 Coiled Tubing Runaway
The CT String can be ejected out of the well, if WHP is high enough to overcome CT
weight below the Stripper and Injector Chains lose their grip or Injector Motor spins
freely
• If the gripper blocks become fouled, or if there is too much weight and
momentum, the tubing may pull through the chains, even with hydraulic pressure
shut off and the motor’s brakes engaged.
• This is a runaway condition
• Steps that may be taken to slow and stop pipe movement: increase traction
pressure
• Make sure chains are running in same direction as pipe
• Increase stripper pressure to maximum and if necessary apply emergency
traction pressure
• Depending on company policy, applying reel brakes and/or closing slip rams
are options.
• However, it should be realized that these options may cause sudden failure
of the tubing.
• The gripper blocks should be cleaned, and skate pressure adjusted before
opening the slip rams.
• In both of the following cases the action to be taken will depend on the
severity of the situation.
• The quickest method, but not necessarily the most satisfactory, would be to close
the shear/seal rams.
CT Runaway and Bird’s Nesting
 THE END
and
THANK YOU