1 Coiled Tubing Interventions

Universidad Nacional - Facultad de Minas

Medellín
8-Nov-16

Instructor: Diego Londono

2 Agenda
 Introduction
 Surface Equipment
 Pressure Control Equipment
 Bottomhole Assembly Components
 Most common CT interventions

3 1. Introduction

4 1.1 Definition
 Coiled tubing is a continuous string of pipe made from steel, flexible enough to be coiled
onto a large reel

 Hydraulic equipment straight the tubing prior to being inserted and is recoiled for
spooling back onto the reel

 Diameter ranges from 0.75 to 4 in. A single reel tubing lengths in excess of 30,000 ft have
been manufactured

 Most common steels have Yield Strengths ranging from 55,000 psi to 120,000 psi
5 Continue
 Coiled Tubing unit is comprised of complete set of equipment necessary to perform
standard continuous-length tubing operations

 Unit consists of five basic elements:

– Reel: For storage and transport of the coiled tubing
– Injector Head: Provide the surface force to run and retrieve the CT
– Control Cabin: From where the operator monitors and controls the unit
– Power Pack: Generate hydraulic/pneumatic power required to operate
– Stripper/BOP: Control the wellbore pressure (PCE)
6

8 Continue

1
  Key benefits:

– Live well intervention: no need to kill the well - reduce damage to formation
– Ability to continuously circulate fluids while moving up or down (run-in hole / pull out of
hole)
– Reduced trip times (less production downtime)
– Cost may be significantly reduced if comparing with a workover rig
– Use on deviated and horizontal wells where wireline intervention is not possible
– Self-contained unit with rapid mobilization and rig-up
– Reduced crew/personnel requirements

9 Continue
 Most common applications:
– Chemical treatments (Stimulation)
– Well unloading (Nitrogen lifting / Kick off)
– Wellbore cleanouts (Fill removal)
– Milling and cutting
– Squeeze Cementing
– High Pressure jetting
– Fishing
– Well Logging
– Perforating
– Fracturing
– Completions
– Drilling
10

11 1.2 Main manufacturers and service providers

 Main equipment manufactures:
– Hydra Rig - Acquired by National Oilwell Varco (NOV)
– Halliburton - only service provider who manufacture their own CTU
– Stewart & Stevenson
 Main string manufacturers:
– Quality Tubing Inc (QTI) – Acquired by National Oilwell Varco (NOV)
– Tenaris – Before Precision Tube Technology
– Global Tubing
 Main service providers:
– Schlumberger
– Halliburton
– Baker Hughes
–
12 2. Surface Equipment

2
13 Introduction
 There are many different manufacturing companies and different equipment designs and
configurations

 The particular environment conditions and the primary application determine the most
appropriate Coiled Tubing Unit or ‘CTU’ design:
– Environment:
Off-shore: Skid mounted; Barge mounted (permanent) or Jacking barge or vessel
On-shore: Road trucks or Mobile mast units
Desert
Artic
– Primary application: CT Drilling / Frac requires larger equipment
14

15

16 2.1 Injector Head

 Provides the force and traction necessary to run and retrieve the string into and out of a
wellbore at a controlled speed
 Operates on friction drive principle: tubing is squeezed between opposing blocks with a
sufficient magnitude of applied normal force
 Resulting tangential friction force developed by squeezing action is higher than axial
tubing live loads
 Should also hold the string stationary in normal operating conditions and in case of a
failure in the system (dynamic braking system)
 Transition from stationary to in-hole and out-of-hole modes should be smooth and easily
controlled
17

18

19

20

21 Injector: Capability
 Maximum pull determines the operating capability of the unit

 Unit is usually named according to the pulling capacity in thousand of pounds of the
injector head

 Injector head pull capacity should be enough to handle the weight of the CT string plus:
– Effect of fluid density inside/outside the CT string
– Overpull (tension) to be applied at the BHA
– Effect of drag (friction) caused by the string or BHA

3
 Effect of drag (friction) caused by the string or BHA
– Friction or drag created by the stripper(s)
22

23 Injector: Examples

24 Injector: Range of use and application

25 2.2 Reel
 Large steel drum used to handle and storage the string

 Powered by a bi-directional hydraulic motor

 Fail-safe spring applied parking brake installed to prevent unintentional motion

 Can be powered in ‘in-hole’ or ‘out-hole’ ways: ‘Out-hole’ option should be selected at all
times

 Reel core diameter should be at least 30 times string diameter
26

27

28

29

30 2.3 Power Pack

 Diesel-hydraulic unit used to provide the power for the unit and PCE
 Encloses:
– Diesel engine
– Hydraulic fluid reservoir
– Hydraulic pumps and Pressure Control valves
– Air compressor
– Heat exchanger
– Accumulators
 Power Pack define CT unit configurations:
– Truck or trailer mounted using the truck engine
– Truck or trailer mounted with an independent engine
– Skid mounted with Control House and Power Pack incorporated
– Skid mounted with Control House separately from Power Pack
31 2.4 Control Cabin
 Contains all of the controls and instruments necessary to allow the operation to be run
from one control station

 Location may vary. However, is generally situated behind the CT reel, in line with the
wellhead/injector head

4
 Location may vary. However, is generally situated behind the CT reel, in line with the
wellhead/injector head

 For maximum visibility, is commonly elevated to allow the operator to monitor all
operations in progress

 The level of control and instrumentation fitted will greatly depend on the model, version
and manufacturer
32 Continue
 Main controlled variables:

– Injector direction/speed “in and out”
– Gripper beam pressure control
– Injector motor pressure control
– Stuffing box energizer pressure
– Reel direction “in and out”
– Reel motor pressure control
– Reel brake release valve
– BOP ram directional “open and close”
33 2.5 Tubing Guide
 Also ‘Gooseneck’, is attached to the top of the injector head to properly support,
straighten, and align the tubing from the Reel into the gripper chains of the injector
 Contoured rollers support and constrain the tubing to ensure it exits the tubing guide arch
concentric with the gripper chains
 Swivels in the horizontal plane to maintain orientation with the Reel and compensate for
fleet angle changes during the spooling
 Designed with a nominal radius of curvature (imaginary distance from the centerline of the
inner rollers) determines the amount of bending fatigue damage applied
34 Continue
 Minimum acceptable guide arch radius is 30 times the CT diameter (some companies use
minimum 48 times)
 Twice as many bending cycles occur at the Tubing Guide arch
 Recommended to use the largest practical radius of curvature

35 2.6 Depth counter
 String depth and speed is monitored at all times

 Two independent sensors are typically required:
– Electronic counter:
Friction-wheel-type between the injector chains and stripper
Considered the principal as it accounts for stretch (elongation caused by weight)
Signal is sent to the Data Acquisition System which calculates and display also the
string speed

5
 string speed
– Mechanical counter:
Installed above the Levelwind are also friction-wheel-type counters
It is considered a back up
Usually it displays large-sized digits (do not sent an analog signal)
36

37 2.7 Data Acquisition System

 Electronically display in the Control Cabin and record all pertinent variables. Estimate and
track performance of string
 Standard acquisition system handle:
– Speed and depth
– Weight
– Tubing (or Circulating) and Wellhead (or annulus) pressure
– Liquid flow rate and cumulative volume
– N2 Pressure, N2 flow rate and cumulative N2 pumped
– Percent life utilized and remaining
– CT string Yield limit calculation
 If a CT inspection device is used, additional parameters as Ovality, OD and Wallthickness
will be included in acquisition software
38

39 2.8 Support structures

 Track Stacks

 Jacking Frame and Substructure

 Lifting Frame
40

41

42 3. Pressure Control Equipment

43 3.1 Primary PCE (Stripper packer)

 A pressure-containing device designed to contain well bore pressure
 Upper tool in the Pressure Control Stack (flange mounted below injector) and primary
pressure control barrier
 Its purpose is to seal around Coiled Tubing in dynamic applications as string is run in and
pulled out
 The force to squeeze packer around string is applied hydraulically, and controlled and
monitored from Control Cabin
 Provides access for pressure sensing (WHP) and for application of inhibitor or lubricant if
required
44

6
45

46

47

48 3.2 Secondary PCE (Blowout Preventers)

 Secondary pressure control barrier to provides a means of holding the string and isolating
wellbore pressure during emergency, unusual and normal situations

 Should be as close as possible to the Production Tree or connection point provided to
access the wellbore to minimize connections below it (potential leaks)

 Configuration of rams and side-port facility allows well control operations to be conducted
under a variety of conditions
49

50

51 BOP: Killing port

 Pump line inlet port (killing port) between the Slip and Shear rams to pump killing fluid
inside CT string after shearing

– It should not be used to take returns from the well nor should be sealed off with plugs
or pressure gauges
–
– It has to be available for pumping during emergency
–
– Usually a pressure tested surface line from the pump to this point is included in
equipment rig up

52

53

54 3.3 Flow Tee or Flow Cross

 Designed as the primary outlet for production (if possible, flow should be taken off of
Production Tree)
 Must be rated for pressure and conditions present
 Two plug valves must be used on any flow tee/cross outlet
 High-pressure and H2S applications require valves flanged:
– Inner valve is used as a shut in device and can be equipped with either a hydraulic
actuator or a manual valve
– Outer valve is used to open and close the flowline for normal operations. It can be
manually or hydraulically controlled (when a minimum of one remote operated valve is
specified this should be the outer valve)

7
 specified this should be the outer valve)
55

56 3.4 Lubricators and Risers

 Lubricators are sections of tubing made up ABOVE the BOP to accommodate long
toolstrings above Swab valve
– Amount to use is then determined by the toolstring
– Positioned between BOP and stripper
– Connections are almost always flanged (although according to particular conditions,
quick unions could be used)

 Risers are section of tubing made up BELOW the BOPs or in BETWEEN separate sets of
BOPs
– Normally used for spacing out of PCE (where Production tree or connection point is
below the rig floor)
– Connections are always flanged
57

58 4. Bottomhole Assembly Components

59 4.1 Tubing End Connectors (TEC)

 Also CT Connector (CTC). Device to connect the bottomhole assembly to string end
providing a threaded connection

 Should be tested in tension (pull test) and in pressure (pressure test):
–
– Pull test: To ensure it will be able to withstand tension during job execution
It depend on connector type and job to be performed
Between 20,000 to 25,000 Lbs for Slip or Dimple type connectors
Between 10,000 to 15,000 Lbs for Roll-on type
–
– Pressure test: to verify that the fluid will be forced to pass through the downhole tool
assembly and not pressure/fluid will be lost
Particularity critical for downhole motor or a ventury junk basket
60 TEC: Roll-on connectors
 Installed internally in the string end (simple to install)
 A swaging, or crimping, tool is used to swage the tubing wall into rounded grooves on the
connector tip. O-rings provide the seal
 Inexpensive as they are most often built in local machine shops
 Main characteristics:
– Dimensions vary with tubing size and wall thickness
– To get hydraulic seal, the internal flash has to be removed before installation
– Can provide the same OD of the string:
Risk of pulling the string out of the stripper (even out of the injector) after completing
the job

8
 Recommended a bigger tool OD to note when stripper is tagged
61 Continue
– It will provide an ID restriction which should be considered when requested to drop balls
to active lower tools in the assembly.
– Have little or no torque carrying capability (not to use with downhole motors)
–
 The Crimping tool is used:
– To swage the Coiled Tubing onto the Roll-On Connector
– To manually cut the Coiled Tubing
62 TEC: Slip connectors
 They can be:
– External slip connectors:
Most used. Use wedge or slip collar arrangement to lock externally in CT string
They are made in two parts, the upper containing a bowl that forces the grapple onto
the outside of the coiled tubing
Single slip: some are threaded to string end for redundant load carrying features
Double slip: does not require threading to the coiled tubing
– Internal slip connectors:
Attach to the string internal diameter using tapered slips
Dimensions vary with the tubing size and also with the wall thickness
ID restriction to drop balls to active lower tools in the assembly
 Multi-slip are similar to double slip but use segmented slips instead of lock rings (large CT
in high tensile and/or high torque applications)
63

64 TEC: Dimple Connector

 No slips. Attached by setscrews that engage in preformed dimples
 Non-rotational highly recommended for tools that produce torque
 Makeup is more complex and takes slightly more time:
– Form the dimples with the dimpling tool
– CT end is prepared for O-ring seal by beveling off the end and smoothing the O-ring
seal area
– Connector is slipped up; setscrews installed and torqued up
 Applications, features, and benefits same as slip-type
 Used to connect nipples, packers, shear subs and other completion equipment to the
string (completion applications)
 Internal Dimple Connector: size specific to wall thickness
65

66 4.2 Double Flapper Check Valves

 Always run immediately below the TEC to provide a barrier to fluid/gas migration up the
string internal side

9
 string internal side

 For redundancy reasons, two flappers (double barrier concept): Double Flapper Check
Valve

 Minimum ID has to be large enough to let pass drop balls to tools below (activate the
hydraulic disconnect)
67 4.3 Hydraulic disconnect
 Run immediately below DFCV to provide a means to release in case the tools become
stuck
 Recommended anytime, especially if tools are larger
 If just nozzle, not mandatory: risk to get stuck on nozzle is minimum
 Requires dropping a ball to land on a seat:
– Set down weight on the toolstring
– Pump a ball down to the seat
– Pressure is applied until some pins shear
– A lug prop shifts downward
– A set of lugs retract from under a lip on the bottom sub
– Top portion of the disconnect, the tools above it and the string can be removed
 Lower sub has an internal fishing neck with a GS profile
68

69 4.4 Rupture disc

 Also “Burst disc” is run when there is a potential for plugging the string flow path:
impossible to circulate a ball to downhole tools
 Located immediately below tool that requires a drop ball (most critical: the Hydraulic
Disconnect)
 If the circulation is lost, a predetermined surface pressure applied to string will burst the
disc in the sub and re-establish circulation
 After bursting the disc, is no possible to seal it again so all circulation will take place for the
created port: it may cause a miss-run if inadvertently opening
 Best practice: run highest rated and confirm disk is new
70

71 4.5 Circulating valve

 Designed to allow circulation by using a drop ball

 Can be adjusted on surface by varying the number and type of shear pin used

 Pressure applied to the drop ball causes the pins to shear and the sleeve to move down
allowing circulation via the side ports

 Same as Rupture disc sub, once activated is no possible to seal it again so all circulation
will take place for the created port

10
 will take place for the created port
72

73 4.6 Motorhead Assembly (MHA)

 Developed in recognition of industry demands for compact, heavy duty, integrated BHA
components

 Consists of DFCV, Hydraulic Disconnect, Rupture Disc Sub and ball drop Circulating Sub

 May simply be made up of all the above tools threaded together, or may be a single tool
with all those features built into the tool

 Initially designed for Downhole Motors, now a days is a very common component because
its versatility

 Not strictly necessary if the correct tools are used
74

75 4.7 Jetting nozzle

 For both jetting and circulating operations inside the wellbore: Acidizing, Cleanouts and
N2 lifting
 They are the last tool in the bottomhole assembly so most of them have very rounded
termination
 A lot of designs with several jet nozzles in all sizes and directions according to the
particular use
76 4.8 Downhole Motor
 Downhole motors (DHM) or Positive Displacement Motors (PDM) are used to rotate mills
or bits to clean out an existing wellbore or for creating new borehole during CT Drilling
applications

 Operate by fluid passage through motor which requires a minimal differential pressure and
flow rate to effectively rotate the device

 Ideal procedure: to feed the CT precisely maintaining a relatively constant pressure
differential

 Best achieved by using pump pressure as main indicator rather than CT weight
77 Continue
 Increasing weight on bit demands more torque and thereby increases differential pressure

 Fluid is bypassed due to seal leakage causing the motor to slow down

 Eventually motor stops rotating (stalled) with all fluid being pumped passing the
rotor/stator seal

11
 rotor/stator seal


78 4.9 Jars
 To impart an upward or downward impact to retrieve stuck tools

 Overcome lack of Coiled Tubing tensile strength

 With the use of an accelerator, resulting jar force can be many times the force introduced
– 3:1 jar provides 3 times the force applied by tensioning the string

 Flow-through design allowing continuous circulation at all times
79

80

81 4.10 Accelerator
 Also intensifiers, are specifically designed for use with CT Hydraulic jars to form a heavy-
duty workstring

 Store the energy required to shear pins, shift sleeves, fish tools, and to pull or run plugs for
jobs in which high-impact forces are required

 They are above the Hydraulic jars

 They can be: Nitrogen filled, Fluid filled or Mechanical



82 5. Most common CT interventions

83 Agenda
5.1 Chemical treatments (Stimulation)
5.2 Well unloading (N2 lifting/Kick off)
5.3 Wellbore cleanouts (Fill removal)
5.4 Milling and cutting
5.5 Squeeze Cementing
84 Introduction
 Coiled Tubing is routinely used as cost-effective solution for numerous applications

 A key advantage of CT is the ability to continuously circulate through the string in a live
well

 Other key features:

12
 
– Inherent stiffness which allows access to highly deviated/horizontal wellbores
– Ability to apply significant tensile or compression forces downhole
– Much faster trip times as compared to jointed pipe operations
85 5.1 Chemical treatments (Stimulation)
 Overall objective is to restore, or even to increase, the natural permeability of the
formation to consequently improve well production

 This can be achieved in two different ways:
– By removing or dissolving material introduced into the formation during drilling,
completion or workover which reduce the formation permeability (skin damage)
– By dissolving the rock and/or formation minerals to increase the formation permeability

 Existing permeability is used to inject radially the acid in the near well bore region at a
pressure at least 10% below the fracture pressure
86 Continue
 Coiled Tubing advantages:
– Accurate placement of the acid with less contamination (vs bullheading)
– Avoids wellhead and completion tubulars exposure to corrosive fluids
– Treatment in live well reducing potential formation damage from killing
– Associated Nitrogen lift operation can be performed as part of the intervention.

 Coiled Tubing disadvantages:
– High friction pressures and low pump rates, which can extend the duration of large
volumes treatments beyond viable limits
– If no diversion technique is used, there is no guarantee that the stimulation fluid will go
into the desired interval, since the difference in permeability from the open intervals
would be the leading mechanism of wellbore fluid intake

87 Chem treatments: Matrix acidizing of Sandstones
 Overall goal is to select a fluid to dissolve clays and other damaging materials trapped in
the larger pores while leaving the sandstone matrix undisturbed, it means minimizing the
formation sensitivity which is critical for the job success

 Desired result is a skin effect reduction but possibly not restoration of the natural
permeability of the formation

 Sensitivity is related to chemical (precipitates during chemical reactions) and also
mechanical problems (fines migration / matrix deconsolidation) and it depends on the
mineralogy, damage type, reaction products, temperature and permeability
88 Chem treatments: Matrix acidizing of Carbonates
 The overall process of carbonates acidizing is significantly different than in sandstones

13
 The overall process of carbonates acidizing is significantly different than in sandstones
formation because the damage is not dissolved but by-passed

 In matrix acidizing of Carbonates, there are two processes used to by-pass the damage
and therefore to decrease the skin factor:
– Create new, highly conductive flow channels (wormholes)
– Enlarging natural fractures or fissures (etching)

 Carbonates are highly soluble in Hydrochloric (HCl) making this the most common acid
used in carbonate acidizing
89 Chem treatments: Diversion
 Diversion technique to improve the treating fluid placement into the desired intervals (less
producing intervals), is critical to the success
 Without any method, injected fluids tend to follow the path of least resistance, then most
of the acid will enter most permeable streaks, large pores, or first treated leaving parts un-
stimulated
 To be effective, diversion effect should be temporary to enable full productivity to be
restored when the treatment is complete
 Same apply for preflushes and overflushes especially in sandstones
 Two types: Mechanical and Chemical

90 Continue
 Mechanical diverter techniques:
–
– Used to mechanically confine and force the treatment into the desired interval by the
use of a thru-tubing inflatable packer or inflatable straddle packers
– When feasible, they provide better chance of success under the right conditions but in
the other hand also increase the treatment time and cost
– They are often ineffective for stimulation projects in long horizontal or extended-reach
wells
– Their use is strictly limited to the cement quality in the interval to be treated
If there is not good quality of cement, its use is not recommended at all because
inevitably the fluid pumped will travel to the most permeable zones through the
annulus casing/formation
91

92 Chem treatments: Surface equipment and BHA

 Additional equipment requirements are:
– Suitable pump unit for corrosive fluids
– Acid transports
– Coiled Tubing filter in surface pumping line
– Adjustable chock manifold to handle flowback returns
– Flowback/spent fluid return frac tanks
– Well test separator if production test to be done before and/or after the stimulation

14
 Well test separator if production test to be done before and/or after the stimulation
 Typical bottomhole assembly
– Tubing End Connector
– Double Flapper Check Valve
– Radial nozzle
93 Chem treatments: Other acid uses through Coiled Tubing
 Tubing Acid Wash:
–
– Acid is used to remove acid soluble scales and corrosion products from wellbore
tubulars and to open perforations that have been blocked by acid soluble precipitates
– Acid is only spotted at the desired depth in the wellbore (not injected into the formation
matrix) and allowed to react before flow back
–
 Tubing Pickling:
–
– To remove any pipe dope (in new wells) or solid materials which adhere to pipe walls of
the Production Tubing
– If not removed they have potential to cause plugging of perforations
94 5.2 Well unloading (N2 lifting or Kick Off)
 To regain production whenever a fluid column is present in the wellbore: after a
stimulation job, when the well has been previously killed or when an exploratory well is
going to be tested

 Displacement of certain amount of fluids to create special conditions before perforating
new wells

 Reduces the hydrostatic head allowing the reservoir to flow again

 If the conditions are suitable (pressure, fluid phase mixture and flow rate), production will
continue after Nitrogen pumping ceases
95 Continue
 Most efficient when gas is mixed with the wellbore fluid at a concentration of 500 scf/Bbl
(rule of thumb when no software run)

 Rate of penetration in the fluid can be calculated:



96 N2 lifting: Optimum injection point

 If Nitrogen is injected below perforations, it may leak off to the zone rather than gas-lift
the fluid in the wellbore

 Optimum injection point may be above perforations or at the heel of a horizontal well

15
 Important
Check wellbore integrity for maximum evacuation depth

 If a specific amount of fluid is to be removed (TCP) and because gas lift has fluid “fallback”,
injection point must run around 10-20% deeper into the fluid to compensate
97

98 5.3 Wellbore cleanouts

 Very common CT applications to remove an accumulation of solid particles in the wellbore
 Main objective: to restore fluid flow and well productivity
 Most common materials are reservoir sand or fines, fracturing sand or proppant and
cuttings or metal fragments from previous jobs
 Typical procedure is to circulate a fluid through the string while slowly penetrating the fill
with a jetting nozzle
 The fill material will be transported in the circulating fluid out of the wellbore through the
CT/Production Tubing annulus
 With very consolidated fill, a downhole motor and bit may be required
99

100 Cleanouts: Annular velocity

 Critical in determining whether solids can be lifted out of the wellbore
 In vertical and near vertical wells (up to 30°), has to exceeds the Terminal Particle Settling
Velocity (TPSV): rate that a given particle will fall through a fluid due to the effects of
gravity
 If sufficient annular velocity not available, the cleaning fluid must be designed with
suspension capabilities as the TPSV is directly dependent upon the fluid density and
viscosity
 Is effective only where the fluid drag on the particle can overcome the effects of gravity:
– In vertical wellbores, should be at least twice the TPSV
– In horizontal or deviated wellbores, should be as high as 10 times the TPSV
101 Continue
 To calculated Annular Velocity the following formula maybe used – pay attention to the
units:



– A rule of thumb used on the field is to have minimum 60 ft/min
– 100 ft/min will be sufficient to easily lift most solids up the wellbore

 Optimum approach is to use a computer model to design the job (it will internally calculate
the TPSV) or at least to calculate the value from available charts in the literature
102 Continue
 Important: Changes in wellbore tubulars internal diameter creates points of velocity

16
 Important: Changes in wellbore tubulars internal diameter creates points of velocity
variations, turbulence and separation which may jeopardize the lifting of the particles







 Same effect would be caused by flow rate changes or sudden loss of rate (plugging)
103 Cleanouts: Hydrostatic of cleaning fluid
 Main factor in determining the fluid to use: any overbalance will cause fluid to enter the
formation and decrease the annular velocity
 Need to calculate the maximum amount of material that can be added to the column of
fluid and still remain in a balanced condition
 Kill fluid weight minus the weight of the cleaning fluid, will give the maximum amount of
material that can be added to the system while remaining balanced
 Job may require to be executed in stages, it means to circulate one stage out of the
wellbore before removing more fill

104 Cleanouts: Travel velocity

 The travel velocity as the string moves inside the column of fill, in a constant flow rate,
determine the concentration of solids transported within the returning fluid

 Hydrostatic pressure differential will increase between the “clean” fluid pumped and the
“dirty” fluid circulated up the annulus

 If the Coiled Tubing is run in to fast:
– Increased hydrostatic pressure of the “dirty” annular fluid may cause the wash fluid to be
forced into the formation
– Annular velocity could be reduced to a point below the TPSV and the solids would fall
back, possibly sticking the string downhole
105 Continue
 To calculate the Travel velocity:



 Fluid Factor is the amount of sand that can be transported per each gallon of fluid coming
out of the CT nozzle:
– Best: Lab test fluid before the job to find its carrying capacity
– If not, typical values used in the field are:
1 Lb/gal for pure water or brines
Between 2 to 3 Lb/gal for gels

17
 Between 2 to 3 Lb/gal for gels
Between 4 and 5 Lb/gal for foams
106

107 Cleanouts: Using foams

 Formed by combining Nitrogen gas, base fluid and a foaming agent
 Base fluid can have a water or oil base
 Main advantage: foam has low density and high viscosity, which contribute to a fluid with
excellent carrying properties
 Higher viscosity foams can be generated by foaming a gelled base fluid using surfactants
 Two factors influence the properties:
– The base fluid
– The proportion of gas in the liquid (Foam Quality)
108

109 Cleanouts: Reverse Circulation

 Alternative fill removal approach: pumping down the CT/Production Tubing annulus and
take returns through the CT string

 Useful for removing large quantities of fills (fracturing proppant) or when is not possible to
get high annular velocities (bigger casings)

 Only performed on wells that have been completely killed and where there is no circulation
of gas and oil

 A special risk assessment has to be done as the CT string has to be run in hole open ended
with no Flapper Check Valves
110 Continue
 Most frequently used after a fracturing job where the well is dead and proppant has been
left in the wellbore, considerably above the top of perforations

 To prevent fluid losses into the perforations and to minimize the chance of a gas bubble
entering into the CT string, reverse sand clean outs are not conducted beyond 100 ft
above top of perforations or laterals

111 5.4 Milling and cutting
 Milling and cutting are Coiled Tubing applications where mechanical removal of hard
material is performed through the use of specialized rotational tools

 Downhole motors is used to rotate a Bit, Mill, Rotary Shoe Or Underramer.

112 Milling and cutting: Downhole Motors
 Also described as Positive Displacement Motors (PDM) are used where rotational services
are required during milling and cutting

18
 Also described as Positive Displacement Motors (PDM) are used where rotational services
are required during milling and cutting

 Used with Bits, Mills, Rotary Shoes or Underreamers when:
– Cleaning scale, fillings or junk
– Removing obstructions or restrictions
– Dressing off tools that cannot be fished easily
– Removing tools designed to be milled out as Composite plugs

 Operate by the fluid passage which requires a minimal differential pressure and flow rate
to effectively rotate the device
113 Continue
 Ideal procedure: feed CT at constant pressure differential; best achieved by using pressure
as main indicator rather than weight

 Increasing weight on bit demands more torque and increases differential pressure:
– Fluid is bypassed due to seal leakage causing motor slow down
– Eventually motor stops rotating (stalled): all fluid bypassing rotor/stator seal
– High pressure can be observed at surface

 Selecting appropriate one is crucial to get higher rates of penetration, extended run times,
reduced milling times, less wear on milling and cutting tools, and increased reliability in
high-stress applications
114

115 Continue
 According to driving mechanism, there are two main types:

– Stator/Rotor type:
Conventional type (most common) which incorporates a rubber Stator bonded to the
inside of the housing and a metal Rotor
When fluid is pumped, the Rotor spins in the Stator
Not suitable for use with hydrocarbon-based solvents and limited T (~300ºF)

– Vane type:
Usually shorter, use a vane design with a stainless steel Stator (no elastomers)
Allow them to operate at higher temperatures (500ºF)
Can be powered by hydrocarbon-based solvents, acids, and gases







19
116

117 Continue
 From Stator/Rotor type, two different motor designs
–
– Conventional stator tube:
Uniform O.D. / I.D. tube with varying rubber thickness
–
– Equidistant stator tube:
Lobes are pre-machined in tube (equidistant rubber)
Rubber content significantly reduced
More torque at the bit/mill
Longer life span and higher max temperature capabilities
118

119 Continue
 DHM stalls: sudden Pressure increment because mill rotation stopped as mill could not
clear obstruction fast enough to rotate free

 To eliminate potential for tool backoff caused by reactive torque (accidental connection
release) you HAVE TO:
– Shut down the pumps
– Let the pressure bleed
– Picking up off bottom

 After picking up from the stall depth, the operation can resume by pumping and run in
hole to the milling depth
120

121

122 Milling and cutting: Mill designs

 A Mill is a very simple type of Bit with a drag type cutting structure and no moving parts
 Are generally used when full ID of tubular needs to be cleaned
 Applications include milling tight spots, cement, tubing, packers, bridge plugs and other
debris
 Mills are manufactured in various shapes and designs
 The mill design, size of inserts and water course dimensions vary greatly among vendors

123 Continue
 Most common types:
–
– Blade Type Mill (Junk Mill):

20
 Blade Type Mill (Junk Mill):
Can be used for junk or cast iron material which will break up.
Concave, convex and flat-bottom designs available

– Flat Bottom Mill:
Very aggressive mill used to mill drillable packers, bridge plugs, retainers, and cement
Sturdy enough for light spudding on the junk to break it up into smaller pieces
Large circulation ports improve fluid circulation for cooling and for cuttings removal
These long lasting mills are safer than using a rock bit because you can’t lose any bit
cones in the hole
124 Continue
– Tapered Mills
Designed for milling through restrictions
Spiral blades and pointed nose make them ideal for reaming collapsed casing and
liners, cleaning permanent whipstock windows, milling through jagged or split guide
shies, and enlarging restrictions through retainers and adapters
Torque encountered governs rotary speeds

– Watermelon/String Mills:
To enable reaming both up and down in collapsed casing and liners
Lower connection enables a stinger to be run below the tool to prevent sidetracking
Mill can also be placed anywhere in a drill or fishing string

125

126 Milling and cutting: Rotary Shoes

 Hollow cylindrical mill used where only material between piece being washedover and ID
of casing/formation needs to be removed
 For stuck CT or tubing, is used to mill away formation, scale or sand, around the fish
 Also used to mill away slips to release packers and bridge plugs
 In cased hole, tool OD must be smooth to minimize damage
 Same as with mills, it is recommended to run jars and drill collars to help prevent toolstring
sticking
 Several design categorized in three main types: Flat Bottom, Scalloped and Tooth type
127

128 Milling and cutting: Underreamers

 Designed to pass through the Production Tubing, open up below and clean the hole to full
gauge, and close up again to be retrieved
 Blades should open to drift a diameter approx less than Liner ID
 Common application is cement removal from squeeze operations
 It is also used to:
– Remove scale sheaths from the Liner
– Hard fill that cannot be removed by jetting with a CT nozzle, or cement caps that were

21
 Hard fill that cannot be removed by jetting with a CT nozzle, or cement caps that were
intentionally placed on top of sandbacks
 Underreamers may also be used to cut Production Tubing
129

130 5.5 Squeeze Cementing

 Forcing cement slurry through perforations or holes against the formation so that the
solids particles filter out on the formation face while the fluid (filtrate) enters the formation
matrix

 The resulting immovable cement filter cake will form an impermeable barrier (node) with
sufficient compressive strength to withstand the differential pressure during production or
injection

 Good quality nodes are created by gradual pressure increments

 Remaining unset cement is circulated out, therefore subsequent drilling or underreaming
operations are avoided

131

132 Continue
 Most often performed to:
– Isolate water or gas channeling or coning
– Isolate injection water or gas breakthrough
– Isolate unwanted or depleted perforated intervals
– Repair a poor primary cement job before well completion
– Repair leaks in well tubulars and restore wellbore integrity

 Advantages over conventional workover rig:
– Associated operations can also be performed (fill removal, acid wash, sand back or N2
lifting)
– Low treatment volumes are required
– Slurry contamination with wellbore and displacement fluids is minimized
– Wellbore cleaning of excess slurry is easily performed

133 Squeeze Cementing: Slurry Design
 Information required to design the particular slurry properties are:
–
– Temperatures: the most important variable affecting hydration
– Pressure: lesser effect on cement hydration but a significant effect on fluid loss
– Mixing equipment and procedure: mixing time can substantially affect the thickening
time
– Expected pump-rate range: time required for pumping the slurry down the CT,
determines the rate of slurry heating which affects the thickening time

22
 Expected pump-rate range: time required for pumping the slurry down the CT,
determines the rate of slurry heating which affects the thickening time
– Estimated job time: include the time required for cleanout of excess cement
134 Continue
 a) Density

– Greatly influence the pressure applied downhole (attention: formation frac P)
–
– Direct relationship with the compressive-strength. A well formed filter cake may reach a
good compressive strength - density not a critical factor
–
– Also affects the filter cake development
–
– For critical situations, should not be more than ± 0.5 ppg of designed value
135 Continue
 b) Thickening Time

– Measure of how long a cement slurry remains pumpable
– Measure of the initial gelling tendency expressed in Bearden units (Bc)
– Do not confuse it with Compressive Strength
– Adequate Thickening Time control is required to safely meet the anticipated job time
(plus a safety factor)
– API considers 70 or 100 Bc as the practical limit but 40 to 70 Bc are typically used (over
~40 Bc a fluid is considered unpumpable for CT)
– Mixing energy has great influence over Thickening Time, so the tests should model the
job as close as possible to expected pumping profile in T and P
– Because of low rates and therefore rapid T increase, test uses BHST whereas API uses
BHCT
136 Continue
– Test result is a chart of Consistency, T and P over time
–
– In the ideal profile
Consistency decreases during the first part because of thermal thinning
It should remain fairly constant afterward until the cement starts to hydrate where
increase rapidly
–
– There are cases where the consistency increases steadily over a longer period which is
less desirable for frictional pressure drop
–
– Slurry design has to be changed if:
Slow consistency increases
Consistency increases but remains flat at an elevated level
Unexplained viscosity spike

23
137

138 Continue
 c) Fluid Loss and Filter Cake

– Fluid Loss additives are used to reduce amount of fluid removed from slurry under
pressure (required to ensure creation of a good quality Filter Cake)
– API Fluid Loss test is used for determining fluid removed after 30 min with a known filter
medium under 1,000 psi differential P at expected T
– Filter medium is a 325-mesh, stainless-steel screen with an effective permeability of >1
darcy and an overall filtration area of 3.5 in2
– Filter Cake thickness or volume, is also of interest:
Little Filter Cake not desired: most will be removed while cleaning excess cement
– Slurry remaining in the test cell is also of interest (likely condition of excess slurry to be
removed): it should be in a liquid state without gelation tendencies
139 Continue
– High fluid-loss:
–
Uncontrolled fluid loss can result in rapid buildup of a thick, relatively permeable
Filter Cake capable of prematurely bridging inside the casing with loss of pressure
transmission and insufficient contact of the cement Filter Cake with the formation

Perforations will not sustain the differential pressure as they were never squeezed

Slurries with high fluid-loss are best suited for low K formations: with a high K, the
slurry will dehydrates rapidly and channels would be bridged off

Some fluid must remain with the slurry for the correct hydration reactions to occur
140 Continue
– Ideal fluid-loss:
Slurries control the rate of cake growth (and fluid loss), and allow a uniform filter cake
leaving only a small node of cement Filter Cake inside the casing
Ideal slurry should show a filter cake within a range of 0.5 to 1.0 in equivalent to a Fluid
Loss between 40 to 100 cc/30 min API
This one measure will aid in controlling the dehydration and premature setting of
cement
–
– Low fluid-loss:
Slurries with low fluid loss can result in an insufficient Filter Cake buildup on the
formation surface
Slurries with low fluid-loss are best suited for squeezing high permeability formations:
with a low permeability formation, dehydrate slowly and tend not to bridge as they
are forced along openings or channels, and the duration of the operations may be

24
 are forced along openings or channels, and the duration of the operations may be
excessive
141

142 Continue
 d) Rheology
– Cement slurries have high viscosity and friction through CT is a real concern
– Lowest rheology possible would be the easiest choice but slurry stability is sacrificed (a
stable slurry have no settled solids and no free water)
– Ideal balance: rheology as low as possible without sacrificing slurry stability
– Most cement slurries behave as a Bingham plastic: the Apparent Viscosity (centipoise or
cP) is dependent on the Yield Point and Plastic Viscosity cannot be significantly
influenced by additives
Yield Point: measure of the attractive forces between the solid particles suspended in
the fluid; force required to initiate flow – measures the forces that cause the
development of gel structure
Plastic Viscosity: measurement of the resistance to flow caused by the friction
between the suspended particles and the liquid phase
143

144 Continue
– Yield Point, and therefore Viscosity, can be altered by adding dispersants:
If too much dispersants are used, slurry will not be stable and settling of cement
solids will occur
–
– The optimum rheological values for CT squeeze slurries are:
Minimum possible Yield Point: 5 to 10 Lbf/100 ft2 ideal
Minimum possible Plastic Viscosity: less than 50 cp ideal (max 80 cp for low CP)

– Rheological properties are measured on a rotational viscometer at atmospheric
conditions. Even with these T and P limitations, useful data can be gathered for
characterizing slurry properties
–
– Some equipment can measure the rheology at downhole T and elevated P
145 Continue
 e) Free Water and Settling

– Slurry must show a consistent performance and prevent downhole separation during
extended static periods
If a cement slurry is left and water separation occurs, it is not stable and this can
create problems with Thickening Time, Strength and other properties compromising
the success of the isolation
Free Water test measures such separation tendency
– Another factor also indicating slurry instability, is the solids settling which can produce a
change in slurry Density

25
 change in slurry Density
Smaller particles at the top of the slurry can remain in suspension for longer and
therefore Free Water may not be observed, howeverer the slurry is unstable
– Free Water must be ZERO for cement slurry
146 Continue
 f) Compatibility

– When fluids are mixed without observing any undesirable chemical or physical reactions,
they are compatible
– During cementing fluid incompatibility can produce gelation, fluid separation, and
sedimentation problems
– Spacers minimize the slurry contamination during job execution and when required, the
washes clean and remove the drilling fluid
– Compatibility between the fluids is basically determined by comparing the Fann
readings of mixtures at different rations
When compatible, the mixtures have equal sets of Fann readings of the base fluid
Incompatibility is evident by mixture readings considerably higher than the base Fann
readings
147 Continue
 g) Compressive Strength

– Amount of compressive load that cement withstands before failure
– For most slurries, a compressive strength of at least 500 psi is sufficient and it is desirable
to obtain around 1,000 psi at 12 hr
– Under most conditions, the compressive strength of the final, fully set filter cake is two
to five times greater than the value for the original slurry
– Apart from the compression uniaxial test, API approved the use of the ultrasonic cement
analyzer (UCA) to measure the compressive strength:
UCA offers the advantage of a continuous measure of compressive strength vs. time
determined from correlations involving sonic transit time
CT cementing is normally associated with minimal wellbore cooling, so compressive
strength tests at BHST, or at 90% of BHST, is acceptable
148 Continue
 h) Gel Strength

– A measure of the ability of the slurry to develop and retain a gel form, based on its
resistance to shear
– Uncontrolled gel strength can be detrimental for the job if the slurry is allowed to
become static
– Gel strength (measured in lb/100 ft2) should remain relatively flat for an acceptable time
if the slurry becomes static
– Slurry gel strength can be measured reliably with the rotational viscometer for obtaining
initial and 10 minute data at atmospheric pressure up to about 180°F
– There is equipment to measure gel-strength under elevated temperature and pressure
conditions (450°F and 20,000 psi)

26
 conditions (450°F and 20,000 psi)
149 Squeeze Cementing: Cement placement techniques
 a) Hesitation squeeze

– Dehydration of cement through intermittent application of pressure separated by
pressure leakoff intervals where filtration loss and penetration takes place
– Process is repeated until a pre-determined max P is achieved, the desired volume of
slurry has been pumped or there is no more slurry left
– Initial leakoff is normally fast (no filter cake) but as the cake builds up and the applied P
increases, filtration periods become longer and higher and higher squeeze pressures are
achieved
– Slurry design and testing is more complex compared to a Running squeeze and fluid
loss additives are required
– Normally slurries has tight fluid loss control (<50 ml)

150

151 Continue
– Final squeeze pressure can be:
Above Fracture Gradient: Usually 500 to 1,500 psi above. Filter cake prevents
formation from fracturing. Max P is dictated by equipment pressure limitation
Below Fracture Gradient: Objective is to fill the perforation cavities with dehydrated
cement so volume is usually small (no slurry pumped into the formation). Max
squeeze P 300 to 500 psi below fracture P until slurry dehydration is complete
– Low squeeze P:
May cause not properly formed cement nodes with a fragile filter cake that will not
withstand differential pressure
– High squeeze P:
Ensure nodes are competent (better capability to resist differential P)
All perforations have opened and accepted slurry
However, excessive P applied too early can fracture the formation or cause
communication with naturally occurring fractures
152 Continue - Cement placement techniques
 b) Running Squeeze
–
– The cement slurry is pumped continuously until the final desired squeeze pressure
(which may be above or below the fracture pressure) is achieved
–
– After pumping stops, the pressure is monitored and, if the pressure falls due to
additional filtration, more slurry is pumped to maintain the final squeeze pressure until
the well maintains the squeeze pressure for several minutes without injection
153

27
154 Continue
– Slurry design is less critical and can often be done without fluids loss control. It can also
be designed for a shorter Thickening Time (if no risk is taken)
–
– Cement volume and pump rate can be very high if injection is high, or very low (0.25 to
0.5 bpm) if performing a Low Pressure Squeeze into a tight zone
–
– Commonly the pump rate is reduced as the filter-cake and pressure builds
–
– When squeeze pressure is not achieved in a running squeeze, it can be repeated several
times allowing cement to set in the formation between stages
–
– If the pressure does not build and hold as required, a Hesitation squeeze technique may
be used to attempt to get target squeeze pressure
155 Squeeze Cementing: Job execution procedure
1. Kill the well by bullheading
2. Fill wellbore and perform Injection Test (also dynamic losses):
– If rate/P between recommended values, continue with step 3
– If P too high, considered clean perforations to achieve enough Injectivity
– If P too low or not positive pressure (well on vacuum), need to reduce losses:
Evaluate static losses by filling wellbore, wait 1 hr and fill wellbore again to 20 psi
Design Lost Control Material (LCM) job according to static losses observed
Run the Coiled Tubing with Nozzle (no check valves to allow reverse circulation)
Execute Lost control Material treatment
Repeat Injection Test. If losses still too high, continue using LCM
Once losses controlled, perform final Injection Test thru both CT and CT/Tubing
annulus
156 Continue
3. Estimate cement slurry volume as per injection test final values
4. Run CT to 10 ft above bottom or isolation barrier
5. Pick up to check weights simulating job execution for at least 150 ft
6. Park CT 10 ft above bottom or isolation barrier
7. Pump through CT and establish direct circulation with returns open
Note: mandatory to have returns: If no returns observed, perform LCM job to reduce
injectivity
8. Mix cement slurry (take into consideration the mixer dead volume)
9. Fill wellbore through CT and again establish direct circulation
157 Continue
10. Pump spacers (if apply), Cement slurry and overflush as designed
– Choke well back (~500 psi) at all times to minimize free falling effect (U-Tube)
– Must guarantee a positive CP while pumping cement (~500 psi)

28
 Must guarantee a positive CP while pumping cement (~500 psi)
– Increase rate as required to avoid free falling of the slurry
11. Once Cement Slurry out of CT nozzle, pick up at predetermined velocity so that the
nozzle remains around 10 ft below the top of the cement (TOC) to minimize
contamination
– Before the job, calculate CT velocity vs. pumping rate for different rate values
– Evaluate returns at all time
12. As the last of the cement volume exits the CT, accelerate the CT pick up velocity to
place the end of the CT nozzle at least 100 ft above the planned TOC
158 Continue
13. Stop pumping and close returns
14. Fill the wellbore for both CT and CT/Tubing annulus to determine volume of cement
slurry already injected into the formation because of hydrostatic column effect
15. Calculate the “Total Slurry Available” volume as follows:

Total Slurry Available = Total Slurry – Slurry across perfs – Slurry into formation

Example:
Total Slurry Available = 25 Bbl – 8 Bbl – 3 Bbl
= 14 Bbl (Volume A)
159 Continue
16. Determine the “Hesitation Volume” – reserved for the last part if Hesitation is required

Hesitation Volume (reserved) = 4 Bbl (Volume B)


17. Calculate the “Effective Slurry Volume” volume as follows:

Effective Slurry Volume = Total Slurry Available – Hesitation volume

= 14 Bbl – 4 Bbl
= 10 Bbl (Volume C)
160

161 Continue
18. Begin the Cement Squeeze into formation via Coiled Tubing using the Running Squeeze
technique.

Possible scenarios:
–
– Case 1. Pressure increase continuously till squeeze pressure: If Squeeze Pressure is
achieved before pumping the volume C, do not continue forcing cement slurry into
formation. Stop pump and maintain the Squeeze Pressure
–
– Case 2. Pressure increasing continuously to around 2/3 of Squeeze Pressure with 70-80%
of the volume C already squeezed into formation: Continue pumping till complete the

29
 of the volume C already squeezed into formation: Continue pumping till complete the
volume A (including the Hesitation volume B) aiming to achieve the target Squeeze
Pressure
162 Continue
– Case 3. Pressure tendency is not to increase: If after pumping continuously the volume C,
the pressure tendency is not increasing, switch to the Hesitation method with the
“Hesitation volume”
–
– Case 4. Pressure not increasing after Hesitation method: If after pumping continuously
the volume A, the pressure tendency is not increasing, over displace cement slurry into
formation. Perform injection test again, use LCM as necessary and repeat the squeeze
job procedure

19. Monitor at all times the volume of cement squeezed into formation to calculate the most
probable Theoretical Top of Cement.
– Take into consideration that because the ballooning effect, not all the pressure observed
represents that all cement was effectively squeezed into formation
20. Proceed with Clean out of excess cement
163

164

165

166

167 Squeeze Cementing: Cleaning out of excess cement

 In traditional squeeze cementing, cement is left static for hydration; excess slurry above the
treatment zone is removed and after Wait on Cement (WOC), set cement is drilled out
 During the nodal buildup technique, washing of all remaining cement is done before
hydration

Some experienced engineers suggest that traditional technique is more reliable for producing
wells as squeeze will be forced to negative differential P during normal conditions
Not the case for injection wells where both techniques should be able to provide a good seal
(positive differential P scenario)
168 Continue
 Methods to clean out the excess cement:

– Reverse circulation of contaminated cement: Cement is contaminated and circulated out
in reverse mode. Scenarios with poor annular hydraulics, minimizes hydraulic agitation
across perforations and avoid to expose downhole equipment. May expose the cement
nodes to higher pressure

– Direct circulation of contaminated cement: When reverse is not an option (small CT),
cement is contaminated and circulated up the annulus

30
 cement is contaminated and circulated up the annulus

– Reverse circulation of live cement: Can be safely performed when slurry designed with
enough Thickening Time (including safety factor)

169 Continue
 Contamination: contaminating and diluting unset cement and increasing hydration time
(Thickening Time) - chemical retarding
 Main advantage of the nodal buildup technique as it minimizes operational time
 Biopolymer gels are commonly used in a 1.5:1 volume dilution ratio
 Exposed cement nodules will also become contaminated and therefore a substantially
longer period of time to achieve the desired compressive strength is required
 Accelerator solutions (completion brines or salts) may be spotted after all cement slurry is
safely out of the wellbore to help offset the weakening of the cement node
170 Continue
 Traditional squeeze cementing technique procedure:

– After completing squeeze, perform a Reverse circulation of live cement slurry above the
treatment zone maintaining a positive Squeeze Pressure at all times
– Pull out of hole Coiled Tubing pumping at low rate to keep the Squeeze Pressure at all
times
– Wait on cement as recommended in cement slurry design maintaining the Squeeze
Pressure
– Make up CT milling assembly
– Run in hole and mill out the set-up cement
171 Continue
 Nodal buildup technique procedure:
– After completing the squeeze and maintaining the Squeeze Pressure at all times,
circulate the contaminating fluid (high polymer load) to the nozzle
– Run in the hole from the expected TOC while jetting at the maximum rate
Use 1.5:1 volume dilution of contamination fluid to cement slurry (1:1 also may be used
as per experience)
Reduce rate in front of perforations to minimize nodes damage
– Circulate out the contaminated cement either in Direct or Reverse mode until clean
returns (in Reverse mode, pick up above the contaminated column)
– If necessary, repeat the process with a lower polymer loading solution
– Circulate an accelerator solution (if required) while pulling out of the hole
– If cleanout was done in direct circulation, switch to slick water (clean water with a friction
reducer), and pull out of the hole washing all downhole equipment

172

31