TODD PAULSON, Weatherford; and LEIGH MCDIARMID, Global Dynamics Inc.
Coiled tubing is a versatile and widely used technology in the oil and gas industry, often used for well intervention operations. This technology is used to clean out wellbore debris, such as sand, scale or paraffin, to restore or enhance production. It can deliver acid or chemicals directly into the well to stimulate production. Cameras and sensors for logging or real-time monitoring of conditions are deployed into the wellbore via coiled tubing. Also, if equipment gets stuck in the well, coiled tubing is often the first choice for operators to fish out the obstruction. At the end of a well’s lifecycle, coiled tubing is used to set plugs and safely plug and abandon a well.
Fig. 1. The SMART-LINK system revolutionizes coiled tubing operations by integrating advanced digital technology and real-time data analytics. The system provides unparalleled insight into well conditions, enhancing decision-making and optimizing performance. It streamlines the flow of information from downhole operations to the surface, effectively overcoming traditional limitations.
Yet, coiled-tubing operations are not without their limitations. Surface-monitored depth is often unreliable. Due to the tubing’s small diameter, there is a risk of sticking and buckling—especially in horizontal, highly deviated wells or in deep wells. Integrating downhole sensors and tools with coiled tubing can be more challenging, compared to conventional drillstrings, due to the continuous nature of coiled tubing. Not only this, but typical data transmission also relies on mud pulse telemetry, electromagnetic telemetry or wireless systems, which may have lower data rates and can be affected by wellbore and operational conditions.
However, there is a way to make coiled-tubing operations smarter, and this method can be used to increase efficiency, reduce costs and minimize risks in a package that integrates into existing coiled tubing procedures, operations and equipment, Fig. 1.
SMARTER INTERVENTION
With real-time data transmission and advanced telemetry methods, the SMART-LINK system delivers high-speed data transfer from downhole sensors directly to surface monitoring systems. This ensures that operators have the latest well condition and real-time operational parameters readily available. The system is equipped with advanced downhole sensors that measure critical parameters, such as pressure, temperature, torque, weight on bit (WOB), vibration and casing collar location (CCL), providing precise data to enhance operational efficiency and safety.
Powerful data analytics and visualization tools are integrated into the system to process and display the collected data, allowing operators to identify trends, predict outcomes and make informed decisions on the fly. Remote monitoring capabilities enable operators to oversee coiled tubing operations from anywhere, enhancing real-time responsiveness while reducing the need for on-site personnel.
The system's advanced sensors for shock and vibration, torque, non-magnetic CCL and weight-on-bit significantly mitigate the risks of sticking and buckling. These sensors also provide valuable insights to minimize tool damage. By leveraging the precise measurements from the system, operators can gather detailed feedback on their operations, thereby enhancing overall operational efficiency.
Additionally, the system enables precise fluid circulation and spotting by monitoring internal and external temperature and pressure conditions. The integrated, non-magnetic CCL ensures accurate bottomhole assembly (BHA) positioning and confirmation, further optimizing the performance and reliability of coiled-tubing operations.
SEAMLESS INTEGRATION
Fig. 2. The surface unit powers and communicates with the telemetry system, records received data and provides real-time monitoring through an intuitive user interface. The downhole connection includes the link to the coiled tubing reel, a slip ring for communication, a surface pack-off for well control, and a tubing-encapsulated cable that runs through the coiled tubing to the integrated cable head and telemetry.
The self-contained SMART-LINK system facilitates a smooth transition to digital operations without extensive overhauls, and it enables remote monitoring and overseeing of all coiled tubing operations from anywhere, enhancing real-time responsiveness while reducing the need for additional on-site personnel.
The system consists of three main components: the surface interface unit, the tubing encapsulated cable (TEC) and the bottomhole sensor assembly, Fig. 2.
The surface unit powers and communicates with the downhole telemetry system, records received data, and provides real-time monitoring through an intuitive user interface.
Installed below the coiled-tubing connector and compatible with ⅛-in, 4-mm or 4.8-mm connectors, the cablehead assembly secures the TEC and provides the electrical connection for downhole connections. These downhole tools are equipped with sensors to measure various downhole and toolstring properties and can interact with any conventional coiled tubing or wireline tools for a diverse range of applications, Fig. 3.
Fig. 3. The cablehead assembly easily connects to other components to meet specific needs. The sensor assembly reduces speed dependency and provides precise, real-time insights into critical parameters. The logging adapter expands the versatility of coiled tubing operations to include wireline tools. The cable protector converts the SMART-LINK cablehead to a mechanical connection that protects and seals the e-connector while allowing the passage of a standard size activation ball.
STREAMLINED ADAPTABILITY
The downhole cablehead assembly and pre-installed TEC provide the flexibility to deploy other components, such as logging and conventional coiled tubing tools, empowering operators to tailor the system to their unique operational requirements, as well as enhancing efficiency and effectiveness in any coiled tubing applications.
The sensor assembly provides precise, real-time insights into critical parameters, supporting more reliable and informed decision-making, while empowering professionals to respond more effectively, ultimately optimizing efficiency and safety.
Wireline tools can be added to any coiled tubing operation with the logging adapter. It performs critical functions, and with an industry-standard GO pin logging connection, the logging adapter allows for easy swapping to logging tools, without the need to rig-in a wireline unit.
The cable protector converts the SMART-LINK cablehead to a mechanical connection. It protects and seals the e-connector on the cablehead and keeps the TEC line anchored/sealed, allowing for the ability to again run standard coiled tubing. One of two drop ball sizes can pass through the SMART-LINK system for a hydraulically activated coiled tubing tool: a ⅞-in ball can pass through the 2 ⅞-in system, while the 2 ⅛-in system can pass a ⅝-in ball.
CASE HISTORY 1
During a drilling operation with a PDM mud motor and nitrogen, a Canadian operator received no surface indication that the motor had become stalled. Faced with operational downtime and project budget overruns, the operator reached out to Weatherford for a solution.
The objective was centered on creating a 98-ft (30-m) open-hole vertical extension in the exploratory formation. Key to the job’s success was maintaining a heavily underbalanced environment while drilling. Weatherford deployed the SMART-LINK weight-on-bit, vibration and torque sensors as a reference to optimize drilling. With that data, experts applied the exact weight on the bit necessary to create the most efficient rate of penetration (ROP) for the drilling string. The technology empowered the operator to know, in real time, if the motor stalled and to take immediate action to pull off the bottom and reset, before continuing to drill.
The operation used only one BHA in a single run, incurring no extra downhole tool costs and negligible nitrogen usage. The rig time savings of 12 hrs equated to $75,000.
The real-time data stream gave the operator enough time to proactively respond to motor condition, which enabled more robust operational planning and CAPEX allocation by utilizing data points previously unavailable.
CASE HISTORY 2
For an operator in Saudi Arabia, an inflow control device (ICD) was shifting without confirmation of the sleeves closing. For greater accuracy and efficiency, field personnel needed the precise location of the sleeve along with the signature that the sleeve is open or closed, per the well plan.
The SMART-LINK system provided the missing information needed to confirm when a selected ICD sleeve was engaged and closed with the coiled-tubing operation. The technology also identified the sleeve’s signature with the CCL sensor and then used the tension/compression (i.e., the WOB) sensor to actively monitor the signature of latching, sliding and closing the sleeves.
The real-time data stream delivered a verifiable result that each sleeve shifted as intended, removing the guesswork as to the status of each sleeve. The system eliminated the need for repeated confirmation runs on each sleeve, as well as the post-closing production logging tool run, increasing overall efficiency and saving approximately $150,000 in costs.
CASE HISTORY 3
In New Zealand, an operator needed six composite plugs removed from a producing well that had low-pressure zones, which required nitrogen to be used for milling. The challenge presented was the loss of downhole motor performance and the interruption of smooth production.
The advanced digital technology and real-time data analytics of the SMART-LINK system enabled the operator to know the instant that the motor started to increase its torque output and relative weight on bit. If the motor then proceeded to stall, there was no delay in cycling the coil up and off the plugs to reset the motor and getting it back down to continue milling operations. In addition, the operator could monitor a trend in motor performance that might indicate a replacement was required and take proactive actions, increasing overall efficiency.
By using the system, the operator completed the job in half the time: four days, versus the conventional eight. Combined with no extra downhole tool costs and minimum nitrogen usage, the operator saved over $200,000.
Coiled tubing is a vital component of efficient well intervention operations, but it is not without limitations. Conventional approaches to address issues like sticking in horizontal wells or lower data rates are constantly affected by wellbore and operational conditions. In these operations, the SMART-LINK system changes everything. It integrates into existing coiled tubing procedures, operations and equipment and makes them smarter. The system’s advanced digital technology and real-time data analytics provide unparalleled insight into well conditions, enhancing decision-making and optimizing performance to accelerate wells back to productivity.
TODD PAULSON is the global product manager for well services conveyance and digital products at Weatherford, where he leads strategic initiatives that bridge field-proven conveyance technologies with cutting-edge digital solutions. With over 16 years in the oil and gas service industry, Mr. Paulson brings deep technical expertise and a strong operational background to his role. Since joining Weatherford in 2015, he has held key leadership, technical and operational roles across the Middle East and the United States. Mr. Paulson is currently based in Houston, Texas.
LEIGH MCDIARMID is senior vice president for Calgary-based Global Dynamic Inc. He has over 12 years of operational, technical, management and sales experience across a range of well service applications, including well intervention, completions and coiled tubing. Mr. McDiarmid oversees Global Dynamics’ field operations and sales.
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