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SPE 54327

Development of a Wireless Coiled Tubing Collar Locator


Michael L. Connell, Robert G. Howard, and Darrell W. Moore, Halliburton Energy Services, Inc.

Copyright 1999, Society of Petroleum Engineers, Inc.


This paper was prepared for presentation at the 1999 SPE/ICoTA Coiled Tubing Roundtable
held in Houston, May 25-26.
This paper was selected for presentation by an SPE Program Committee following review of
information contained in an abstract submitted by the author(s). Contents of the paper, as
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to
correction by the author(s). The material, as presented, does not necessarily reflect any
position of the Society of Petroleum Engineers, its officers, or members. Papers presented at
SPE meetings are subject to publication review by Editorial Committees of the Society of
Petroleum Engineers. Permission to copy is restricted to an abstract of not more than 300
words. Illustrations may not be copied. The abstract should contain conspicuous acknowledgment of where and by whom the paper is presented. Write Librarian, SPE, P.O. Box 833836,
Richardson, TX 75083-3836, U.S.A, fax 01-972-952-9435.

Abstract
Achieving proper depth control with coiled tubing has been a
problem since the service was introduced, and several improvements have been attempted with limited success. A newly developed tool overcomes depth-control problems by providing accurate depth locations of downhole devices. This tool allows realtime depth indication with standard coiled tubing, and requires
no logging cable.
Introduction
When coiled tubing was used primarily for well cleanout, depth
control was of little concern. Standard mechanical counters
yielded adequate depth control. However, as coiled tubing has
evolved into a more reliable means of servicing wells, it has been
used for services that require greater depth accuracy. Services
such as tubing-conveyed perforating, plug or packer setting, and
critical fishing operations require much greater depth control
than is currently available.
Surface Measurement Devices. To date, coiled tubing depth is
controlled with a steel measuring wheel of a known circumference that contacts the coiled tubings surface. When the coiled
tubing is raised or lowered, the wheel rolls along the tubing and
rotates an output shaft that is coupled to a mechanical footage
counter or an optical encoder. The encoder sends pulses to an
electronic counter, which is usually located in the control cabin.
Wheel counters can give inaccurate depth readings for several
reasons. Errors can result from wheel slippage on the surface of
the pipe, or from wear on the wheels surface, which reduces the
wheels circumference. These problems and others have led to
References at the end of the paper.

intricate and complicated proposals1,2 for solving depth inaccuracies.


Even if surface counters worked perfectly, other variables
such as tubing stretch and thermal effects can create inaccuracies. A recently discovered phenomenon is the tendency for
coiled tubing to elongate as it is used. Newman et al.3 showed that
coiled tubing length can grow substantially, even during one trip
into a well. Therefore, surface-measurement devices alone can
never reliably locate the downhole end of the coiled tubing.
Tubing-End Location Devices. To help ensure greater accuracy, service companies sometimes use tubing-end location
devices. These tools are run on the downhole end of the coiled
tubing and rely on heavy bowsprings, collet fingers, or catch
arms to snag the end of the production tubing as the tools are
retrieved back into the tubing. These tools expand outwardly as
they leave the tubing, while travelling downward. When the
operator is sure the tools are past the end of the tubing, he moves
them back up into the production tubing while watching the
coiled tubing weight indicator. A weight increase should be
indicated as the tubing-end locator collapses to fit back into the
production tubing.
These tubing-end location tools have met with limited success for several reasons.
The weight increase is often minimal, making the tubing end
difficult to detect. Detection is especially difficult in deviated wells, where the drag of the coiled tubing against the
tubing wall can mask or dampen the weight increase.
The tubing may not be exactly on depth. Unless the end of
the tubing was positioned with well-logging tools, the actual
depth can vary substantially because of strapping errors,
stretch, thermal effects, or human error.
Many wells contain only casing and no tubing.
The tubing-end locator gives only one depth-correlation
point, and this point could be thousands of feet from the zone
of interest.
Memory Tools. A second method of determining downhole
depth involves running a memory gamma ray collar locator on
the first trip into the well. Usually, the memory tool is run down
to the zone of interest, and the coiled tubing is marked with a flag

DEVELOPMENT OF A WIRELESS COILED TUBING COLLAR LOCATOR

at the surface. The depth measurement of this flag is noted, and


the memory log is run. The tools are pulled out of the well and
the depth data is downloaded. The subsequent log is correlated
to the existing log, and depth correction is determined. On the
next trip into the well, the coiled tubing is run into the well until
the flag is located. Then, the depth correction is applied so that
the coiled tubing is positioned on depth.
Two major problems are associated with memory tools:
They require an extra trip into the well, and elongation between
runs can be substantial, which introduces error into the correlation process.
CT Logging Reels. Because of the problems with tubing-end
locator devices and memory tools, operators have relied on
coiled tubing logging reels, which contain logging cable. These
reels can convey conventional logging collar locators and gamma
ray tools for critical depth-control situations. When this approach is used, depth accuracy equivalent to that of wireline can
be achieved.
However, two major drawbacks exist:
The cost is substantial. The cost of a logging unit and crew,
a coiled tubing logging unit and crew, and the associated
tools can be triple the cost of a comparable job with a
standard coiled tubing unit (CTU) and a tubing-end locator.
In many parts of the world, coiled tubing logging units are
in short supply.
New Specifications. Recognizing the shortcomings of existing
depth-control techniques, the designers established specific parameters for the new tool. The tool must do the following:
operate on a standard CTU without wireline
provide real-time depth indication at the surface
operate in tubing and casing during the same trip
provide a flow path to the tools below
generate an API-log format that can be correlated with
existing well logs
The Slickline Collar Locator
Larimore et al.4 discussed a new slickline tool for locating
collars. This tool uses drag blocks with electromagnets that
energize each time the tool passes a collar. When the electromagnets energize, the slickline tension increases slightly. As slickline
tension vs. depth is recorded, a log output is created for data
correlation.
Slickline units have weight-measurement systems that are
sensitive enough to detect the small tension increase generated
by the drag blocks, but most CTUs do not. This limitation, plus
the need for locator tools to work in tubing and casing during the
same trip, led developers of the coiled tubing collar locator to
pursue a different means of transmitting a signal. However, many
of the design features of the slickline collar locator were incorporated into the coiled tubing collar locator.

SPE 54327

Testing the Feasibility of Pressure Pulses


Developers of the coiled tubing collar locator determined that
the most practical way to transmit data was through a pressure
pulse sent up the fluid column in the coiled tubing.
For the feasibility test, the developers used a 20,000-ft string
of 1.50-in. OD coiled tubing. A pressure transducer was attached
in the plumbing between the pump and the coiled tubing reel, and
a simple hand-operated ball valve was attached to the downhole
end of the coiled tubing. The pressure data were recorded on a
computer, and all testing was done at the surface.
With the ball valve open, fluid was pumped at low rates
through the coiled tubing. The ball valve was closed for 2 to 3
seconds and then reopened. Various flow rates were selected to
determine the best rate for recording purposes. The best flow
rates for generating a log output were between 0.5 and 1.0 bbl/
min, which was well within standard, working flow rates for that
size of coiled tubing. At these flow rates, pressure pulses of 200
to 400 psi were easily detected at the surface. Fig. 1 (Page 4)
shows a plot of the test data.
Tool Development
When the tool was developed, a collar-locator sensor with
magnets and coil, like that used in logging collar locators, was
chosen (Fig. 2, Page 4). In these sensors, a magnetic field is
created with two opposing magnets, and a coil is placed between
the magnets. When a change in metal mass disturbs this field, the
current changes. The sensor is protected within a nonmagnetic,
beryllium copper housing.
AA alkaline batteries were chosen as the power source
because of their low cost, availability, and high performance.
Slickline collar-locator testing proved the batteries performance up to 300F. The batteries fit in a composite tube,
containing four holes for batteries and one hole in the center,
where the flow tube can pass. Four banks of eight batteries
provide a total output of 24 V.
The biggest challenge in developing the tool was designing
the solenoid valve section. The initial concept of using a solenoid
directly coupled to a sliding valve was impractical. A solenoid
that could provide sufficient stroke, yet still fit in the tool
housing, was not available and would have required a much
larger battery section. Instead, the tool designers considered a
pilot-operated valve configuration. This design uses a smaller
solenoid valve to route a small volume of fluid to a piston that
subsequently strokes down, blocking circulation ports on the
side of the tool. Nozzles in the ports create the differential
pressure required to stroke the piston. The backpressure required
for effectively stroking the piston is 300 to 400 psi over the
hydrostatic pressure. The piston is normally in a pressurebalanced environment, unless the solenoid valve is actuated,
allowing internal backpressure to stroke the piston.
Below the solenoid-valve section, a pressure barrier prevents fluid from passing through the tool until the logging
operation is complete. This barrier ensures that the pressure

SPE 54327

M.L. CONNELL, R.G. HOWARD, AND D.W. MOORE

pulse is easily detected at the surface. After the depth has been
correlated, the pressure barrier is opened, allowing fluid to pass
through the collar-locator tool.
The slickline collar-locators electrical circuitry was modified slightly for use with the coiled tubing collar locator. Fig. 3
(Page 5) is a flowchart of the circuit logic. The circuit board
allows a 25-minute test period in which the tools functions can
be tested at the surface. At the end of that period, the collardetection circuitry is disabled so that battery power is preserved
during the trip into the well.
The time during which the collar-detection circuitry is
disabled is referred to as sleep time. This period can be preset at
the surface, depending on the well depth. When the sleep time
lapses, the collar-detection circuitry is re-enabled and remains
on until the tool is retrieved to the surface. A flow-activated
switch, which could be used to start the collar-detection circuitry, is designed into the circuit board, but it is not used in the
current design. After the collar-detection circuitry is re-enabled
downhole, any change in metal mass on the casing or tubing
string will activate the solenoid valve in the tool. Such changes
could be triggered by collars, nipples, packers, and many other
types of completion equipment.
Because the collar locator is designed to work in any size of
casing or tubing, a gain setting for adjusting the sensitivity of the
detection circuitry is built into the circuit board. A relatively high
setting is required in large casing, especially when the tool is
centralized. A lower setting is required for small tubing, such as
2 7/8-in. tubing. In small tubing, a high sensitivity setting could
cause the tool to react to corrosion inside the tubing, which could
generate a false reading.
Software
A software package developed for recording the log output of the
collar-locator tool uses a standard API format. The software
includes drivers for continuous-feed printers, which are used for
the log output, and will run on most IBM-compatible computers.
A delay time for allowing the signal to travel the length of the
coiled tubing is built into the software. The delay time from the
collar detection to the peak pressure reading can be defined by
the following equation:

Signal delay time = Fluid travel time + Solenoid


valve power duration
The solenoid-valve power duration is set at 2.9 seconds by
the circuit-board design. Therefore, the delay time for an
18,000-ft coiled tubing string with fresh water would be:

T = (189 microseconds/ft 18,000 ft) + 2.9 sec


T = 6.3 sec
A collar log with a flat baseline can be plotted with a
differential pressure curve. To generate this curve, the system

must compare pressure readings at two different depths that are


a known distance apart.
Tool Operation
The collar locator is operated as follows:
1. A steady pump rate is established. Usually, for coiled tubing
with an OD less than 2.00 in., 0.50 bbl/min is best. Fluid
circulates through the ports in the side of the tool.
2. The coiled tubing travel speed is set in the range of 30 to 40
ft/min. The tool can be logged while it moves up or down the
wellbore, but logging during upward movement is preferred
to remove buckling from the coiled tubing.
3. As the collar-locator sensor passes a collar, the circuitboard logic sends power from the battery pack to the
solenoid valve. A flow path is opened from the central flow
tube to the chamber above the piston. The backpressure
inside the tool causes fluid to flow through this path, and the
piston to stroke down against a spring.
4. The downstroke of the piston blocks the circulation ports,
and the pressure in the coiled tubing builds. The solenoid
valve remains open for 2.9 seconds.
5. At the end of 2.9 seconds, the power to the solenoid valve is
shut off. The spring-loaded piston returns to the open
position and circulation resumes.
6. During the logging operation, the software records pressure
vs. depth, and a log output is printed.
After the correlation log is obtained, a ball is circulated
down to a seat in the tool, blocking the side circulation ports.
Pressure is applied to the shear pins in the ball seat, which shifts
a sleeve and opens the ports, allowing flow out the bottom of the
tool. At this point, operations can be performed with tools below
the collar locator.
Testing
Test 1. The first full-scale test of the tool with a CTU was
performed on a 2,200-ft test well. The coiled tubing had a
1.25-in. OD and was 18,000 ft long. The fluid was fresh water.
The test well was configured as follows:
A string of 2 7/8-in. EUE tubing was run inside 13 3/8-in.
casing to 440 ft.
The 13-3/8-in. casing continued to 718 ft.
At 718 ft, the 13 3/8-in. casing was swaged back to 10 3/4in. casing, which ran to 2,200 ft.
The tool performed well in the casing, but it was very
sensitive in the tubing. From the test results, the designers
determined that a lower sensitivity setting on the circuit board
was needed for small tubing.
Figs. 4 through 6 show sections of the log obtained in the
2 7/8-in. tubing (Fig. 4, Page 6), 13 3/8-in. casing (Fig. 5, Page
7), and 10 3/4-in. casing (Fig. 6, Page 8). The three tracks in each
figure represent the following:

DEVELOPMENT OF A WIRELESS COILED TUBING COLLAR LOCATOR

Test 2. A second test was conducted later for determining the


tools response in wells with higher hydrostatic pressure than
could be achieved in the initial test well. A test fixture was
assembled at the surface with a joint of 2 7/8-in. tubing. One
adjustable pressure-relief valve was installed at the pump, and
another was installed at the bottom of the tubing. The collarlocator tool was inserted into the tubing, and a pump was
attached to the top of the tool. This fixture allowed pressure to be
applied on the outside of the tool, simulating hydrostatic pressure. Fig. 7 (Page 8) shows an illustration of the test chamber.
The tool was successfully function-tested up to 7,800 psi
annulus pressure, which was the safe limit of the test fixture.

4,000

Tubing Pressure (psi)

Track 1 (left) shows a differential-pressure curve. The peaks


represent the collar depth.
Track 2 (center) shows the absolute-pressure curve.
Track 3 (right) shows the flow-rate curve and the fluidvolume curve.
All three sections were obtained in a single logging pass with
a 7.5 gain setting.

SPE 54327

3,500

1 bbl/min

3,000
2,500
2,000
1,500
1/
2

1,000

bbl/min
1/
4

500

bbl/min

0
1

51

101

151

Seconds

201

251
om000045

Fig. 1Plot of the feasibility test data.

Conclusions
Because of the inadequacies of current coiled tubing depthmeasurement systems and depth-determination devices, the development of a wireless, coiled tubing collar locator was required. This project led to the development of a tool with a
2.25-in. OD that could function up to a 300F maximum working
temperature and a 15,000-psi maximum working pressure.
The tool provides depth accuracy comparable to wireline at
a much lower cost than coiled tubing logging reels. The tool can
provide depth control for coiled tubing-conveyed perforating
guns, drillable or retrievable plugs, cement retainers, inflatable
tools, and many other types of coiled tubing tools.
Acknowledgements
The authors thank Halliburton Energy Services Inc. for its
support in developing this product and publishing this paper.
References
1.

2.

3.

4.

Connell, M.L.: Refining Coiled Tubing Depth Control, presented at the 1993 North American Conference on Coiled Tubing
Technology and Application, Phil Crouse Conference, Calgary,
Jun. 14-15.
Pessin, J.L. and Boyle, B.W.: Accuracy and Reliability of Coiled
Tubing Depth Measurement, paper SPE 38422 presented at the
1997 North American Coiled Tubing Roundtable, Montgomery,
TX, Apr. 1-3.
Newman, K.R., Sathuvali, U.B., and Wolhart, S.: Elongation of
Coiled Tubing During Its Life, paper SPE 38408 presented at the
1997 North American Coiled Tubing Roundtable, Montgomery,
TX, Apr. 1-3.
Larimore, D.R., Fehrmann, G.Z., and White, S.: Field Cases of
Cost Efficient Well Interventions Performed with Advanced
Slickline Technology, paper SPE 38097 presented at the 1997
SPE Asia Pacific Oil & Gas Conference, Kuala Lumpur, Apr. 1416.

om000038

Fig. 2Cutaway of the wireless coiled tubing collar locator.

SPE 54327

M.L. CONNELL, R.G. HOWARD, AND D.W. MOORE

om000039

Fig. 3Flowchart of the circuit logic.

DEVELOPMENT OF A WIRELESS COILED TUBING COLLAR LOCATOR

Fig. 4Log section in 2 7/8-in. tubing.

Fig. 5Log section in 13 3/8-in. casing.

om000041

om000042

SPE 54327

SPE 54327

M.L. CONNELL, R.G. HOWARD, AND D.W. MOORE

Fig. 6Log section in 10 3/4-in. casing.

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Fig. 7Test chamber for simulating hydrostatic pressure.

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