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Section 110

COILED TUBING SERVICES MANUAL

Rev A - 98

CT STRING MANUFACTURE

Contents
1
2

Page

Introduction .................................................................................................... 2
CT STRING DESIGN ..................................................................................... 2
CT STRING MANUFACTURE ......................................................................... 4
2.1 Strip Production Process ...................................................................... 4
2.2 Skelp Production Process ..................................................................... 6
2.3 Tubing Production Process .................................................................... 6
2.3.1 Strip Preparation ................................................................................... 6
2.3.2 Forming the tube ................................................................................... 8
2.4 Laboratory Testing ............................................................................... 12
2.5 Documentation Package ..................................................................... 13
2.6 Delivery and Spooling ......................................................................... 13
2.6.1 Spooling .............................................................................................. 13

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Section 110
Rev A - 98

COILED TUBING SERVICES MANUAL

CT STRING MANUFACTURE

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Introduction

1 CT STRING DESIGN

Coiled tubing (CT) is manufactured from low-alloy carbon

steel. To enable delivery of a reliable product with predictable performance, stringent quality control and assurance
systems are applied throughout the manufacturing process
- beginning as the steel alloy is produced continuing through
until the delivery of the completed string and documentation package.

There are many design criteria, or specifications, applied to

CT string manufacture, many of which relate to the specific
conditions (operational) for which the string is being manufactured. However, the following general requirements
typically apply to most CT strings:

Limitations in the steel strip manufacturing processes

meant that early CT strings were fabricated from several
short tube lengths butt-welded together to form the required
string length. The resulting tube to tube welds were points
of potential failure due to fatigue induced in the unavoidable
heat effected zone (HAZ) located at either side of the weld.

Meet oil and gas industry specifications for oilfield

tubulars (e.g. NACE MR-01-75 for use in H2S environments).
Be strong enough to withstand reasonable burst and
collapse pressures.
Have a reasonable resistance to corrosion and erosion.

Improved steel manufacturing and rolling processes combined with new tube manufacturing techniques enable
modern CT strings to be manufactured without butt welds.
This has contributed greatly to the general reliability and
greater acceptance of CT services.

Be sufficiently ductile to be stored on a reel and passed

over the injector head gooseneck without deforming.

There are many steps in the manufacturing process,

however there are three distinct phases relating to the
location of the manufacturing facilities.

Possess good welding characteristics, not only in the

manufacturing process but also in the less controlled
conditions during field welding of the CT string.

Steel mill - master coils of the required material specification are cast and rolled.

Have a minimum number of butt welds (girth welds) which

are potential weak spots in the string.

Slit mill - the master coil is slit accurately into the strips
(skelps) of the required width for the size (OD) of tubing to
be formed.

Be economically acceptable, since the tubing string will

have a finite life and is therefor regarded as a consumable
product.

Tubing mill - In a two-stage process, skelps are assembled

to the desired string length and then passed through the
tubing mill to form the completed CT string.

The principal limitation imposed on safe running depth for

a CT string comes from the hanging weight of the tubing
itself. Simply increasing the wall thickness throughout the
string provides no benefit since the increased string weight
counteracts the increase in load capacity. However, a
compromise is made by designing a tapered CT string,
making it possible to run long lengths of tubing while
maintaining the overall load on the tubing within a desired
safety factor of 80% of the tubing yield strength.

Have a good resistance to fatigue caused by cycling the

tubing and the corresponding plastic deformation.

Tapered strings are commonly used in deep well applications, where heavy walled tubing is required at the surface
to support the load while thinner walled tubing is used
toward the downhole end to reduce the load.

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COILED TUBING SERVICES MANUAL

CT STRING MANUFACTURE

Section 110
Rev A - 98

Figure 1. CT string design - tapered string configurations.

Tapered strings are manufactured by welding two or more

segments of different gauge (wall thickness) strip. If the
increment between the thick and thinner walled sections is
too large, it may not be possible to obtain a reliable joining
weld. In such cases, short strips of intermediate wall
thickness are used to form a more gradual taper in the
string.
A further development in tapered string design uses strip
segments which are manufactured with a wall thickness
reduction over the length of the strip (Figure 1). This
eliminates the requirement for multiple tapered strips and
associated bias welds, In addition, the stress concentrations due to non-uniform load transfer caused by joining
differing gauge materials is also reduced.
The exact design of a tapered string depends on the
application for which it is intended. However there are
several criteria that should be considered when a tapered
string is designed.

The production lengths of tubing will be approximately

3,500 feet. If possible the string should be made from
elements of this length, (with the exception of the intermediate wall sections).
The intermediate sections should be at least 1,000 feet in
length, to enable damaged sections to be removed without
the risk of removing the intermediate section.
During operations no part of the string should exceed 80%
of the published yield. For the purpose of designing the
tapered section, no part of the string should exceed 60% of
the published yield.
The taper design should allow for the maximum amount of
tension in each element based on the capacity of the
section at the injector head and the rating of the injector
head, whichever is lower.

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Section 110

COILED TUBING SERVICES MANUAL

CT STRING MANUFACTURE

Rev A - 98

2 CT STRING MANUFACTURE
The following CT string manufacturing sequence details the
process, and associated checks or tests, performed in a
series of manufacturing steps conducted in several locations and manufacturing facilities, including:

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sulfur. In the steel making process most of the carbon is

oxidized along with virtually all the silicon and much of the
manganese. Phosphorus and sulfur, which can be detrimental to steel quality, are also reduced. Manganese
however, is later reintroduced in measured amounts to
increase the alloy strength and ductility.
The alloy produced is relatively pure iron containing less
than 1.7% carbon.

Strip production - steel mill

Skelp production - slit mill
Tube production - tubing mill

Arc Furnace
2.1 Strip Production Process
The majority of steel produced for CT string manufacture
originates in Japan (CT manufacturing plants in U.S.A.) or
France (CT manufacturing plants in UK). The following
production stages are common to most steel strip providers.

Iron and steel scrap are fed into the furnace through the
open roof. The roof is swung into place and carbon
electrodes are lowered until they are in near contact with the
furnace charge. The power is applied and an arc temperature of approximately 6,000 F melts the alloy materials.
When the specified steel requirements are met, the furnace
is tapped and the steel run off into the casting ladle.

Blast Furnace
Casting Ladle
The blast furnace is charged with iron ore, sinter, coke and
limestone, as they descend they are met by a rising volume
of hot gas formed by combustion of the coke in a forced air
stream (preheated to 1,800 F). Carbon monoxide produced
from the burning coke reduces the iron oxide to iron, while
the limestone removes impurities from the ore. The molten
iron (at 2,700 F) is tapped at the base of the furnace into
ladles.
Iron from the blast furnace contains approximately 5%
carbon, up to 1% of both manganese and silicon, and much
smaller but still significant amounts of phosphorus and

Immediately after the furnace is tapped, the ladle of liquid

steel, at a temperature of approximately 2,950 F, is moved
to the refining station. Here the steel is agitated with an inert
gas to provide a uniform temperature and composition.
At the casting ladle, the alloy is tested to ensure that its
chemical composition meets predefined criteria. The table
in Figure 2 shows a typical specifications for CT string
material. On conclusion of successful testing, the steel
then passes to the continuous caster.

TYPICAL CT MATERIAL CHEMISTRY/COMPOSITION

Chemical composition - %:

Carbon:

0.10 to 0.15 range

Manganese

0.60 to 0.90 range

Phosphorus

0.03 maximum

Sulfur

0.005 maximum

Silicon

0.30 to 0.50 range

Chromium

0.45 to 0.70 range

Copper

0.40 maximum

Nickel

0.25 maximum

Figure 2. Typical CT material chemistry/composition.

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COILED TUBING SERVICES MANUAL

CT STRING MANUFACTURE

Section 110
Rev A - 98

Blast furnace
ARC furnace

Casting ladle

Continuous
caster
Slab reheat

Rolling mill

Pickling
Oiling

Master coil

Figure 3. CT manufacturing process - master coil.

Continuous Caster

Rolling Mill

The continuous caster produces steel strip in a semifinished form. The ladle of liquid steel is tipped into an
intermediate, smaller ladle that feeds a water-cooled copper mould. The partially solidified steel is slowly drawn into
a series of rollers that transfers the cast material from a
vertical to a horizontal orientation. A travelling torch cuts
the ingot or slab into manageable lengths.

Heated, semi-finished steel slabs are passed through the

hot-strip rolling lines comprising sets of rollers that progressively squeeze the slab reducing it to the required thickness. This reduction in thickness is achieved with a
corresponding increase in length and, to a lesser degree
width.

Slab Reheat
Since the steel slabs are produced in a continuous process,
some of the slabs may have to wait before entering the
rolling mill. To maintain the correct temperature the material
is held in a slab reheat facility. If, during the rolling process
the slab temperature drops too much, it may also be
returned to the reheat facility for reconditioning prior to
finishing.

The rolling process must be carefully monitored to ensure

the finished strip is within the strict CT wall thickness
tolerances.

Pickling Line
The rolled strip is passed through an acid spray and bath to
remove surface scale and oxides which may have been
picked up during the rolling process. The final pickling
process includes a treatment to ensure residual chemicals
are neutralized.

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Section 110
Rev A - 98

COILED TUBING SERVICES MANUAL

CT STRING MANUFACTURE

Oiling
Immediately following pickling, the strip is sprayed (coated)
with a viscous oil preparation which prevents atmospheric
corrosion or contamination while in storage or during
transportation to the tube manufacturing facility.

Master Coil
Following pickling and oiling, the strip is wound into a spool
known as the master coil and prepared for shipment to the
slitting mill. Representative strip material from each mill
heat is submitted for chemical composition analysis to
ensure that the steel meets the required specification.
Each master coil is uniquely identified and supported with
a documentation package which includes details of the
steel specification, manufacturing process, overall length
and thickness.
2.2 Skelp Production Process
Skelp production is a relatively simple process conducted
at special slit mill facilities located in the U.S.A. or UK.
The master coil is spooled down and cut into strips (slit) by
means of rotating blades, the width of the strip being
determined by the required OD of the finished tubing. The
resulting strip, or skelp, is then individually prepared and
uniquely identified before shipping to the tubing mill.

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closed tube are welded using a high frequency induction

welding system.
Each skelp received from the slit mill is dimensionally
checked for width and gauge and the strip edges visually
inspected for any slitting process defects. A unique identification number, referencing the master coil identification,
is assigned to each strip to ensure traceability throughout
the tube forming process.
2.3.1 Strip Preparation
Individual skelps are spooled down and spliced to form a
continuous strip the length of which is determined by the
length of the CT string required (i.e., CT string length + pre
and post-mill manufacturing excess).

Bias Welding
To ensure the weld joining each strip forms an integral part
of the assembled strip, the end of the strip is cut at a bias
angle which precisely matches the cut in the tail of the
preceding strip. The strips are then welded together using
a plasma arc welder with an inert gas shield to form one
continuous strip.
When the tube is formed, this bias weld takes on a helical
profile making the tube less prone to failure than a tube-totube (butt) weld.

Radiographic Inspection
2.3 Tubing Production Process
The tubing production process is typically completed in two
distinct phases.
Stage 1 - The relatively short lengths (approximately 3500
ft) of flat steel strip, of the required properties and
dimensions, are bias welded to form the complete length
of the CT string. Each weld is heat treated in a closely
controlled process to remove any HAZ from the strip
material. The assembled strip is wound onto a accumulator reel for transport to the next stage of the manufacturing process.

The weld is visually examined then passed through a

radiographic inspection station where it is examined for the
following faults:
Gas porosity
Concavity of the bead
Uneven surface of the bead
Surface misalignment
Undercut parent material

Stage 2 - The flat strip from the accumulator reel is passed

through the forming mill where several sets of rollers bend
the strip to gradually form the tubular profile. Prior to
passing through the final roller set, the edges of the

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Any defective weld is cut out and a new joint prepared.

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COILED TUBING SERVICES MANUAL

CT STRING MANUFACTURE

Section 110
Rev A - 98

Slitting
Bias welding

Radiography

Planishing
Machining

Heat treatment
Lay er 1
LAS E R

1
2
3
4
5

MPI inspection
Width inspection

Length check

Strip spool

Figure 4. CT manufacturing process - strip preparation.

Longitudinal weld

Bias weld

Figure 5. CT biased and longitudinal welds.

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COILED TUBING SERVICES MANUAL

CT STRING MANUFACTURE

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Heat Treatment

for the tubing mill.

Accepted welds are induction heated to raise the temperature of the weld area, thereby eliminating the hardness and
embrittlement which occurs during any welding process (in
the heat affected zone).

Due to the exacting welding processes and subsequent

extensive inspection procedures, strip assembly typically
requires more time to complete than the tube milling
process. Consequently, there are typically several accumulator reels prepared to enable the tube mill to be operated
efficiently.

Planishing
This optional process minimizes the amount of material
removed in the next step by passing the weld area between
high-pressure rollers to smooth and prepare the weld area.

Machining
In order to achieve a smooth transition between strips, and
over the weld itself, excess material remaining after welding and planishing is removed by a precision grinding
process.

Magnetic Particle Inspection

The surface of the strip is sprayed with a magnetic particle
solution and placed in a magnetic field. With the field active,
indications of imperfections will become apparent when the
site is viewed in ultraviolet light.

Dimensional Inspection
The strip at the weld site is checked for thickness, width,
hardness and alignment, each measurement must fall
within the original strip tolerances before the weld is
ultimately accepted.

2.3.2 Forming the tube

The second stage of tube manufacture involves several
continuous phases which form the flat steel strips into
tubing of the desired physical properties. The process must
be highly controlled and uninterrupted if a high-quality,
consistent product is to be produced.
Due to the nature of the product, destructive testing of
material samples can only be conducted at the beginning
or end of the mill run. Also, physical tests cannot be
conducted on the material during manufacture. To ensure
the correct heat treatments are applied, an initial sample is
milled at the beginning of each string. The mill is stopped
and the sample tested for the following properties and
characteristics before the milling process is restarted.
Once started, the milling process cannot be interrupted
without jeopardizing the properties or integrity of the tubing
string. To confirm that the desired properties have been
maintained throughout the mill run, a test sample is
retrieved from the tail end of the milled string. The tests and
checks listed below are performed, with a tubing sample
identified and stored for quality assurance purposes.

When the weld has passed inspection, a unique number

identifying the weld is assigned and marked on the strip at
both sides of the weld. Documentation relating to the weld
is retained for inclusion in the CT string manufacturing
record.

Dimensional checks

Length Counter

Seam-weld mismatch

The strip length is measured as it leaves the assembly area

prior to being wound onto the strip accumulator reel.

Crush test

Ovality
Wall thickness

Flare test

Accumulator Reel
Tensile test
The assembled strip is spooled up on an accumulator reel
which is used to store and transport the strip in preparation

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COILED TUBING SERVICES MANUAL

CT STRING MANUFACTURE

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The following steps or phases are included in the tube

milling process.

Section 110
Rev A - 98

Two basic techniques are used for flash removal:

Flash material cut and removed at the tubing mill

Forming Stands
The forming stands comprise a series of rollers that
gradually form the tube from the flat skelp. This manipulation is designed to evenly work the material and avoid
areas of high stress. The tube forming process also
incorporates the longitudinal welding process which occurs
immediately the two skelp edges are closed.

Longitudinal Welding
The longitudinal weld is made using a high frequency
electrical induction weld system. Heat for the weld is
generated by electrical resistance induced by a coil which
encircles the tubing. The heat produced (approximately
2500 F) is confined to a narrow area along the edges of the
closing tube. The final set of forming rollers force the edges
together at fusion temperature to produce the weld. Since
no filler material is added during the welding process, the
composition of the weld is the same as the body of the tube.
The tubing is welded slightly oversize with the emphasis on
the weld quality rather than on the final dimension.

Flash material cut at the tubing mill and then removed

during the string flushing process following manufacture

Seam Annealer
The formed tube passes to the seam annealer which heat
treats the weld area (approximately 1650 F) to recrystallize the material in the heat affected zone. This process
relieves the stresses resulting from the welding process.

Cooling Station
The tube is slightly cooled before progressing to the next
stage of the manufacturing process.

Weld Inspection
Electronic inspection of the seam weld is carried out using
an electromagnetic (eddy current) testing system. The
testing station continually records the inspection data and
automatically identifies and precisely marks any area that
may require further inspection by magnetic particle testing
and radiography.

Flash Removal
Sizing Stand
A small quantity of weld flash material is extruded on the
inner and outer surfaces of the tube. This is removed from
the outer surface by a contoured cutting tool located
directly after the welding station. On larger CT sizes (>1-3/
4-in.) the internal weld flash can also be removed if desired.

After inspection the tubing is drawn through the sizing mill

where precisely set rollers form the final string OD.

PHYSICAL PROPERTIES OF 70,000 YIELD STRENGTH MATERIAL

Physical properties:

Minimum yield strength:

70,000 psi

Minimum tensile strength:

80,000 psi

Minimum elongation:

30%

Minimum hardness:

22C Rockwell

Figure 6. Physical properties of 70,000 yield strength material

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Section 110
Rev A - 98

COILED TUBING SERVICES MANUAL

CT STRING MANUFACTURE

Forming stand

Strip spool

Weld inspection

Water cooling

Diameter check

Stress relief

Flash removal

Longditudinal
weld

Final sizing

Air cooling

Hydro-testing

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Seam anealling

Length check

End fitment
welding

Drift and purge

Weld inspection

Spooling

Figure 7. CT manufacture - tube forming process.

Length Check

Dual Axis Laser

The formed tubing is accurately measured to confirm that

the overall length is that of the required CT string. The
length recorded at this station is considered string length
as manufactured.

A dual axis laser continuously scans the outer surface of

the tube to ensure the diameter of the tube is within the
selected specifications.

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COILED TUBING SERVICES MANUAL

CT STRING MANUFACTURE

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Rev A - 98

Full Body Stress Relief

Spooling

The tubing passes through a reheat station where the entire

tube body is heated to between 900 and 1400 F. The exact
heat treatment specifications are carefully controlled to
achieve the desired physical characteristics from the
material being milled. The heat treatment ensures a consistent material grain structure throughout the body of the tube
and relieves any residual stress induced during manufacture. The characteristics of the tubing material combined
with the heat treatment at this stage determine the ultimate
physical characteristics of the completed CT string (Figure
6).

When the CT string is spooled onto a shipping drum the

string is spooled back to front, i.e., the downhole end of the
CT string is at the spool core. This ensures the string will
be correctly oriented when it is eventually spooled onto the
CT work reel. While this may not be so important for parallel
strings, it is obviously essential that tapered strings are
correctly handled and spooled.

End Fitment Welding

The end fitting, typically a WECO 1502 wing-half , is
welded to the string to simplify the spooling (to work reel)
operation. This connection makes up to the corresponding
connection on the reel axle.

Air Cooling
In preparation for spooling, the tubing is air cooled over an
interval between the tubing mill and spooling stand.

Coiled Tubing OD (in.)

1-3/4
2-3/8

Nom. Wall
Thickness (in.)

1-1/4

1-1/2

0.075

1.000

0.080

1.000

1.1875

0.087

0.875

0.095

2-3/8

3-1/2

1.1875

0.875

1.1875

1.375

0.102

0.875

1.1875

1.375

0.109

0.875

1.1875

1.375

0.116

0.875

1.1875

1.375

0.125

0.875

1.125

1.375

2.000

0.134

0.875

1.125

1.375

2.000

0.145

0.875

1.125

1.375

1.875

2.500

0.156

0.750

1.0625

1.250

1.875

2.375

0.175

0.750

1.0625

1.250

1.875

2.375

3.000

0.190

1.000

1.250

1.875

2.375

3.000

0.204

1.000

1.250

1.875

2.375

3.000

0.224

1.1875

1.750

2.250

2.875

0.250

1.125

1.750

2.250

2.875

0.280

1.625

2.188

2.750

0.300

1.625

2.125

2.750

Figure 8. Recommended CT gauge-ball sizes.

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CT STRING MANUFACTURE

Rev A - 98

Weld Inspection
The end fitting weld undergoes radiographic inspection.
Typically, three shots are taken at 120 intervals around
the circumference of the weld, offset from the weld centre.
The resulting film is inspected for the following flaws and,
on successful conclusion of the checks, placed in the
string file:

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On completion of the pressure testing procedure, the test

fluid is purged from the string using air or nitrogen and an
internal corrosion inhibitor applied to protect the tubing
during transportation and storage. If the string is to be
delivered or stored in a cold climate, freeze protection may
also be applied to prevent damage from freezing of any
residual water/moisture.

2.4 Laboratory Testing

Gas porosity
Concavity of the bead

Tubing samples taken from the beginning and end of each

mill run are subjected to the following tests or checks.

Uneven surface of the bead

Dimensional Checks

Surface misalignment

Samples are dimensionally checked for:

Undercut parent material

Ovality

Hydro Testing

Wall thickness

The completed CT string is hydro tested to 90% of the string

yield pressure for a minimum of thirty minutes. The test
pressure and duration are recorded on a chart and become
part of the permanent string record.

Seam-weld mismatch

Crush Test
Completely flattens a test section of tubing with the seam
weld orientated at the apex of the fold. No open defects are
permitted in the weld.

Drifting And Purging

While the string is being filled with water, a steel gauge ball
of a specified diameter is run through the tubing to ensure
there are no obstructions. Recommended gauge ball sizes
are shown in Figure 8.

Crush

Flare

Ovality

Seam weld
mismatch

Tensile

Figure 9. CT string manufacture - laboratory testing.

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Wall thickness

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Section 110
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Flare Test

Weld log including bias weld and butt weld positions

Stretches the open end of the tubing over a mandrel with a

60 taper, the tubing must expand 21% above the initial
diameter before failure (splitting). Failure should not occur
at the seam weld. Crush and flare tests are carried out in
accordance with ASTM A450.

Hydrostatic test pressure including:

Test duration
Maximum pressure
Minimum pressure
Temperature
Test fluid

Tensile Test
Details of purging/drying or freeze protection procedures
Full section test samples are marked to enable % elongation to be determined, placed in a tensile test facility. A
tensile load is gradually applied until the sample is tested
to destruction. The resulting data is used to determine:

Details of drift ball pumping program

Record of spooling during the manufacturing and testing
program.

Yield strength
2.6 Delivery and Spooling
Ultimate yield strength
Elongation

On receipt of a new CT string there are several inspection

and check procedures necessary before the string is
spooled to the work reel.

2.5 Documentation Package

The documentation package prepared for each tubing
string comprises data relating to the string material, manufacturing processes and test or inspection procedures. Not
all information contained in the package will be provided
with the string on delivery. However, a complete package
is archived at the tubing mill in the event of subsequent
enquiry.
The documentation package should contain the following
information or data.

Visual inspection of shipping spool and string including:

Protective crating
Spool hub and handling/mounting points
String union/connection for reel core (WECO)
General condition of visible wraps
Review of documentation package/string record, including:
Confirmation of material order and delivery note
Confirm the required certification package is complete

Tube grade and serial numbers

Prior to spooling, all protective crating and banding is

removed from the shipping spool. In addition, any nitrogen
pressure contained within the string for shipping should be
carefully released.

Chemical composition

2.6.1 Spooling

Heat number(s)

The shipping spool is mounted on a stand which enables

rotation, under a controllable back tension, while the string
is spooled to the work reel. Accurate spooling is essential,
especially on the reel bed wraps, to ensure no damage is
caused to the string.

Unique string identification number

Mechanical properties:
Hardness
Tensile strength(s)
Yield strength(s)
Identification and position of tapered string segments

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COILED TUBING SERVICES MANUAL

CT STRING MANUFACTURE

Several checks or inspections should be made at time of

spooling, including:
Confirm length - at least two independent measuring
devices should be used to confirm the string length.
OD monitoring - the string should be run through a UTIM
(Universal Tubing Integrity Monitor) to enable a base
record of diameter/ovality to be established.
Surface protection - application of an external surface
corrosion inhibitor (or similar) should be considered.
Pressure test - Once the CT string is fully spooled onto the
CT reel, the complete assembly is pressure tested to the
working pressure of the CT string (nominally 5,000 psi)
using water as the testing medium. On completion of the
test the water is completely purged from the string with air
or nitrogen. If the string is to be stored before use, an
internal corrosion inhibitor may be applied.
String File Record - The documentation package provided
with the string should be used to start the string file or
record. If an electronic string monitoring and recording
system is used, the string details should be entered.

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