Coiled Tubing Control System for Runaway Descent Prevention
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Solution Overview
Problem
Current control systems for coiled tubing units in the oil and gas industry lack precise control over the movement rate of coiled tubing strings within wellbores, leading to potential damage and uncontrolled descents due to human error or excessive weight, which can result in clogging and equipment damage.
Innovation Solution
A control system that automatically adjusts the movement rate of the coiled tubing string based on feedback from surface and downhole instrumentation, using a controller to maintain an initial rate unless a predetermined threshold is reached, at which point it defaults to a safe rate to prevent damage and ensure controlled movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If human operators control the coiled tubing movement manually, then operational flexibility is maintained, but precise rate control is lost leading to runaway descent and equipment damage
Solution Approach 1:
The control system continuously monitors the actual movement rate of the coiled tubing string and compares it against the desired rate, automatically adjusting the injector head operation to maintain precise rate control and prevent runaway descent
Solution Approach 2:
The system uses automated control algorithms that independently manage the coiled tubing injection rate without requiring continuous human intervention, allowing the system to self-correct rate deviations and maintain safe operating parameters
2Productivity
If the coiled tubing string is moved at high speed, then productivity increases, but the risk of clogging and equipment damage increases due to improper degradation of plugs and materials
Solution Approach 1:
The control system dynamically adjusts the coiled tubing movement rate based on real-time conditions, allowing high speeds when safe and automatically reducing speed when threshold parameters indicate potential clogging or equipment damage risks
Solution Approach 2:
The system monitors key parameters such as weight on bit, pump pressure, and flow rate, and automatically changes the movement rate parameter in response to threshold exceedances, ensuring productive operation within safe limits
3Stability of the object's composition
If the coiled tubing string weight is increased to maintain position, then position stability is improved, but uncontrolled descent occurs when the weight forces the string into runaway movement
Solution Approach 1:
The control system continuously monitors position and movement trends, detecting early signs of runaway descent and automatically adjusting the injection rate to maintain position stability while preventing uncontrolled acceleration
Solution Approach 2:
The system applies counteracting forces through controlled injection rate adjustments before runaway descent fully develops, using feedback from position sensors to preemptively counteract gravitational pull and maintain stable positioning
Data Source
AI summary
A control system for moving a bottom hole assembly at an end of a coiled tubing string in a wellbore includes a controller configured to move the bottom hole assembly at an initial rate, unless the controller determines that moving the bottom hole assembly at the initial rate causes a predetermined threshold parameter to be reached, whereupon the controller is configured to default to moving the bottom hole assembly at a safe rate.