Next-Gen Coiled Tubing: Automation Meets Expertise

Modern Coiled Tubing (CT) operations remain heavily manual, relying on the tacit knowledge of experienced operators. However, since the 2014 industry downturn, the experience level of CT operators has stagnated or declined, with no comprehensive data available. High workforce turnover, driven by factors such as cyclical business trends, economic downturns, and an aging workforce, limits operators’ training opportunities, resulting in repeated mistakes. This paper addresses the urgent need to bridge the experience gap through automation. An advanced control system has been developed to automate key CT processes and replicate the decision-making capabilities of a seasoned operator. This system enables operators with limited experience to perform at expert levels by automating running in hole (RIH) and pull out of hole (POOH). It also includes pre-programmed pull tests and completion restriction speed control, with automated motor pressure (torque) regulation to reduce the risk of over-pull and over-snubbing incidents. Additionally, the system optimizes tubing speed through automatic control of variable speed and motor displacement while managing injector head traction, tubing tension, and reel tension. The advanced control system is built as an add-on to the existing proven safety system (Fig. 1). This safety system continuously monitors real-time operational parameters and acts as a fail-safe mechanism. If an operator performs an action that could lead to unsafe conditions, the safety system immediately intervenes by reducing the injector motor pressure to prevent accidents or equipment damage. This ensures that even in manual or semi-automated modes, operational integrity and safety are always maintained. The advanced controls system leverages fuzzy logic and cascade control algorithms to simplify complex manual tasks. It operates the CT unit to a target depth at a defined rate (ft/min) with minimal operator intervention, while continuously monitoring safety parameters. If anomalies are detected, the existing proven safety system overrides automation to ensure operational integrity. This paper presents the testing methodologies and integration techniques used to connect office-engineering design software with field execution systems. The result is an auto-pilot automation approach that enhances safety, consistency, and efficiency—empowering the next generation of CT operators while bridging the experience gap. By enabling less experienced operators to perform at advanced levels, the system delivers significant client value through improved operational reliability, reduced downtime, and optimized performance.