Challenges and Best Practices for Recovering Stuck Coiled Tubing Pipe Conveying a Cable

Stuck coiled tubing (CT) is a main operational risk leading to delays, deferred production, or even loss of a well. Despite general commonalities, each CT recovery can face unique challenges including managing high pressure, working under limited spatial or lifting constraints, establishing well control, or handling a cable inside the CT. This study consolidates learnings and proposes a general workflow for a basic stuck pipe scenario, rig-up, recovery pressure control equipment and well control, CT free point evaluation, bottomhole assemblies (BHAs) and workflows for cutting and freeing the CT pipe downhole, and recovery of the CT at surface. A consolidation of published case studies provides specific examples of the hardware, workflows, and operational considerations. In addition, presentation of a recent case study extends the discussion to the challenges introduced by the presence of a cable in the stuck CT and its respective solution. This case study reviews the planning and execution of a CT recovery, including the use of decision trees to guide the decision-making process. It details fit-for-purpose hardware for safely anchoring the cable; packoffs for accessing, tensioning, and recovering it with slickline; an opening for deploying the wireline cutting BHA; and valves for pressure testing and well control. That workflow successfully freed 6,818 ft of stuck CT and allowed recovering the pipe without a workover rig on location, eliminating 11 days of rig time during subsequent tubing pulling. This is the first documented such recovery case worldwide based on a thorough literature review.