Abstract
Summary A primary consideration with coiled tubing (CT) is that it is consumed by fatigue loading during routine operations. Also, rugged oilfield conditions routinely lead to corrosion and other mechanical surface damage. Since fatigue is a surface phenomenon, the presence of a surface imperfection has a significant influence on fatigue-damage mechanisms. This paper describes the study of magnetic-flux-leakage (MFL) inspection signals caused by surface defects in the form of milled circumferential grooves in steel CT. The focus of the investigation is to identify and estimate the size of surface defects on the basis of characteristic MFL signal features. It is demonstrated that this effort is greatly enhanced by finite-element analysis (FEA). The ultimate objective is to extract surface-flaw dimensions accurately from conventional MFL signals. These dimensions are used in computer CT life-prediction models. An axisymmetric FEA model is developed and used to calculate leakage flux density solutions for milled circular and rectangular shaped grooves in 1.75-in.-outside-diameter (OD), 0.156-in.-wall-thickness (WT), 90-ksi CT samples. FEA results are compared to axial and radial MFL signals measured with an experimental inspection unit. Favorable agreement is observed between experimental and FEA data. Furthermore, signal features are correlated with the known slot geometries to identify basic geometry-recognition patterns for different circumferential grooves. Signal features reveal qualitative and quantitative trends relative to surface-flaw dimensional characteristics. The need persists to make the operator's string-management decision-making process more reliable and automatic with respect to determining fatigue life expectancy. The obstacle here is that because of the inherent inaccuracies in commonly used MFL inspection techniques, reliable real-time flaw-evaluation and -characterization capability is limited.
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