Prior to the invention of FlatPak, the handling of three coiled tubing strings was a physical challenge as well as an HS&E hazard. To this end, the FlatPak was designed to simplify the handling of multiple coiled tubing strings using one manageable unit. To assure HS&E compliance, the strippers and rubbers for the BOP were modified to comply with the rectangular shape of the encapsulated coiled tubing and were pressure tested for integrity.
Conventional injector chains posed another problem. Because the blocks on the chains are designed for round coiled tubing, they were not compliant for the rectangular shaped of the FlatPak. This proved to be a minor challenge, solved by modifying the forged blocks and milling the gripper section into a flat shape.
The possibility for the injector chains to impart surface damage on the plastic encapsulation proved to be of little concern. The first prototype was run through the chains under pressure as a first level qualification test. Further field testing in a well proved that the plastic matrix containing the coiled tubing does almost no damage to the plastic, even with 90,000 plus running feet.
During its extensive research, CJS experimented with different encapsulation materials to find cost effective and durable solution. The resulting product, Thermoplastic Vulcanizate (TPV), boasts the following characteristics:
  • Temperature Resistance
  • Abrasion Resistance
  • Oil Resistance / Gas Resistance to permeation
  • Stiffness / Crush Resistance

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A specialized hanger and wellhead system has been designed that utilizes a unique multiple slip and rubber configuration.  This system delivers simple well control and safety for the final nipple up phase of the completion. The coiled tubing strings are fed through the hanger and wellhead by conventional means used in typical hang off or velocity string completions.
Because the coiled tubing used to date has been carbon steel, the reliability, cycle fatigue, and tube specifications have met industry standards and meet or exceeded any wellbore requirements. Based on pump design requirements, the umbilical can be designed to meet specific wellbore chemistry, pressure/temperature parameters, outside diameter, and tubing wall thickness. Further, there are outside diameter coatings and alternative alloys available, making this system compliant for sour applications.
The thermoplastic material used is an EPDM/Polypropylene blend that has had years of field experience in similar completion applications for coating control lines for Subsurface Control Valves, Downhole Chemical Injection, and advanced SmartWell completion technology. The plastic has been fully tested in a variety of the standard oilfield solutions and has shown to be resilient in most applications.

Manufacturing FlatPak

Products like TPV have been used for years to encapsulate control lines and down-hole cables in offshore applications. This material is impermeable to all oilfield solvents and chemicals and features a wear index of five.
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