Composite Coiled Tubing (CCT) has been field tested on a number of applications with generally good results. This paper will summarize these field experiences and how the tubing has been improved from early versions to the latest product. Introduction Over the past seven years Fiberspar has developed continuous spoolable composite tubing technology, building upon work done by Conoco in the previous five years. Early development centered on downhole applications as a low fatigue and corrosion resistant alternative to steel coil tubing, but after this initial development period, market pull re-focused the technology on surface applications. As a result, the technology was first commercialized in 1999 as LinePipe, for surface gathering and injection applications. Almost two million feet has now been manufactured and installed successfully in these surface applications, mostly in North America. The technology has proven to be a reliable and cost effective alternative particularly for any corrosive application. It has also enabled innovative installation techniques, which are rapid, safe and require little manpower, and is setting new standards in installation speed and reliability for the small diameter pipe construction industry. As operating companies realize the promised benefits in installation and performance, the momentum in this area is gathering and composite spooled tubing has become a realistic alternative to existing corrosion resistant solutions such as lined steel, and discrete length reinforced fiberglass pipe8. The range of applications is growing as the technology matures and develops. The technology, and in particular the development of the manufacturing processes, has greatly benefited from this commercial success and volume production. When the technology was first developed, many industry experts believed that the biggest risk to establishing a commercial rather than a technical success would be the ability to manufacture long continuous lengths to a consistent high quality standard. Now, product is routinely made in lengths of 18,000 feet, and occasionally longer, in a highly automated, 24 hour, continuous process. The process is not labor intensive, and is very robust. Length limitations are a result of the product packaging rather than process reliability. While not the top priority over the last three years, some development of the technology for downhole applications has continued. The surface applications are reaching a point of maturity, which will now allow some additional focus on the downhole market. Although the basic technology for use in surface and downhole applications is broadly similar, several changes have been implemented to make the pipe suitable for these applications. Field testing as well as lab testing was undertaken and this paper will review some of these field experiences, lessons learned and further improvements which were made as a result. It will also briefly cover the planned strategy and focus areas for expanding the use of the technology for downhole applications, and some current development, which will further extend the capabilities and applications of Composite Coiled Tubing. Tube Design The basic design of the spoolable composite tubing consists of an internal fluid barrier- normally a thermoplastic extrusion, on which the reinforcement is wound in a continuous process. (See Figure 1).

Increasingly, spoolable fiber-reinforced line pipe has gained acceptance for use in transport of high-pressure oil field fluids in applications including wellhead production gathering lines, flow lines, and injection lines. The high corrosion resistance and low connector count make these products a very reliable choice for new installations.Another extremely attractive use of spoolable fiberreinforced line-pipe is in the rehabilitation of conventional jointed steel sub-sea flow lines that have either been decommissioned or derated after years of service. In these applications spoolable composite line-pipe is either "pulledthrough" or "pushed-through" the existing steel line which then acts as a passive conduit for the protection of the fully pressure capable spoolable composite. In most cases the lower flow-friction coefficient of the spoolable composite combined with the enhanced pressure capability results in the full restoration of the flow capacity of the original line.In the Gulf of Mexico a significant length of steel line-pipe has been rehabilitated for a major operator using spoolable reinforced line-pipe. In this shallow water application steel flow lines, which had been experiencing regular failures were brought back into production using Fiberspar spoolable composite linepipe. Installation of the spoolable composite utilized a wire-line unit in a "pull-through" operation or a modified coiled tubing injector in a "push-through" operation to quickly draw the composite linepipe through each separate line with minimal or no disturbance of the existing steel flow line.The application of the spoolable composite line pipe resulted in rapid installation, low connector count and minimal sea bed disturbance contributed to a significant project cost savings over options requiring the removing or retrenching of jointed flow-lines. The design requirements, installation technologies and cost benefits of this case study are discussed. Spoolable Composite Line PipeFiberspar Corporation has been active since 1995, in advanced development of composite technology to provide continuous, fiber-reinforced, spoolable pipe solutions, building on technology initiated at Conoco in the late 1980's. The first commercial applications of spoolable composite line pipe were for flow and injection lines. Since the first installations just over three years ago, almost 2 million feet of spoolable composite line pipe has been installed in dozens of different applications. About one-third of the total installed to date has been onshore in North America in applications to rehabilitate existing flow lines, the balance being used for new installations.Design and Manufacture Spoolable composite pipe ( Figure 1) consists of a thermoplastic pressure barrier or liner, bonded to a structural reinforced fiber layer or laminate. The thermoplastic pressure barrier uses the same High Density Polyethylene (HDPE) or crosslinked Polyethylene (PEX) materials that are now commonly used by the oil industry. As a result, a great deal of institutional knowl...