Hot reduced coil tubing
Continuous coil tubing made from shorter lengths of flat metal strip which are spliced end-to-end and formed into tubular form and seam welded and thereafter introduced into a forging or hot reduction process. Finished coil tubing is withdrawn from the process at a different rate than flat metal strip is fed into the process. Welds made to the flat metal strip blend into and substantially disappear from the finished coil tubing.
1 . A continuous length of coil tubing having a means to withstand repeated coiling and uncoiling stresses, said coil tubing being made by:
trimming a trailing end of a first length of flat strip stock having a first leading end and a first trailing end and a first center section and further having a first width and a first thickness, trimming a leading end of a second length of flat strip stock having a second leading end and a second trailing end and a second center section and further having a second width and a second thickness substantially the same as the first width and first thickness of said first length of flat strip stock;
while advancing the first leading end and first center section of said first length of flat strip stock at a first rate of feed speed in a tube forming process, stopping the first trailing end of said first length of flat strip stock;
transversely welding the second leading end of said second length of flat strip stock to the stopped first trailing end of said first length flat strip stock to form a composite strip;
while advancing the first leading end and first center section of said first length of flat strip stock at a first rate of feed speed in a tube forming process, stopping the first trailing end of said first length of flat stock and finishing the composite strip by conforming the transverse weld to the width and thickness of the first and second flat strip stock;
forming the finished composite strip into tubing-in-process having a first outside diameter and a first wall thickness by welding opposing edges of the composite strip to form a longitudinal weld;
introducing the tubing-in-process into a hot reduction mill at the first feed speed;
reducing the outside diameter of the tubing-in-process to a second outside diameter less than the first outside diameter;
hot forging the tubing-in-process to realign the grain structure of the tubing-in-process at the location of the transverse weld and the longitudinal weld to alter the grain structure of the longitudinal weld and the end weld to a grain structure more like the grain structure of the tubing-in-process having the second outside diameter;
withdrawing tubing from the hot reduction mill at a second feed speed different from the first feed speed.
2 . The coil tubing of claim 1 wherein the wall thickness of the tubing withdrawn from the hot reduction mill is less than said first wall thickness.
3 . The coil tubing of claim 1 wherein the wall thickness of the tubing withdrawn from the hot reduction mill is the same as said first wall thickness.
4 . The coil tubing of claim 1 wherein the wall thickness of the tubing withdrawn from the hot reduction mill is greater than said first wall thickness.
5 . The coil tubing of claim 1 wherein the transverse weld is made using at least one of the following forms of welding: forge welding, plasma welding, laser welding, HFERW, or TIG welding.
6 . The coil tubing of claim 1 wherein the transverse weld is a 90 degree butt weld.
7 . The coil tubing of claim 1 wherein the transverse weld is a 90 degree offset weld.
8 . The coil tubing of claim 1 wherein the transverse weld is a 90 degree ramp weld.
9 . The coil tubing of claim 1 wherein at least some of the tubing withdrawn from the hot reduction mill is quench and tempered.
10 . The coil tubing of claim 1 wherein the second rate of feed speed of withdrawing the tubing from the hot reduction mill is constant.
11 . The coil tubing of claim 1 wherein the second rate of feed speed of withdrawing the tubing from the hot reduction mill varies over the length of coil tubing.
12 . The coil tubing of claim 1 wherein the second rate of feed speed of withdrawing the tubing from the hot reduction mill is less than the first rate of speed.
13 . The coil tubing of claim 1 wherein the second rate of feed speed of withdrawing the tubing from the hot reduction mill is greater than the first rate of speed.
14 . The coil tubing of claim 1 wherein the tubing includes a substantially smooth internal wall surface at the locations of the longitudinal weld and the transverse weld.
15 . The coil tubing of claim 1 and further including the step of inspecting the transverse weld with a non-destructive inspection test to confirm the integrity of the weld.
16 . A continuous length of coil tubing comprising:
a spool for carrying a length of coil tubing;
a length of coil tubing coiled on said spool;
a means to withstand repeated coiling and uncoiling stresses in said length of coil tubing, said means comprising:
a first length of flat strip stock having a width and a thickness dimension and having edges, flat surfaces, and a trailing end;
a second length of flat strip stock having a width and a thickness dimension substantially the same as that of said first length of flat strip stock and having edges, flat surfaces, and a leading end;
an end weld between said trailing end and said leading end of said first and second lengths of flat strip stock respectively, said end weld joining said first and said second lengths to form a composite strip;
a longitudinal weld joining the edges of the first and second strips to form tubing having a first outside diameter; and
means to change the outside diameter of the tubing from said first outside diameter to a second outside diameter less than said first outside diameter and to alter the grain structure of the longitudinal weld and the end weld to a grain structure more like the grain structure of tubing having said second outside diameter.
17 . The coil tubing of claim 16 wherein the means to change the outside diameter of the tubing further includes means to reduce the wall thickness of the coil tubing.
18 . The coil tubing of claim 16 wherein the means to change the outside diameter of the tubing further includes means to maintain the same wall thickness of the coil tubing.
19 . The coil tubing of claim 16 wherein the means to change the outside diameter of the tubing further includes means to increase the wall thickness of the coil tubing.
20 . The coil tubing of claim 14 wherein the end weld is made using at least one of the following forms of welding: forge welding, plasma welding, laser welding, HFERW, or TIG welding.
21 . The coil tubing of claim 14 wherein the end weld is a 90 degree butt weld.
22 . The coil tubing of claim 14 wherein the end weld is a 90 degree offset weld.
23 . The coil tubing of claim 14 wherein the end weld is a 90 degree ramp weld.
24 . The coil tubing of claim 14 wherein at least some of the tubing withdrawn from the means to change the outside diameter and alter the grain structure is quench and tempered.
25 . The coil tubing of claim 14 and further including means for withdrawing at a constant rate of speed the tubing from the means to change the outside diameter and alter the grain structure.
26 . The coil tubing of claim 14 and further including means for withdrawing at a variable rate of speed the tubing from the means to change the outside diameter and alter the grain structure.
27 . The coil tubing of claim 14 and further including means for forming a substantially smooth internal wall surface at the locations of the longitudinal weld and the end weld.
28 . The coil tubing of claim 14 and further including means for inspecting the end weld with a non-destructive inspection test to confirm the integrity of the weld.
29 . A method of making continuous length of coil tubing, said method comprising:
trimming a trailing end of a first length of flat strip stock and a leading end of a second length of flat strip stock, the first length of flat strip stock having a leading end and a trailing end and a center section and further having a width and a thickness, the second length of flat strip stock having a leading end and a trailing end and a center section and further having a width and a thickness that are substantially the same as the width and thickness the first length of flat strip stock;
welding the leading end of said second length of flat strip stock to the trailing end of said first length flat strip stock to form a composite strip transverse weld;
feeding the finished composite strip into a tube forming process to form tubing having a first outside diameter and a first wall thickness by welding opposing edges of the composite strip to form a longitudinal weld;
introducing the tubing coming out of the tube forming process into a hot reduction mill at a first feed speed;
reducing the outside diameter of the tubing to a second outside diameter less than the first outside diameter;
hot forging the tubing to realign the grain structure of the welds to a grain structure more like the grain structure of the tubing having the second outside diameter; and
withdrawing the tubing from the hot reduction mill at a second feed speed greater than said first feed speed.
30 . The method of claim 29 wherein the tubing withdrawn from the withdrawing step has a second wall thickness less than the first wall thickness.
31 . The method of claim 29 wherein the tubing withdrawn from the withdrawing step has a second wall thickness substantially the same as the first wall thickness.
32 . The method of claim 29 wherein the tubing withdrawn from the withdrawing step has a second wall thickness greater than the first wall thickness.
33 . The method of claim 29 wherein the welding to form the transverse weld includes at least one of the following forms of welding: forge welding, plasma welding, laser welding, HFERW, or TIG welding.
34 . The method of claim 29 wherein the welding to form the transverse weld includes a 90 degree butt weld.
35 . The method of claim 29 wherein the welding to form the transverse weld includes a 90 degree offset weld.
36 . The method of claim 29 wherein the welding to form the transverse weld includes a 90 degree ramp weld.
37 . The method of claim 29 and further including the step of quench-and-temper heat treating at least some of the coil tubing.
38 . The method of claim 29 and further including the step of withdrawing at a constant rate of speed the tubing from the withdrawing means.
39 . The method of claim 29 and further including the step of withdrawing at a variable rate of speed the tubing from the withdrawing means.
40 . The method of claim 29 and further including the step of forming a substantially smooth internal wall surface at the locations of the longitudinal weld and the end weld.
41 . The method of claim 29 and further including the step of inspecting the transverse weld with a non-destructive inspection test to confirm the integrity of the weld.