A system is provided including a coiled tubing reel apparatus including a reel drum for storing a coiled tubing string spooled on the reel drum and a hydraulic reel drive motor that controls rotation of the reel drum. The system further includes a reel controller that determines an estimated reel back tension for a portion of the coiled tubing string between the reel apparatus and the injector based on a set of parameters related to a coiled tubing operation. The reel controller determines a target reel back tension to be applied to the portion of the coiled tubing string by adjusting the estimated reel back tension based on a historical job dataset. The reel controller then determines and sets a target hydraulic pressure of the reel drive motor to achieve the target reel back tension in the portion of the coiled tubing string.

The present invention relates to a fluid-controlled wire tension mechanism including a sealed container, a control valve, and a delivery spool. The sealed container has a space. The control valve is coupled to the sealed container to control fluid pressure in the space. The delivery spool is coupled to the sealed container with a compression end and a reel. The compression end is placed in the space, and the reel is located outside the sealed container to send out a cutting wire. Wherein, a fluid enters the space and applies pressure on the compression end. The present invention utilizes the fluid pressure to produce the rotating impedance to the delivery spool, so that the component is wear-proof, the line tension is easily controlled and the stream of the cutting wire can be stable for a long time. Therefore, the cutting effect and the shape are more precise.

A system is provided including a coiled tubing reel apparatus including a reel drum for storing a coiled tubing string spooled on the reel drum and a hydraulic reel drive motor that controls rotation of the reel drum. The system further includes a reel controller that determines an estimated reel back tension for a portion of the coiled tubing string between the reel apparatus and the injector based on a set of parameters related to a coiled tubing operation. The reel controller determines a target reel back tension to be applied to the portion of the coiled tubing string by adjusting the estimated reel back tension based on a historical job dataset. The reel controller then determines and sets a target hydraulic pressure of the reel drive motor to achieve the target reel back tension in the portion of the coiled tubing string.

A creel system includes a plurality of tension controller apparatuses that hold spools of wire. The tension controller apparatuses apply tension to the wire and may be manipulated to fine-tune or control the tension applied to the wire. The creel system may further include a plurality of sensors that measure operation of the creel system as well as the condition of the wire. In such embodiments, the creel system may include a user-interface that provides data to the operator in real time and with which the operator may interact to control operation of the creel system.

A creel system includes a plurality of tension controller apparatuses supporting wire spools, an air pressure control system operatively connected to the tension controller apparatuses, a loose wire detection system configured to detect a loose wire condition upon contact between a sensor bar and one or more wires, and a central control system in communication with the air pressure control system and the loose wire detection system. The central control system ascertains a wire tension of one or more wires based on data from an apparatus sensor and the air pressure control system, and the central control system is configured to actuate the air pressure control system in response to the wire tension to maintain air pressure between upper and lower pressure thresholds. The central control system is configured to generate a loose wire alarm when the loose wire detection system detects the loose wire condition.