Breaking the Reach Barrier

CoilFUSE was developed to help the industry move past that reach barrier with a safer, repeatable approach to deploying segmented coiled tubing strings in ultra-reach laterals. Rather than treating extended reach as a single-tool problem, CoilFUSE brings together connector technology, well control, downhole agitation, and modeling—so operators can plan and execute longer interventions with greater confidence.

At the center of the system is the CoilFUSE Connector, a patent-pending, field pressure- and hydraulic pull-testable redressable joint that is fully field-assembled. The connector enables safe mid-string connections without risky surface welding, using visual markers and hydraulic verification to make each connection reliable and repeatable.

This mid-string connection is the foundation for segmented coiled tubing deployment, enabling operators to run coiled tubing in sections as lateral reach and operational logistics demand. The approach is particularly relevant for today’s ultra-long horizontals, where conventional methods can struggle to maintain downhole conveyance to the toe.

A distributed energy approach to friction reduction

CoilFUSE is also built to support friction management in extended laterals by enabling the installation of a second TerraPULSE™ Agitator™ mid-string. By applying energy at multiple points along the string, the system uses a distributed energy approach to reduce friction more effectively, helping extend reach beyond conventional limits.

"The goal is consistent conveyance in laterals that are simply longer than what traditional setups were designed to handle," said Workman. "CoilFUSE creates a practical, repeatable way to connect segmented strings and apply friction reduction where it can have greater impact.​​​​‌"

Built-in well control support for safer operations and safe rig down

Extended reach operations demand strong well control planning, especially during deployment and when coming out of hole. The CoilFUSE Well Control System, consisting of the CoilFUSE Safety Valve and Well Control Sub, adds an additional layer of protection and supports safe rig down.

CoilFUSE also incorporates operational tools that support safe execution:

• The CoilFUSE Cutting System provides a safer environment to cut coiled tubing and assists in installing the spoolable connector while tripping out of the well.

• A reusable spoolable swivel connector enables pad-to-pad reuse, improving efficiency and supporting multi-well operations.

Purpose-built service to deploy CoilFUSE safely and consistently

Because CoilFUSE introduces segmented deployment and mid-string connection processes that go beyond a conventional coiled tubing run, successful execution depends on disciplined procedures and experienced crews. NOV field service technicians receive specialized training and certification to deploy CoilFUSE, helping ensure connections are made and verified correctly, well control processes are followed consistently, and the overall workflow is executed safely.

This service component is designed to complement customer teams, not replace them, by bringing repeatable practices, job planning support, and field learnings that help improve performance across multi-well programs.

Verified connection integrity: pressure test and pull test capability

A core differentiator of CoilFUSE is its patented ability to pressure test and pull test the connection, bringing an added level of verification that supports operational confidence. This capability helps crews validate the integrity of the mid-string connection as part of a repeatable field process.

Modeling that supports better planning and placement

For ultra-long laterals, execution starts with planning. NOV’s proprietary Cerberus™ simulation modeling supports the workflow by helping teams optimize tool placement and predict performance, enabling better decision-making before deployment begins.

The future of coiled tubing

CoilFUSE reflects a broader shift happening across completions: laterals are getting longer, and the industry is responding with more integrated approaches that combine tools, modeling, and service execution. In that context, CoilFUSE is positioned not merely as a new tool, but as a platform approach that helps coiled tubing maintain and expand its role in modern completions.

Importantly, extending coiled tubing reach at scale will not be solved by any single company or product alone. It will require continued collaboration across operators, service providers, and technology teams—sharing learnings, refining processes, and improving safety and repeatability with each run.