Patent Publication Number: US-11643296-B2

Title: Expandable reel assembly for a well system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims benefit of U.S. provisional patent application Ser. No. 63/025,322 filed May 15, 2020, and entitled “Expandable Reel Assembly for a Well System,” which is hereby incorporated herein by reference in its entirety for all purposes. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     BACKGROUND 
     Coiled tubing systems are used to run continuous pipe into and out of wellbores. Continuous pipe may be referred to as coiled tubing because it is stored on a coiled tubing reel. Coiled tubing can be used for drilling operations, and is likewise well-suited for servicing and/or producing hydrocarbons from existing wells. Coiled tubing can be inserted into and removed from a wellbore extending through a subterranean earthen formation without having to first erect a complex drilling rig or other structure at a well site at which the wellbore is located. During operation, a coiled tubing of the coiled tubing may be subjected to bending and associated bending strains at varying bending radii. Additionally, the coiled tubing may have a minimum allowable bend radius the coiled tubing is designed to sustain, where the minimum allowable bend radius of the coiled tubing may be a function of the diameter and other properties of the coiled tubing. The reel of the coiled tubing system may be designed such that the coiled tubing does not exceed its designed bending radius when the coiled tubing is stored on the reel. 
     BRIEF SUMMARY OF THE DISCLOSURE 
     An embodiment of an expandable reel for a well system comprises a support frame configured to receive a torque from a motor, and a core assembly configured to couple to the support frame and receive a tubular of the well system about an outer surface of the core assembly, wherein the core assembly is actuatable between a first configuration and a second configuration while remaining coupled to the support frame, wherein the core assembly comprises a first outer diameter when in the first configuration and a second outer diameter when in the second configuration that is different from the first outer diameter. In some embodiments, the expandable reel comprises an actuation assembly coupled to the support frame and configured to actuate the core assembly between the first configuration and the second configuration. In some embodiments, the actuation assembly comprises a cylinder coupled to the support frame and a piston at least partially disposed in the cylinder and coupled to the core assembly, wherein the piston is extendable from the cylinder. In certain embodiments, the expandable reel comprises a control system operable by a user of the expandable reel and configured to selectably operate the actuation assembly to actuate the core assembly between the first configuration and the second configuration. In certain embodiments, the core assembly comprises a plurality of circumferentially spaced panel assemblies configured to radially translate relative to a central axis of the expandable reel in response to actuation of the actuation assembly. In some embodiments, each panel assembly comprises an arcuate panel and a support member coupled to the arcuate panel, wherein the arcuate panel comprises a radially outer surface that defines an outer surface of the core assembly and wherein the support member is configured to couple to the actuation assembly. In some embodiments, the support frame comprises a pair of inner spoke assemblies, a plurality of core support members positioned radially between the plurality of panel assemblies and a central axis of the expandable reel, and a pair of outer spoke assemblies, wherein the plurality of panel assemblies are positioned between the pair of outer spoke assemblies. In certain embodiments, each panel assembly comprises a guide assembly configured to slidably engage an outer spoke of one of the outer spoke assemblies. 
     An embodiment of an expandable reel for a well system comprises a support frame configured to receive a torque from a motor, and a core assembly configured to couple to the support frame and receive a tubular of the well system about an outer surface of the core assembly, wherein the core assembly comprises a plurality of circumferentially spaced panel assemblies that are radially translatable relative to a central axis of the expandable reel. In some embodiments, a circumferential spacing between each of the plurality of panel assemblies is increased in response in response the actuation of the core assembly between a first configuration and a second configuration when coupled to the support frame. In some embodiments, each panel assembly comprises an arcuate panel and a support member coupled to the arcuate panel, wherein the arcuate panel comprises a radially outer surface that defines an outer surface of the core assembly and wherein the support member is configured to couple to the actuation assembly. In certain embodiments, the support frame comprises a pair of inner spoke assemblies, a plurality of core support members positioned radially between the plurality of panel assemblies and a central axis of the expandable reel, and a pair of outer spoke assemblies, wherein the plurality of panel assemblies are positioned between the pair of outer spoke assemblies. In some embodiments, each panel assembly comprises a guide assembly configured to slidably engage an outer spoke of one of the outer spoke assemblies. In certain embodiments, the guide assembly is configured to limit the core assembly to a single degree of freedom relative to the support frame. In certain embodiments, the core assembly is actuatable between a first configuration and a second configuration when coupled to the support frame, and wherein the core assembly comprises a first outer diameter when in the first configuration and a second outer diameter that is different from the first outer diameter. In some embodiments, the expandable reel comprises an actuation assembly coupled to the support frame and configured to actuate the core assembly between the first configuration and the second configuration. 
     An embodiment of a method for operating an expandable reel for a well system comprises (a) actuating a core assembly of the expandable reel between a first configuration comprising a first outer diameter and a second configuration comprising a second outer diameter that is different from the first outer diameter. In some embodiments, the method comprises (b) operating the expandable reel to reel or unreel a first tubular having a first diameter from the core assembly when the core assembly is in the first configuration, and (c) operating the expandable reel to reel or unreel a second tubular having a second diameter from the core assembly when the core assembly is in the second configuration, wherein the second diameter is different from the first diameter. In some embodiments, (a) comprises increasing a circumferential spacing between each of a plurality of panel assemblies of the core assembly. In certain embodiments, (a) comprises operating an actuation assembly of the expandable reel to actuate the core assembly between the first configuration and the second configuration. 
     Embodiments described herein comprise a combination of features and characteristics intended to address various shortcomings associated with certain prior devices, systems, and methods. The foregoing has outlined rather broadly the features and technical characteristics of the disclosed embodiments in order that the detailed description that follows may be better understood. The various characteristics and features described above, as well as others, will be readily apparent to those skilled in the art upon reading the following detailed description, and by referring to the accompanying drawings. It should be appreciated that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes as the disclosed embodiments. It should also be realized that such equivalent constructions do not depart from the spirit and scope of the principles disclosed herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a detailed description of exemplary embodiments of the disclosure, reference will now be made to the accompanying drawings in which: 
         FIGS.  1 ,  2    are schematic views of an embodiment of a well system including a coiled tubing system in accordance with principles disclosed herein; 
         FIG.  3    is a perspective view of an embodiment of an expandable reel of the well system of  FIGS.  1 ,  2    in accordance with principles disclosed herein; 
         FIG.  4    is a side view of the expandable reel of  FIG.  3   ; 
         FIG.  5    is a top view of the expandable reel of  FIG.  3   ; 
         FIG.  6    is a perspective view of an embodiment of a support frame of the expandable reel of  FIG.  3    in accordance with principles disclosed herein; 
         FIG.  7    is a side view of the support frame of  FIG.  6   ; 
         FIG.  8    is a perspective view of an embodiment of an arcuate panel assembly of the expandable reel of  FIG.  3    in accordance with principles disclosed herein; 
         FIG.  9    is a bottom view of the arcuate panel assembly of  FIG.  8   ; 
         FIG.  10    is a cross-sectional view along lines  10 - 10  of  FIG.  9    of the arcuate panel assembly of  FIG.  8   ; 
         FIG.  11    is an orthogonal cross-sectional view along lines  11 - 11  of  FIG.  5    of the expandable reel of  FIG.  3   ; 
         FIG.  12    is a perspective cross-sectional view along lines  12 - 12  of  FIG.  5    of the expandable reel of  FIG.  3   ; and 
         FIG.  13    is a flow chart of an embodiment of a method for operating an expandable reel for a well system in accordance with principles disclosed herein. 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     The following discussion is directed to various exemplary embodiments. However, one skilled in the art will understand that the examples disclosed herein have broad application, and that the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment. 
     Certain terms are used throughout the following description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function. The drawing figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in interest of clarity and conciseness. Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints, and open-ended ranges should be interpreted to include only commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary. 
     In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct engagement between the two devices, or through an indirect connection that is established via other devices, components, nodes, and connections. In addition, as used herein, the terms “axial” and “axially” generally mean along or parallel to a particular axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to a particular axis. For instance, an axial distance refers to a distance measured along or parallel to the axis, and a radial distance means a distance measured perpendicular to the axis. Any reference to up or down in the description and the claims is made for purposes of clarity, with “up”, “upper”, “upwardly”, “uphole”, or “upstream” meaning toward the surface of the borehole and with “down”, “lower”, “downwardly”, “downhole”, or “downstream” meaning toward the terminal end of the borehole, regardless of the borehole orientation. As used herein, the terms “approximately,” “about,” “substantially,” and the like mean within 10% (i.e., plus or minus 10%) of the recited value. Thus, for example, a recited angle of “about 80 degrees” refers to an angle ranging from 72 degrees to 88 degrees. 
     As previously described, coiled tubing systems may include a reel assembly and a coiled tubing which may be spooled or stored on a core of the reel assembly. The coiled tubing may have a minimum allowable bend radius that may be a function of the diameter and other properties of the coiled tubing. Bending of the coiled tubing at a radius less than the minimum allowable bend radius of the coiled tubing may induce excessive bending strain within the coiled tubing which may damage the coiled tubing or otherwise decrease the operational life of the coiled tubing. Thus, the core of the reel assembly may have an outer diameter sized such that the bend radius to which the coiled tubing is subjected when spooled on the reel assembly is at least as great as the minimum allowable bend radius of the coiled tubing. 
     During operation of the coiled tubing system, a first coiled tubing may be unspooled the reel assembly and injected into a wellbore using a coiled tubing injector of the coiled tubing system. Additionally, during operation of the coiled tubing system, it may be desirable to retrieve the first coiled tubing from the wellbore and inject a second coiled tubing into the wellbore having properties that differ from the first coiled tubing. For example, it may be desirable to inject a coiled tubing having a diameter, and thus a minimum allowable bend radius, that differs from the diameter of the first coiled tubing for various reasons. For instance, it may be desirable to position a tool within the wellbore which requires a coiled tubing having a diameter that differs from the diameter of the first coiled tubing. 
     In conventional coiled tubing systems, in order to replace a first coiled tubing having a first diameter with a second coiled tubing having a second diameter, a first core of the reel assembly of the coiled tubing system must be replaced with a second core having an outer diameter that differs from the outer diameter of the first core. For instance, if the second coiled tubing has a larger diameter than thus a larger minimum allowable bend radius, the first core of the reel assembly may be replaced by a second core having a larger outer diameter to ensure the second coiled tubing is not subjected to bends having a radius less than the minimum allowable bend radius of the second coiled tubing. The need to replace the core of the reel assembly of the coiled tubing system may introduce delays and extend the overall time and expense required in replacing the coiled tubing of the coiled tubing system, thereby increasing the overall time and expense required in performing a coiled tubing operation. 
     Embodiments disclosed herein include expandable reels for well systems that include a core assembly configured to receive a tubular of the well system and actuate between a first configuration and a second configuration when coupled to the support frame, wherein the core assembly comprises a first outer diameter when in the first configuration and a second outer diameter that is different from the first outer diameter. Additionally, embodiments disclosed herein include expandable reels for wells systems that include a core assembly configured to couple to the support frame and receive a tubular of the well system, wherein the core assembly comprises a plurality of circumferentially spaced panel assemblies that are radially translatable relative to a central axis of the expandable reel. Further, embodiments disclosed herein include methods for operating expandable reels for well systems that include actuating a core assembly of the expandable reel between a first configuration comprising a first outer diameter and a second configuration comprising a second outer diameter that is different from the first outer diameter. In this manner, embodiments of core assemblies disclosed herein may be actuated between a plurality of configurations configured to receive a plurality of tubulars (e.g., coiled tubing strings) having varying minimum bend radii without needing to remove or exchange the core assembly. 
     Referring to  FIG.  1   , an embodiment of a well system  10  comprising a coiled tubing system  20  located at a surface  3  of a wellbore  12  is shown. In the embodiment of  FIG.  1   , well system  10  comprises a system for servicing or completing the wellbore  12  which extends through a subterranean earthen formation  5 ; however, in other embodiments, well system  10  may comprise a system for drilling wellbore  12  or a system for producing hydrocarbons from wellbore  12 . 
     Coiled tubing system  20  is generally configured to inject or stab coiled tubing (e.g., first coiled tubing  22  shown in  FIG.  1   ) into wellbore  12  and/or pull or retract coiled tubing  22  from wellbore  12 . In this embodiment, coiled tubing system  20  generally includes a reel truck  24  comprising an expandable reel  100  rotatable by a motor  26 , a mast truck  30  comprising a mast  32 , a wellhead  40 , a blowout preventer (BOP)  42 , and a coiled tubing injector  44 ; however, in other embodiments, the configuration of coiled tubing system  20  may vary. 
     During operation of coiled tubing system  20 , first coiled tubing  22  may be unwound from a core assembly  160  of the expandable reel  100  in response to the operation of motor  26 . The unwinding from, and winding onto, core assembly  160  of first coiled tubing  22  may be performed or assisted by a tubing tensioner (not shown) of reel truck  24  that is powered by a hydraulic unit. The displacement of first coiled tubing  22  into and out of wellbore  12  may also be facilitated by a guide arch  46  extending from coiled tubing injector  44 . Mast  32  of coiled tubing system  20  extends telescopically from mast truck  30  and is coupled to and physically supports coiled tubing injector  44  at a location distal mast truck  30 . Along with being telescopically adjustable, mast  32  may also be swiveled or rotated relative to mast truck  30  to control the positioning of coiled tubing injector  44  relative to wellbore  12 . In this manner, mast  32  may align coiled tubing injector  44  with wellhead  40  and BOP  42  to ensure smooth feeding of coiled tubing  22  into and out of wellbore  12 . 
     Wellhead  40  is positioned at the surface of wellbore  12  and physically supports BOP  42  which is mounted or coupled thereto. BOP  42  may be used to control the circulation of fluids from wellbore  12  and the surrounding environment at the surface  3 . In this embodiment, a lubricator string  48  extends from BOP  42  to coiled tubing injector  44 , where lubricator string  48  provides lubrication to coiled tubing  22  as first coiled tubing  22  is extended into or retracted from wellbore  12 . A variety of tools may be coupled to the terminal end of coiled tubing  22  for performing various operations in wellbore  12 . For example, a perforating tool may be coupled to the terminal end of first coiled tubing  22  for selectably perforating a casing string positioned in wellbore  12  whereby fluid connectivity between formation  5  and wellbore  12  may be enhanced. Reel truck  24  may include a control room (not shown) for transmitting signals to and receiving signals from (e.g., electronic signals and/or data) tools attached to the terminal end of first coiled tubing  22 . Additionally, fluids may be transported between reel truck  24  and tools attached to the terminal end of first coiled tubing  22  via one or more fluid flow passages extending through coiled tubing  22 . 
     First coiled tubing  22  comprises a first diameter and a corresponding first minimum allowable bend radius. The core assembly  160  of expandable reel  100  comprises a first or retracted configuration shown in  FIG.  1    in which core assembly  160  comprises a first outer diameter  107  sufficiently large such that the bend radius of first coiled tubing  22  when wound about core assembly  160  is not less than the first minimum allowable bend radius. 
     Referring to  FIGS.  1 ,  2   , as described above, it may desirable during the operation coiled tubing system  20  to exchange the first coiled tubing  22  (shown in  FIG.  1   ) for a second coiled tubing  23  (shown in  FIG.  2   ) comprising a second diameter and a corresponding second minimum allowable bend radius that is larger than the first minimum allowable bend radius of first coiled tubing  22 . For instance, it may desirable to deploy a tool in wellbore  12  requiring a coiled tubing having a larger diameter than first coiled tubing  22 . 
     As will be discussed further herein, the core assembly  160  of expandable reel  100  may be reconfigurable between the retracted configuration shown in  FIG.  1   , where core assembly  160  has a first outer diameter  107 , and a second or expanded configuration shown in  FIG.  2    where core assembly  160  has a second outer diameter  109  that is different form the first outer diameter  107 . Particularly, the second outer diameter  109  of core assembly  160  may be larger than the first outer diameter  107  and have a size sufficient such that the bend radius of second coiled tubing  23  when wound about core assembly  160  is not less than the second minimum allowable bend radius of second coiled tubing  23 . In this manner, the outer diameter of core assembly  160  of expandable reel  100  may be adjusted between a plurality of outer diameters (e.g., outer diameters  107 ,  109 ) without needing to replace at least some components of core assembly  160 , decreasing the amount of time and expense (due to e.g., increased time as well as the need for additional components) required for exchanging a first coiled tubing (e.g., first coiled tubing  22 ) having a first minimum allowable bend radius for a second coiled tubing (e.g., second coiled tubing  23 ) having a second bend radius that is different from the first bend radius. In some embodiments, the core assembly  160  may be reconfigurable between three or more configurations providing three or more different outer diameters. 
     Referring to  FIGS.  3 - 5   , an embodiment of the expandable reel  100  for the well system  10  of  FIGS.  1 ,  2    is shown in  FIGS.  3 - 5   . Expandable reel  100  is rotatable about a central or longitudinal axis  105 , and generally includes a support frame  102 , a core assembly  160 , and an actuation assembly  200 . While expandable reel  100  is described above as comprising a component of the coiled tubing system  20  shown in  FIGS.  1 ,  2   , expandable reel  100  may be used in a variety of coiled tubing systems, as well as other systems associated with the drilling, completion, and production of hydrocarbons from subterranean, earthen wellbores. 
     Referring to  FIGS.  6 ,  7   , views of the support frame  102  of expandable reel  100  are shown. Support frame  102  is generally configured to physically support the core assembly  160  and actuation assembly  200  of expandable reel  100 . Additionally, support frame  102  may couple expandable reel  100  with motor  26  whereby torque may be transmitted from motor  26  to expandable reel  100 . Support frame  102  generally includes a central axle  104 , a pair of inner spoke assemblies  110 , a plurality of circumferentially spaced core support members  120 , a pair of outer spoke assemblies  130 , and a pair of outer hubs  140 ; however, in other embodiments, the configuration of support frame  102  may vary. In some embodiments, components of support frame  102  (e.g., inner spoke assemblies  110 , core support members  120 , outer spoke assemblies  130 , etc.) may each comprise steel tubing (e.g., square tubing, etc.); however, in other embodiments, the configuration of the components of support frame  102 , including the materials forming support frame  102 , may vary. 
     Central axle  104  of support frame  102  is generally cylindrical and central axis  105  of expandable reel  100  extends centrally through a central bore or passage of axle  104 . Motor  26  shown in  FIGS.  1 ,  2    may couple with axle  104  to transfer torque to axle  104  and thereby drive the rotation of reel  100 . Inner spoke assemblies  110  are positioned proximal longitudinally opposed ends of central axle  104 . As shown particularly in  FIG.  7   , each inner spoke assembly  110  may generally include a generally cylindrical inner collar  112  and a plurality of circumferentially spaced elongate inner spokes  114  which extend radially outwards (relative central axis  105 ) from the inner collar  112 . Inner collar  112  may be coupled to an outer surface of central axle  104 , preventing relative rotation between inner spoke assemblies  110  and central axle  104 . Additionally, a radially inner end of each inner spoke  114  may be attached (e.g., welded, etc.) to the outer surface of inner collar  112 . In other embodiments, each inner spoke  114  may attach directly to the central axle  104  of support frame  102 . 
     The outer spoke assembly  120  of support frame  102  may comprise a plurality of elongate core support members  122  and a pair of outer spoke assemblies  130 . Each core support member  122  is radially offset from central axis  105  and extends substantially parallel with the central axle  104  of support frame  102 . In this configuration, core support members  122  are positioned about or at least partially surround central axle  104 . Core support members  122  may be generally configured to physically support core assembly  160  when core assembly  160  is in the retracted configuration as shown in  FIGS.  3 - 5   . Outer spoke assemblies  130  are positioned at longitudinally opposed ends of core support members  122 . 
     Each outer spoke assembly  130  of support frame  102  generally includes a plurality of circumferentially spaced elongate outer spokes  132  which extend radially outwards (relative central axis  105 ) from core support members  122  to one of the outer hubs  140  of support frame  102 . Particularly, an inner in end of each outer spoke  132  is coupled (e.g., welded, etc.) to a longitudinal end of one of the core support members  122  while a radially outer end of the outer spoke  132  is coupled (e.g., welded, etc.) to one of the outer hubs  140 . While in some embodiments a pair of outer spokes  132  may be coupled to a corresponding core support member  122 , in other embodiments, each core support member  122  and the pair of outer spokes  132  extending from the longitudinal ends thereof may comprise a single, monolithically formed member. Outer hubs  140  of support frame  102  may define a maximum outer diameter of expandable reel  100 . Additionally, outer spoke assemblies  130  and outer hubs  140  may assist with retaining a coiled tubing (e.g., coiled tubing  22 ,  23  shown in  FIGS.  1 ,  2   ) on core assembly  160  as the coiled tubing is reeled onto or extended from expandable reel  100 . 
     Referring to  FIGS.  3 - 5 ,  8 - 10   , the core assembly  160  of expandable reel  100  may generally comprise a plurality of arcuate panel assemblies  162 . As will be described further herein, arcuate panels assembly  162  may couple to the support frame  102  of expandable reel  100  via actuation assembly  200  whereby arcuate panel assemblies  162  may be radially expanded and retracted relative central axis  105  of expandable reel  100  by actuation assembly  200 . 
     As shown particularly in  FIGS.  8 - 10   , each arcuate panel assembly  162  of core assembly  160  may generally include an arcuate tubing support panel  164 , an elongate central support member  170 , a pair of outer support members  174 , and a pair of guide assemblies  180  located at the opposing ends of the arcuate panel assembly  162 . The tubing support panel  164  of each panel assembly  162  is generally configured to physically support tubing coiled about core assembly  160 . In this embodiment, tubing support panel  164  comprises a pair of longitudinal ends  165 , a pair of lateral sides  166 , a radially outer (relative central axis  105 ) surface  167 , and a radially inner surface  168 . Radially outer surface  167  of the tubing support panel  164  may physically contact and support or contact a tubular (e.g., coiled tubing  22 ,  23  shown in  FIGS.  1 ,  2   ) extending about core assembly  160 . The radially outer surfaces  167  of the tubing support panels  164  of core assembly  160  may also define an adjustable or reconfigurable outer diameter (e.g., outer diameters  107 ,  109  shown in  FIGS.  1 ,  2   ) of the core assembly  160 . 
     Support members  170 ,  174  of the panel assembly  162  may each extend longitudinally between the longitudinal ends  165  of tubing support panel  164 . Central support member  170  may be positioned centrally between lateral sides  166  of tubing support panel  164  between outer support members  174 . Additionally, each outer support member  174  may be positioned proximal one of the lateral sides  166  of tubing support panel  164 . Each support member  170 ,  174  may couple with (e.g., welded to, etc.) the radially inner surface  168  of the tubing support panel  164 . In some embodiments, support members  170 ,  174  of each panel assembly  162  may each comprise steel tubing (e.g., square tubing, etc.); however, in other embodiments, the configuration of support members  170 ,  174  may vary. 
     Guide assemblies  180  of each panel assembly  162  may guide the respective panel assembly  162  between a radially inner (relative central axis  105 ) position corresponding to the retracted configuration of expandable reel  100  and a radially outer position corresponding to the expanded configuration of reel  100 . Each guide assembly  180  comprises a pair of opposed guide members  182  that form a radially extending guide receptacle  184  therebetween. Each guide member  182  may couple to an arcuate rib  186  positioned at one of the longitudinal ends  165  of tubing support panel  164 . Each arcuate rib  186  may extend orthogonal the radially inner surface  168  of tubing support panel  164  between a radially outer end and a radially inner end. The radially outer end of each arcuate rib  186  may couple with (e.g., welded to, etc.) the radially inner surface  168  of the tubing support panel  164 . In some embodiments, a pair of arcuate ribs  186  may be positioned at each longitudinal end  165  of tubing support panel  164 . Additionally, in some embodiments, additional arcuate ribs  186  may be positioned between longitudinal ends  165  to provide structural support to the panel assembly  162 . For example, in the embodiment shown in  FIGS.  8 - 10   , an additional pair of arcuate ribs  186  are positioned centrally between longitudinal ends  165  of tubular support panel  164 ; however, in other embodiments, the number of arcuate ribs  186  of each panel assembly  162  may vary. Additionally, in other embodiments, each panel assembly  162  may not include arcuate ribs  186  and guide members  182  may couple with another component of the panel assembly  162  such as, for example, the central support member  170 . 
     The arcuate ribs  186  positioned at the longitudinal ends  165  of tubing support panel  164  couple with (e.g., via fasteners, welded, etc.) the guide members  182  of guide assemblies  180  to attach guide members  182  to tubing support panel  164 . In some embodiments, each guide member  182  may comprise a planar member or plate oriented orthogonal the radially inner surface  168  of the tubing support panel  164 . The guide receptacle  184  formed between the pair of opposing guide members  182  of each guide assembly  180  may be configured to slidably receive one of the outer spokes  132  of one of the outer spoke assemblies  130 . For example, the receptacle  184  of a first guide assembly  180  of a given panel assembly  162  may receive one of the outer spokes  132  of a first outer spoke assembly  130  while the receptacle  184  of a second guide assembly  180  (positioned opposite the first guide assembly  180 ) of a given panel assembly  162  may receive one of the outer spokes  132  of a second outer spoke assembly  130  positioned opposite the first outer spoke assembly  130 . 
     The interaction between the guide assemblies  180  of each panel assembly  162  and the outer spoke assemblies  130  of support frame  102  (e.g., sliding contact between guide members  182  and outer spokes  132 ) may limit the degrees of freedom of the panel assembly  162  relative to the support frame  102 . For example, referring to  FIG.  11   , the interaction or contact between guide assemblies  180  and outer spoke assemblies  130  may limit each panel assembly  162  to one degree of freedom relative to support frame  102 —travelling rectilinearly between the radially inner and outer positions of the panel assembly  162  along a radius  185  extending from central axis  105  and centrally through the panel assembly  162  (e.g., extending through central support member  170  of the panel assembly  162 ) as controlled by the operation of actuation assembly  200 . Thus, the interaction between the guide assemblies  180  of each panel assembly  162  and the outer spoke assemblies  130  may prevent panel assemblies  162  from pivoting or otherwise deviating from rectilinear travel along the radius  185  extending centrally through the panel assembly  162 . 
     In this manner, an equidistant circumferential spacing  175  between adjacent panel assemblies  162  may be maintained when expandable reel is in both the retracted and expanded positions. However, the magnitude or size of the circumferential spacing  175  between adjacently positioned panel assemblies  162  may change in response to the actuation of core assembly  160  between the retracted and expanded configurations. Particularly, circumferential spacing  175  may increase in response to actuation of core assembly  160  from the retracted configuration to the expanded configuration. Circumferential spacing  175  may conversely decrease in response to actuation of core assembly  160  from the expanded configuration to the retracted configuration However, the circumferential spacing between each panel assembly  162  remains equidistant in both the retracted and expanded configurations. 
     Referring to  FIGS.  11 ,  12   , actuation assembly  200  of expandable reel  100  is generally configured to actuate expandable reel  100  between the retracted configuration (shown in  FIG.  11   ) and the expanded configuration (shown in  FIG.  12   ), and may generally include a plurality of circumferentially spaced actuators  202 . In some embodiments, each actuator  202  may be coupled between one of the inner spokes  114  of inner spoke assemblies  110  and one of the panel assemblies  162  of core assembly  160  whereby the actuator  202  may displace the panel assembly  162  along the radius  185  extending therethrough between the radially inner (shown in  FIG.  11   ) and radially outer (shown in  FIG.  12   ) positions of the panel assembly  162 . 
     In some embodiments, each actuator  202  of actuation assembly  200  generally comprises a linear actuator such as a hydraulic actuator including a cylinder  210  and a piston  220  slidably received in the cylinder  210 . A radially inner end  212  of the cylinder  210  of each actuator  202  may be pivotably coupled to a first pivotable connector  204  while a radially outer end  222  of each piston, opposite the radially inner end  212  of the cylinder  210 , may be pivotably coupled to a second pivotable connector  206 . The first pivotable connector  204  may be coupled to (e.g., welded, etc.), or formed integrally with, one of the inner spokes  114  of inner spoke assemblies  110 . Particularly, the radially inner end  212  of cylinder  210  may be pivotally coupled to one of the inner spokes  114  via first pivot connector  204  at a location proximal the radially outer end of the inner spoke  114 . Additionally, the second pivotable connector  206  may be coupled to (e.g., welded, etc.), or formed integrally with, the central support member  170  of one of the panel assemblies  162  of core assembly  160 . Thus, each actuator  202  of actuation assembly  200  may be coupled between one of the inner spoke assemblies  110  of support frame  102  and one of the panel assemblies  162  of core assembly  160 . 
     The cylinder  210  of each actuator  202  may also comprise a radially outer end  214  opposite the radially inner end  212 , a central passage  213  extending between ends  212 ,  214 , a radially inner port  216 , a radially outer port  218 , and an annular seal assembly  219  located proximal the radially outer end  214  thereof. The piston  220  of each actuator may also comprise a radially inner end  224  opposite the radially outer end  222 , and an annular seal  228  located proximal radially inner end  224 . The annular seal  228  of piston  220  may sealingly engage an inner surface of cylinder  210  and may divide the central passage  213  of cylinder  210  into a first actuation chamber  215  and a second actuation chamber  217  that may be sealed or fluidically isolated from the first actuation chamber  215 . First actuation chamber  215  is positioned between annular seal  226  and a radially inner end of the central passage  213  of cylinder  210 , and second actuation chamber  217  is positioned between annular seal  226  and a radially outer end of central passage  213 . 
     The radially outer end  222  of piston  220  may be extend and retract linearly along a radius extending parallel the radius  185  extending through the central support member  170  to which the radially outer end  222  of piston  220  is coupled. Particularly, the radially outer end  222  of piston  220  may be extended radially outwards away from cylinder  210  in response to the pressurization of first actuation chamber  215  and corresponding venting of second actuation chamber  217 . Extension of the radially outer end  222  of piston  220  may force the panel assembly  162  coupled to the piston  220  radially outwards from the radially inner position of the panel assembly  162  to the radially outer position thereof. Conversely, the radially outer end  222  of piston  220  may be retracted radially inwards towards cylinder  210  in response to the venting of first actuation chamber  215  and the corresponding pressurization of second actuation chamber  217 . Retraction of the radially outer end  222  of piston  220  may force the panel assembly  162  coupled to the piston  220  radially inwards from the radially outer position of the panel assembly  162  to the radially inner position thereof. 
     Although in the embodiment described above actuation assembly  160  comprises a plurality of hydraulic actuators (e.g., actuators  202 ), in other embodiments the configuration of actuation assembly  160  may vary. For example, in other embodiments, actuation assembly  160  may comprise one or more pneumatically or electrically powered actuators. 
     Referring briefly again to  FIGS.  1 ,  2   , expandable reel  100  may comprise a control system  230  generally configured to control the actuation of the actuators  202  of actuation assembly  200 . In this embodiment, control system  230  may comprise a hydraulic control system configured to control the hydraulic pressurization and venting of the actuation chambers  215 ,  217  of each actuator  202  of actuation assembly  200 . Although not specifically shown in  FIGS.  1 ,  2   , control system  230  may comprise a hydraulic fluid source, a pump, hydraulic lines, and other equipment for controlling the pressurization and venting of the actuation chambers  215 ,  217  of each actuator  202 . In other embodiments, control system  230  may selectably supply pneumatic or electric power to actuators  202  (when actuators  202  comprise pneumatic or electric actuators) to control their operation. Control system  230  may include an input/output (I/O) unit through which personnel of coiled tubing system  20  may control the operation of actuation assembly  200  of expandable reel  100 . In this manner, personnel of coiled tubing system  20  may selectably actuate expandable reel  100  between the retracted and expanded configurations. In other embodiments, control system  230  may be controlled a by a control system of the coiled tubing system  20 . 
     Referring to  FIG.  13   , a method  300  for operating a reel of a coiled tubing system is shown in  FIG.  12   . In some embodiments, method  300  may be practiced with expandable reel  100 . Thus, in describing the features of method  300 , continuing reference will be made to expandable reel  100 . However, it should be appreciated that embodiments of method  300  may be practiced with other systems, assemblies, and devices. Additionally, one or more of the steps of method  300  may be individually repeated and/or a plurality of method steps may be repeated in sequential order) repeated. Further, the steps of method  300  described below need not be performed in the ordering described below and shown in  FIG.  13   . 
     Initially, method  300  includes operating an expandable reel with a first coiled tubing extending about a core assembly of the expandable reel at method block  302 . Method block  302  may include unreeling the first coiled tubing from the core assembly of the expandable reel and/or reeling the first coiled tubing onto the core assembly when the core assembly is in a first configuration providing a first outer diameter. For example, method block  302  may include reeling and/or unreeling first coiled tubing  22  (shown in  FIG.  1   ) from core assembly  160  of the expandable reel  100  to inject first coiled tubing  22  into wellbore  12  and/or retract first coiled tubing  22  from wellbore  12 . As the first coiled tubing  22  is reeled and/or unreeled from core assembly  160 , core assembly  160  may be in the retracted configuration shown in  FIG.  1    where core assembly  160  comprises a first outer diameter  107 . First outer diameter  107  may be defined by the radially outer surfaces  167  of the tubing support panels  165  of core assembly  160 . 
     Method  300  proceeds at method block  304  by actuating the core assembly from a first configuration providing a first outer diameter to a second configuration providing a second outer diameter that is different from the first outer diameter. In some embodiments, the first coiled tubing may be removed from the expandable reel prior to actuating the core assembly from the first configuration to the second configuration. The first and second outer diameters of the core assembly may each be defined an outer surface of the core assembly. For example, core assembly  160  of expandable reel  100  may comprise a first outer diameter  107  and a second outer diameter  109  that is different from first outer diameter  107 , where both the first and second outer diameters  107 ,  109  are defined by the radially outer surfaces  167  of the tubing support panels  164  of panel assemblies  162 . In some embodiments, method  300  may include, in lieu of or in addition to method block  304 , actuating the core assembly from the second configuration to the first configuration. 
     In some embodiments, the first outer diameter may be less than the second outer diameter. For example, the first outer diameter  107  of core assembly  160  shown in  FIG.  1    may be less than the second outer diameter  109  of core assembly  160  shown in  FIG.  2   . Additionally, in some embodiments, the first configuration may correspond to the retracted configuration of core assembly  160  shown in  FIGS.  1 ,  11    and the second configuration may correspond to the expanded configuration of core assembly  160  shown in  FIGS.  2 ,  12   . 
     Method block  304  may include operating an actuation assembly of the expandable reel to actuate the core assembly from the first configuration to the second configuration. For example, method block  304  may comprise operating the actuation assembly  200  of expandable reel to actuate core assembly  160  from the retracted configuration shown in  FIGS.  1 ,  11    to the expanded configuration shown in  FIGS.  2 ,  12   . Method block  304  may also include operating one or more actuators of the actuator assembly (e.g., actuators  202  of actuation assembly  200 ) to actuate the core assembly from the first configuration to the second configuration. This may include supplying hydraulic, pneumatic, and/or electrical power to the actuators to control their operation. Method block  304  may further include operating a control system of the expandable reel (e.g., control system  230  shown in  FIGS.  1 ,  2   ) to operate the actuation assembly and actuate the core assembly from the first configuration to the second configuration. Personnel of a coiled tubing system (e.g., coiled tubing system  20  shown in  FIGS.  1 ,  2   ) may operate the control system through an I/O unit thereof. In other embodiments, the control system may be operated by a separate controller or control system, such as a control system for a coiled tubing system. 
     In some embodiments, method block  304  may include releasably and mechanically coupling or fastening (e.g., bolting, etc.) the guide members  182  of each guide assembly  180  to one of the outer spokes  132  of outer spoke assemblies  130  to secure core assembly  160  in the expanded configuration. Once mechanically secured in the expanded configuration, one or more actuators  202  of actuation assembly  200  may be depowered or depressurized. Guide members  182  of each guide assembly  180  may be decoupled from outer spokes  132  prior to core assembly  160  being actuated back into the retracted configuration. 
     Method  300  continues at method block  306  by operating the expandable reel with a second coiled tubing extending about the core assembly. Method block  306  may include unreeling the second coiled tubing from the core assembly and/or reeling the second coiled tubing onto the core assembly when the core assembly is in the second configuration providing the second outer diameter. For example, method block  306  may include reeling and/or unreeling second coiled tubing  23  (shown in  FIG.  2   ) from core assembly  160  of the expandable reel  100  to inject second coiled tubing  23  into wellbore  12  and/or retract second coiled tubing  23  from wellbore  12 . As the second coiled tubing  23  is reeled and/or unreeled from core assembly  160 , core assembly  160  may be in the expanded configuration shown in  FIG.  2    where core assembly  160  comprises second outer diameter  109 . 
     Referring generally to  FIGS.  1 - 13   , the outer diameter (e.g., outer diameters  107 ,  109 ) of core assembly  160  may be altered when core assembly  160  is coupled to support frame  102 . Thus, expandable reel  100  may provide a plurality of outer diameters for accommodating tubulars of various diameters without needing to exchange or replace core assembly  160 . For instance, core assembly  160  may be disposed in the retracted configuration shown in  FIGS.  1 ,  11    to receive the first coiled tubing  22  shown in  FIG.  1   . When it is desired to replace first coiled tubing  22  with second coiled tubing  23  shown in  FIG.  2   , first coiled tubing  22  may be removed from core assembly  160  and actuation assembly  200  may be operated (e.g., via personnel of coiled tubing system  20  using control system  230 ) to actuate core assembly  160  from the retracted configuration to the expanded configuration to thereby increase the outer diameter of core assembly  160  while core assembly  160  is coupled to support frame  102 . Following the actuation of core assembly  160  into the expanded configuration, second coiled tubing  23  may be wound about core assembly  160  without subjecting second coiled tubing  23  to bending in excess of the minimum allowable bend radius of second coiled tubing  23 . 
     In the manner described above, multiple coiled tubing strings of varying diameters may be deployed from expandable reel  100  without needing to replace core assembly  160 , thereby minimizing the cost of operating expandable reel  100  and minimizing the amount of time for performing a coiled tubing operation using coiled tubing system  20 . 
     While exemplary embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the systems, apparatus, and processes described herein are possible and are within the scope of the disclosure. For example, the relative dimensions of various parts, the materials from which the various parts are made, and other parameters can be varied. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. Unless expressly stated otherwise, the steps in a method claim may be performed in any order. The recitation of identifiers such as (a), (b), (c) or (1), (2), (3) before steps in a method claim are not intended to and do not specify a particular order to the steps, but rather are used to simplify subsequent reference to such steps.