Section 210

Schlum berger COILED TUBING SERVICES MANUAL

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COILED TUBING UNIT

Contents Page
Introduction .................................................................................................... 2
1 COILED TUBING INJECTOR HEAD ............................................................... 2
1.1 Description ........................................................................................... 2
1.1.1 Principal Functions ............................................................................... 2
1.2 Features ............................................................................................... 3
1.2.1 Drive and Brake Systems .................................................................... 3
1.2.3 Traction and Tension Systems ............................................................ 11
1.2.4 Guide Arch Assembly ........................................................................ 13
1.2.5 Weight Indicator ................................................................................. 14
1.2.6 Depth Measurement Equipment ......................................................... 14
1.2.7 Stripper Mount ................................................................................... 14
2 COILED TUBING REEL ................................................................................ 15
2.1 Description ......................................................................................... 15
2.2 Features ............................................................................................. 16
2.2.1 Reel Drum .......................................................................................... 16
2.2.2 Reel Drive/Brake Systems ................................................................. 18
2.2.3 Reel Swivel and Manifold ................................................................... 19
2.2.4 Levelwind Assembly .......................................................................... 20
2.2.5 Tubing Measurement Accessories ...................................................... 21
2.2.6 Tubing Lubrication Equipment ............................................................. 21
2.2.7 Crash Protection Frame ...................................................................... 21
3 CT POWER PACK ........................................................................................ 21
3.1 Description ......................................................................................... 21
3.2 Features ............................................................................................. 22
3.2.1 Power-Pack Engine ............................................................................ 23
3.2.2 Hazardous Area Designation .............................................................. 23
3.2.3 Zone II Engine Protection Equipment ................................................. 23
3.2.4 Hydraulic Pumps ................................................................................ 24
3.2.5 Pressure Control Valves ..................................................................... 24
3.2.6 Hydraulic Fluid Reservoir .................................................................. 25
3.2.7 Filters and Strainers ........................................................................... 25
3.2.8 Hydraulic Fluid ................................................................................... 25
3.2.9 Accumulator ....................................................................................... 26
4 CONTROL CABIN ........................................................................................ 26
4.1 Description ......................................................................................... 26
4.2 Features ............................................................................................. 28
4.2.1 Injector Inside Chain Tension .............................................................. 28
4.2.2 Injector Outside Chain Tension ........................................................... 28
4.2.3 Injector-Head Drive ............................................................................. 29
4.2.4 Reel Controls ..................................................................................... 29
4.2.5 Lubrication Controls ........................................................................... 29
4.2.6 Engine Controls .................................................................................. 30
4.2.7 Blowout Preventers (BOP) ................................................................. 30
4.2.8 Strippers ............................................................................................ 30
4.3 Operating Technique ........................................................................... 31
4.4 Instrument Scanning .......................................................................... 32
5 CTU COMPONENTS - APPROXIMATE SIZES ............................................ 33

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Introduction
There are many different designs and configurations of CT
unit. Most have evolved over a relatively short period as the
understanding of criteria critical to the reliability of CT
services have become better understood. In addition, the
operating conditions in many geographical areas often
determine the most appropriate CTU design.
Regardless of manufacturer, model and design, every CTU
comprises the following principal items.
• Injector head
• CT reel
• Power pack
• Control cabin
• Pressure control equipment
The following section provides an overview of these items
of CT equipment, describing their function and principal
components or subsystems.
1 COILED TUBING INJECTOR HEAD
1.1 Description
The coiled tubing injector head provides the effort and
traction necessary to run and retrieve the CT string into and
out of a wellbore. Several hydraulic systems are used to
enable the coiled tubing unit (CTU) operator to exercise a
high degree of control over any CT string movement. A
thorough understanding of the injector head control and
monitoring systems is essential to ensure the equipment is
operated efficiently, safely and without risk of damage to
the well equipment, pressure control equipment, CT string
or the CTU.
1.1.1 Principal Functions
The basic functions required of all CT injector heads
includes safely pulling, pushing and holding the CT string
under the specific wellbore and treatment conditions.
However, there are several secondary or support functions
that are vital to ensure safe and reliable CT operations.
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The following functions apply to the majority of injector
heads.
• Pull the CT string
• Push the CT string
• Hold the CT string
• Guide and support the CT string
• Secondary/support functions include:
• Weight indicator mount
• Depth system mount
• Stripper mount
Pull (Tensile Force)
The injector head pull capacity should be compatible with
the weight of the CT string in use plus:
• Effect of fluid density inside/outside the CT string
• Overpull (tension) to be applied at the BHA
• Effect of drag (friction) caused by the string or BHA
• Friction or drag created by the stripper(s)
Push (Snubbing Force)
The injector head snubbing capacity should be compatible
with:
• The force required to overcome the wellhead pressure
• Acting on the cross-sectional area of the CT string
• Friction or drag created by the stripper(s)
Hold
The injector head should be capable of safely holding the
CT string stationary. This holding function should be
available with the hydraulic systems or power pack in both
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normal operating conditions and disabled modes. In addi-
tion, the transition from stationary to in-hole and out-of-hole
modes should be smooth and easily controlled.
Guide the tubing
Components of the injector head (guide-arch or gooseneck)
serve to support and guide the CT string from the delivery
(fleet) angle of the reel into the wellbore.
Weight indicator mount
Injector heads are typically configured with the traction and
drive components mounted on a “floating” inner chassis.
This is contained within a fixed outer frame with the weight
indicator sensor(s) connected between the two frames.
Depth system sensor
The injector head provides a convenient mounting position
for friction wheel depth measurement systems. At least two
independent sensors are typically required on every CT
operation, e.g., one reel mounted and one injector head
mounted system.
Stripper mount
The primary stripper is generally permanently mounted to
the injector head. Unless the injector head is otherwise
supported, the mounting point bears all of the forces
necessary to run and retrieve the CT string. The stripper
mount also provides a reference point with which the drive
chains and guide-arch are ultimately aligned.
1.2 Features
The design and configuration of injector heads have devel-
oped over several years to meet specifications which
reflect the evolving nature of CT applications. The trend
toward larger tubing sizes which enable greater circulation
rates, requires the injector head be capable of handling a
wider range of tubing. Similarly, since CT has commonly
become the preferred intervention method in extended
reach or horizontal wells, the “average string” length has
increased in recent years. These factors, especially in
combination, demonstrate the increased demands being
placed on injector heads and other key items of CT handling
equipment.
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The global CTU fleet includes several injector head models,
the most common of which are shown below.
The explanation of systems and components in this manual
section will be generic although some of the more signifi-
cant variations in design, specification and operation may
be outlined.
The principal features and components of injector heads
are illustrated in Figures 1 through 5.
The capacity (maximum pull) of an injector head is the
major factor in determining the operating capability of the
CTU. The table in Figure 5 summarizes the key perfor-
mance data and specifications of common injector head
models
The principal components of an injector head can be
categorized in the following systems or major assemblies.
• Drive and brake system
• Chain assembly
• Traction and tension system
• Guide-arch assembly
In addition, secondary or support systems, include:
• Weight indicator
• Depth sensor mounts
• Stripper mount
1.2.1 Drive and Brake Systems
Note: The injector head drive and brake systems are
capable of exerting high forces on the CT string, wellbore
tubulars or wellhead equipment. Significant damage may
result if the systems are not operated, controlled or moni-
tored correctly. Therefore, it is vital that the CTU operator
is aware of the design and layout of the specific system in
use. The operator must be familiar with the location and
setting of the system control and relief valves. In addition,
the limitations of the CT string must be understood when
adjusting system pressures etc. to avoid the application of
excessive force to the string.
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Gooseneck

Lubricant reservoir

Stripper assembly

Injector drive motor

Inside chain
tension system

Accumulator

Stripper assembly

Figure 1. Typical injector head.

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Figure 2. - Hydra-Rig HR 480.

Figure 3. - Hydra-Rig HR 440. Figure. 4 Stewart and Stevenson SS 400.

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R T- 20

M A R I TI M E H YD R AU L I CS ( CA N) L TD .
CA L
G AR Y, ALB ERTA, CANA DA

Figure 5. Stewart and Stevenson SS 800.

Injector Model Approximate Dimensions Snub Pull CT Size Range

Height Width Depth Weight Capacity (in.)
(in.) (in.) (in.) (lb) (x1,000 lbs)

HR240 164 52 55 7,800 20 40 1 to 1-3/4

HR260 180 52 55 9,200 20 60 1 to 2-3/8

HR440 80 52 55 6,750 20 60 1 to 2-3/8

HR480 109 60 60 11,200 40 100 1-1/4 to 3-1/2

SS 400 82 42 58 5,700 20 40 3/4 to 3-1/2

SS 800 82 42 58 6,125 20 80 3/4 to 3-1/2

Figure 6. Injector head specification table.

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All injector heads currently in common use are hydraulically
driven using either two or four hydraulic motors. The motors
are typically connected and synchronized through a gear
system located at the top of the injector head. Drive is
directed to the chain drive sprockets (one for each injector
chain set) via the drive shafts located at the top of the
injector head.
The direction of rotation and speed of the motors is
controlled and shifted by a four-way hydraulic control valve
located on the CTU power pack. The functions of the
hydraulic valve, plus the hydraulic system pressure and
rate, are remotely controlled from the CTU control console.
Protection devices, such as pressure relief valves and
crossover relief valves, are installed in the system to
protect the tubing and hydraulic components from damage
due to operator error or component failure.
The injector-head brake is generally mounted integral to the
motor assembly and is hydraulically controlled. Hydraulic
pressure is required to release the brake so the system is
considered fail-safe in operation. Application of the brake is
typically automatic and controlled by the drive system
hydraulic pressure, i.e., the brake is applied when the drive
system hydraulic pressure falls below a preset value.
Figure 7. CT chain assembly on tubing
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Some early injector heads are equipped with hydraulic
brakes controlled manually from the control console. On
early models of Uniflex injector heads, external pneumati-
cally operated disc brakes were fitted.
Several injector head hydraulic motors are equipped with an
internal speed shift facility which provides a high/low gear
option that can be selected remotely from the CTU the
control console. Two speed capability allows the injector
head to operate more efficiently with the available hydraulic
power supply, i.e. supply pressure and rate. When set in low
speed mode the injector drive motors can apply maximum
torque or pulling force. In high speed mode, available pulling
force is typically halved and the running speed doubled.
The injector head drive system includes several compo-
nents necessary for control and safety purposes. Almost
all injector heads are equipped with two pilot-operated
counterbalance valves, located on the injector drive sys-
tem lines between the drive motors and the pressure filters.
The valves function as load holding valves by closing the
motor outlet line until a pilot pressure, obtained from the
motor inlet line, is sufficient to open the valve. This
arrangement enables a smooth transition between station-
ary and operating modes. In addition, it enables the weight
of the CT string to be supported by the hydraulic fluid
trapped by the counterbalance valve, effectively providing
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a fail-safe facility in the event of brake failure.
The hydraulic lines between the counterbalance valves and
the motor are high-pressure welded steel pipe. This is a
safety feature since the line can contain hydraulic fluid at
high-pressure while the string load is held by the counter-
balance valve.
High pressure filter assemblies are fitted on the injector
head to protect the motor from extraneous materials which
may be trapped during rig-up of the drive hose connections.
Hydraulic Supply System Overview
Coiled tubing units are designed with two basic options for
the primary injector drive hydraulic system, i.e., open or
closed loop. Actual operation of the injector head and CTU
differs little between the two systems, however, each
system has associated advantages and disadvantages.
System pressure is controlled by pilot operated relief
valves located on each circuit. The maximum pressure for
each circuit is preset by adjusting the relief valve (typically
located on the power pack). The system pressure can then
be controlled from zero up to the preset maximum by
Figure 8. HR240/260 chain assembly
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operating the pilot valve on the control console. These
systems enable the operator to preset the maximum force
that can be applied to the tubing.
Some injector heads are offered with auto-driller control
options. The purpose of auto driller control systems is to
increase the operator’s ability to control the injector head at
very slow speeds, such as may be encountered during
drilling operations. Most systems also enable finer control
of the force exerted on the tubing.
1.2.2 Chain Assembly
The majority of injector heads are configured with two sets
of opposing endless chains on which are mounted a series
of gripper blocks. The gripping profile of each block is
precisely shaped to suit a specific tubing size. To facilitate
larger tubing sizes and the increasing range of sizes
commonly used, chain designs with removable gripper
inserts are commonly specified on most new injector
heads. The gripper insert enable a range of tubing sizes to
be run without the need to remove and replace the entire
chain assembly. This facility reduces the time and effort
required to reconfigure the injector head when running a
different size of CT string. In addition, gripper inserts
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reduce the inventory items (quantity and cost) required for
replacement when the gripper contact area becomes worn,
or redressing when another tubing size is to be run.
The force required for the chain to provide adequate grip on
the tubing string is provided by the inside chain tensioner
system (also known as the skate system or traction
tensioner system). This force is applied to the back of the
chain assembly. To enable the chains to rotate easily with
relatively high loads applied, the chains are fitted with
bearings which roll smoothly over the tensioner system
components while transmitting the load.
Some special applications may require tapered OD string
to be run, e.g., 1-1/2-in. and 1-3/4-in strings joined and hung
off in a velocity string installation. The ability to change the
chain gripper inserts as the tubing join passes through the
injector head provides a clear advantage in such applica-
tions.
The entire CT string load is held by the face of the gripper
block or insert. This is often achieved under significant
force. Therefore, the selection, operation and maintenance
of chain components should be undertaken with a view to
minimizing the risk of damage to the CT string and
optimizing the life expectancy of consumable components.
Recent studies indicate that even relatively light damage
on the string surface can have a significant effect on the
Figure 9. HR480 chain assembly.
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predicted fatigue life of the string. Consequently, the effect
of any components and equipment in contact with the string
surface should be understood and carefully monitored.
The majority of chain systems are assembled from stan-
dard ANSI chain components and custom built parts
enabling relatively easy replacement of worn or damaged
items. The principal chain components and assemblies
commonly found on injector heads are shown below. A
relatively recent chain design featuring a single chain
traction system is also included.
HR 240/260 Chain Assembly
The HR 240/260 chain assembly incorporates a single
piece gripper block design which is compatible with only
one tubing size. This design was generally regarded as the
industry standard until the introduction of chain with re-
placeable inserts. With the introduction of larger tubing
sizes, a limitation of the single piece gripper resulted from
the limited space afforded by the relatively small chain
pitch used in early injector heads. Larger pitch chains were
introduced on some injector head models, However, the
flexibility of the insert chain system brought obvious
advantages.
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Figure 10. SS800 chain assembly.

Figure 11. Dreco Chain Assembly - open. Figure 12. Dreco Chain Assembly - closed.

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HR 480 Chain
The HR 480 chain assembly incorporates carrier blocks
each of which contains two gripper inserts. The inserts are
supported by elastomeric elements which help ensure an
even application of the gripping force transmitted to the CT
string. This system is designed to reduce the risk of
distorting the CT string when high loads are applied in deep
or heavy-duty applications. The gripper block contact face
is machined with a smooth surface and profile to minimize
the risk of damaging the CT string surface. Gripper inserts
are available in a range for 1-1/4-in. to 3-1/2-in.
Gripper inserts are secured to the carrier block by a detent
profile and held in place by a locking pin which locates
through the side of the carrier block.
SS 800 Chain
Stewart and Stevenson injector heads are equipped with
the Varia-Block chain system which can be fitted with
gripper inserts to suit a range of CT string sizes from 1-in.
through to 3-1/2-in. The gripper insert is secured within the
gripper block by a detent profile and locked in place by a
Figure 13. HR240/260 chain tension assembly.
Section 210
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spring loaded locking pin which protrudes from the carrier
block into the back surface of the insert.
The Varia-Block chain system is designed so the as-
sembled chain has a flat back which rides on the rollers
mounted on the chain tension or traction system, i.e.,
unlike conventional chains the Varia-Block chain assembly
has no roller bearings.
DRECO Chain
The DRECO chain and drive system features a unique
single chain system. A hinged gripper assembly is housed
in a carrier assembly (bucket) which in turn is attached to
the drive chains. The chain assembly is aligned with the
tubing axis thereby reducing eccentric loading on the chain
and gripper components. In addition, the hinged gripper
arrangement ensures that the gripping force is isolated from
the drive chain components. These features are intended
to provide smooth operation and long component life.
Gripping force is applied to the tubing through the action of
the hinged gripper block. The cam rollers on the griper block
arms are forced closed by pressure beams which are in
effect the equivalent of conventional skates or tensioner
bars. Hydraulic rams are used to control the force applied
by the pressure beams using a control and monitoring
system similar to convention hydraulic tensioners.
Chain Lubrication
Injector head chains are submitted to significant forces and
a high degree of movement during operation. To ensure the
components function efficiently over an optimized chain
life, efficient lubrication of moving components is required.
This should be achieved without jeopardizing the essential
friction between the tubing and the gripper block or insert.
The lubricating oil is typically SAE 30, or equivalent.
The fluid reservoir and control manifold are typically mounted
on the injector head enabling the system to be remotely
activated from the CTU control cabin. In addition to lubricat-
ing the chain components, the lubrication system is also
sometimes used to lubricate the timing gears which syn-
chronize the multiple motor and chain drive train.
1.2.3 Traction and Tension Systems
The injector head traction or inside chain tensioner system,
(also known as the skate system) provides the force
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required to securely grip the tubing in the chain gripper

blocks. The necessary force is provided by a hydraulic
system which is typically split into three distinct sub-
systems, i.e., top, middle and bottom traction systems.
This enables some flexibility in operation and provides a
high degree of contingency or back-up for one of the most
important injector head functions.
The inside chain tensioner pressure required during a CT
operation is a function of the tubing load, size, condition,
gripper-block condition and presence of oil or similar
between the tubing and block. Since the consequences of
attempting to run CT with too little inside tension on the
chains can be catastrophic, the natural tendency of the
operator is to apply excessive pressure to the system.
While in operating terms this should ensure adequate
control over the tubing slip, it will almost certainly be
sufficient to significantly affect the life span of the injector
chain bearings and the CT.
The force is hydraulically applied through three separate
sets of hydraulic cylinders. Each set is independently
controlled and monitored from the control cabin. The use of
three separate sets reduces the risk of a major operating
failure should a component in the system fail.
To ensure adequate tension is maintained in the chain
section outside the vertical drive plane, the injector head is
fitted with an outside chain tensioner system. Current
production injector-head models are equipped with a hy-
draulic tensioner system which is controlled and monitored
from the control console. Hydraulic rams provide the
tension by acting on the external idler gears. The idler gears
are allowed to float horizontally allowing both chains to be
tensioned with a single set of rams. Early injector head
designs required that the tension be checked and adjusted
manually through a mechanical adjustment mechanism.
The chain tension applied is based on the injector-head
manufacturer’s recommendations for the specific operat-
ing conditions. The outside chain tension is critical while
the tubing is being injected with a negative load on the
injector chains (while snubbing against high wellhead
pressures). Damage to the CT string and chain drive
components may result if outside chain tension is not
properly applied under these conditions.

Recommended Guide Arch Radii

Coiled Typical Reel Typical Tubing

Tubing OD Core Radii Guide Arch Radii
(inches) (inches) (inches)
0.750 24 48
1.000 20-30 48-54
1.250 25-36 48-72
1.500 30-40 48-72
1.750 35-48 72-96
2.000 40-48 72-96
2.375 48-54 90-120
2.875 54-58 90-120
3.500 65-70 96-120

Figure 14. Comparison of guide arch sizes and recommended guide arch radii.

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1.2.4 Guide Arch Assembly

The gooseneck and pipe straightener (where fitted) act as

a guide, turning the tubing through the angle between the
wellhead and the CT reel. The CT string is supported by
rollers located at ±10-in. intervals around the gooseneck
circumference. The top rollers used to restrain the tubing
are removable to enable easier installation and removal of
tubing from the injector head. The guide arch rollers are
typically profiled with a “V” of 120° and may be manufac-
tured from steel, aluminum or polyurethane. Most guide
arch designs incorporate a flared end which reduces the
risk of damage to the tubing caused by misalignment when
the tubing is being spooled to the edges of the reel drum.
This is especially noticeable when the reel is located close
to the injector head.

The guide arch radius has a significant influence on the

fatigue induced in the CT string, e.g., a 50 in. radius guide
arch will have a more detrimental effect on tubing life than
a 72-in. radius guide arch. Guidelines extracted from API
RP 5C7 are shown in Figure 14 for various tubing sizes.

The pipe straightener, where fitted, is located immediately Figure 15. Weight indicator equipment.
above the injector head. It performs two main functions.

Figure 16. Depth measurement equipment.

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• Ensures the tubing is as straight as possible before
entering the injector-head chains.
• Guides the tubing cleanly into the injector-head chains,
thereby reducing damage caused by misalignment.
1.2.6 Depth Measurement Equipment
Depth measuring equipment, electronic or mechanical, is
frequently mounted on the injector head. Depth information
is commonly gathered by two methods.

The pipe straightener generally consists of one adjustable • Mounting a friction-wheel-type counter assembly between
roller located between two fixed opposing rollers. the injector chains and stripper, or

1.2.5 Weight Indicator • Mounting an encoder assembly to the injector-head chain

The weight-indicator load cell (or strain gage on electronic
weight indicators) is typically located on the lower front
edge of the injector head. The weight or load information is
transmitted, from the load cell to the weight-indicator dial or
display, either electronically or hydraulically.
The injector-head frame is typically constructed in two
distinct assemblies comprising the inner and outer frames
(see Stripper Mount section). Pivot points between the
frames enable the weight-indicator load cell to accurately
measure the force between the assemblies. Such force
may act up or downward, resulting from the weight of the CT
string (tension) or action of high wellhead pressure (com-
pression).
drive shaft.
1.2.7 Stripper Mount
The outer frame of the injector head is equipped with a
stripper mount facility which secures the injector head to
the pressure control stack. The stripper is generally perma-
nently bolted in place. With the injector head outer frame
fixed to the pressure control stack and the inner injector
head assembly supporting the tubing string, some limited
movement is allowed to ensure correct alignment and
operation of the weight indicator load cell.
In some larger models of injector head, the stripper is
mounted on a subassembly which can be removed during
transportation.

Tubing
measurement
and coating
accessories

Levelwind
assembly

Reel drum

Figure 17. Typical CT reel configuration.

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2 COILED TUBING REEL
2.1 Description
The primary function of the coiled tubing reel is to safely
store and protect the CT string. This should be achieved
while avoiding excessive damage to the string through
fatigue (bending) or mechanical damage from spooling. In
addition, the reel typically incorporates several features
which, although less obvious, are equally important to the
successful operation of the CTU. Most significant of which
is the swivel facility which enables fluids to be pumped
through the tubing string while the reel drum rotates.
Figure 18. Truck mounted reel (fixed).
Figure 20. Skid mounted reel.
Section 210
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Almost all reels rely totally on hydraulic power to operate
the drive, braking and spooling guide (levelwind) systems.
Previous reel designs have used pneumatics, or a combi-
nation of pneumatics and hydraulic power, to control some
of the brake and levelwind systems.
The reel levelwind is frequently used as a mounting position
for a variety of tubing protection, monitoring and measuring
equipment.
Figures 17 identifies the principal components of a typical
CT reel.
Figure 19. Truck mounted reel (skid).
Figure 21. Special application reel.
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2.2 Features
CT Reels are commonly available in a number of configu-
rations and can be categorized as shown below. Local
conditions and the nature of the CT operations will deter-
mine the type of reel required.
• Truck mounted (fixed) - permanently fixed to the truck
chassis (Figure 18)
• Truck mounted (skid) - may be changed out (Figure 19)
• Skid mounted - for offshore operations (Figure 20)
• Trailer mounted - for large capacity (length) or heavy
weight strings
• CT logging reel - fitted with electrical swivel/collector
• Special application reel - typically for completion applica-
tions (Figure 21)
With the advent of larger CT sizes, that are installed as
completion tubulars, there is increased use of special reels
and spooling stands designed to handle large tubulars.
These structures typically enable the shipping spool to be
fitted in place of the drum assembly, thereby avoiding
unnecessary spooling, which in large tubing sizes can be
difficult and hazardous.
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The evolution of CT string sizes and the general trend
toward longer CT work strings has resulted in many
different reel designs, many of which are still in common
use. However, the facilities and components identified
below are found on almost all reels:
• Reel drum
• Reel drive and brake systems
• Reel swivel and manifold
• Levelwind assembly
• Depth measurement accessories
• Tubing lubrication equipment
• Crash protection frame
2.2.1 Reel Drum
The reel drum assembly typically consists of a reel drum,
axle, flanged connection on the axle to allow the swivel to
be connected, and chain sprocket on the axle by which the
drum is driven. A second chain sprocket on the axle is often
used to drive the levelwind leadscrew. Direct drive reels
have a motor and gearbox mounted directly on the axle. The
reel axle bearings are mounted and secured on support
posts which form part of the reel chassis.
 COILED TUBING SERVICES MANUAL Section 210
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COILED TUBING UNIT Rev A - 98

A facility to lock the reel drum while being transported is

Freeboard required on all reels. This is commonly achieved by
securing with a chain and binder between the reel drum rim
and a point on the reel chassis. This must be in addition to
A
any hydraulic or pneumatic brake which is operated from
the control cabin. Reels that have wireline installed require
a modified axle to allow an electrical collector to be fitted to
the axle.

The theoretical tubing capacity (Figure 22) of any drum can

C be calculated using the procedure shown below. This
method of calculation assumes perfect spooling across the
width of the drum. Since in practice this is difficult to
achieve, an allowance must be made to maintain the reel
capacity within its practical limitations.

L = (A+C) (A) (B) (K)

where:
L = tubing capacity (ft)
B A = tubing stack height (in.)
B = width between flanges (in.)
C = reel drum core diameter (in.)
K = K value for different tubing sizes.
Figure 22. Reel drum capacity.

Figure 23. Reel back tension.

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The K values for different tubing sizes are: 2.2.2 Reel Drive/Brake Systems

Tubing OD (in.) K value All reels are hydraulically driven, although the control
1 0.262 system and type of motor vary between manufacturers and
1-1/4 0.168 reel models. Most reels can be powered in an “in-hole” and
1-1/2 0.116 “out-hole” direction. However, during normal operations,
1-3/4 0.086 only the out-hole option should be selected, since it is the
2 0.066 action of the reel drive motor in this direction that provides
2-3/8 0.046 the back tension applied to the CT string while running in
2-7/8 0.032 and out of the well.
3-1/2 0.021
The hydraulic pressure in the drive system can be varied to
control the torque output of the motor which allows the
The freeboard is the amount of clearance between the OD tension on the tubing (between the injector head and reel)
of the reel flanges and the OD of the wrapped tubing at to be varied. Generally, only sufficient tension to keep the
maximum capacity (L). The minimum recommended free- tubing straight between the reel and injector head should be
board varies with the tubing size: applied (Figure 23). Applying excessive tension may result
in premature failure of the hydraulic and drive components
Tubing OD (in.) Freeboard (in.) or damage to the tubing. This combined with incorrect
1 and 1-1/4 1.5 spooling will almost certainly result in some tubing damage.
1-1/2 and 1-3/4 2.0
2 3.0 The amount of hydraulic pressure required to achieve a
>2 10.0 satisfactory tension will depend on the amount of tubing
contained on the reel and the distance from the injector

Figure 24. Typical reel manifold configuration.

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head. The distance from the reel axle to the top tubing wrap
may be regarded as a lever through which the drive system
torque must be transmitted to tension the tubing string. The
greater the distance, the more torque will be required to
maintain a constant tension. To increase the torque output
of the drive system, the hydraulic pressure must be
increased. Therefore, while pulling out of the well, the
distance from the reel axle to the top wrap is increased,
requiring that the hydraulic pressure in the drive system
must be increased to keep a constant tubing tension. While
running in the hole (RIH), the pressure required to maintain
sufficient back tension will reduce as the number of wraps
on the drum is reduced.
In addition to the torque changes with varying reel capacity,
the change in weight will also affect the pressure required
to drive the reel. This is particularly noticeable when
starting from rest especially when the reel contains high-
density fluids or electric cable.
The reel drive motor is either mounted on the base of the
reel chassis, or mounted directly on the axle. If mounted on
the reel chassis, it is connected by a chain and sprocket to
the reel axle.
Reel brake systems may be air or hydraulically operated.
Most current models have a hydraulic reel brake incorpo-
Figure 25. Reel levelwind assembly.
Section 210
Rev A - 98
rated within the motor assembly. This is set/released by a
dedicated hydraulic circuit which is controlled from the
control cabin.
Generally, the reel brake is applied whenever the tubing is
stationary. However, consideration must be given to the
consequences of actions or operations which may affect
the stability of the CT string in the injector head, e.g. if high-
density fluid is to be pumped through the CT at depth, the
increase in weight may cause the CT to slip through the
injector chains. With the reel brake applied, the resulting
force/tension would then be applied to the reel.
2.2.3 Reel Swivel and Manifold
The design and configuration of reel swivels and manifolds
vary according to the manufacturer and model of the reel.
Early models were of simple design and often contained
threaded connections on the swivel or manifold. It is a
requirement many organizations that all treating equipment
be of integral or of non-pressure union construction. This
restriction also prevents the use of Swagelok fittings to
connect the tubing end within the reel core. Therefore, the
CT string is typically terminated with a 1502 Weco union
which has been welded in place and has undergone the
required quality control procedures.
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All reels should have a valve fitted as close as practical to

the end of the CT string. This valve can be closed in the
event of a swivel seal failure while the CT is being run,
thereby isolating the contents of the string. Reels that have
wireline installed require a modified manifold to enable
wireline access (pressure bulkhead) downstream of the
isolation valve.

The reel fluid manifold is generally considered in two parts

- the external manifold which consists of treating iron
outboard of the swivel, and the internal manifold which is
mounted within the reel core.

2.2.4 Levelwind Assembly

Accurate and even spooling of the CT onto the reel drum is

important for several reasons:

• Badly spooled damage is liable to damaged at the contact

Figure 26. UTIM device mounted on CT reel
levelwind.
points. Even apparently minor surface damage can affect
tubing life or performance.
• For the reel drum to achieve maximum capacity the CT
must be properly spooled.

Figure 27. CTL reel configuration.

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• Poorly spooled tubing may shift and slacken on the reel
while being transported. This may result in damage or
problems when the tubing is drawn from the reel for the
next operation.
• Corrosion protection of the external surface is more
effective if the tubing is closely and evenly spooled.
To help achieve a satisfactory spooling standard, the
levelwind assembly guides the tubing onto the reel drum
and automatically follows the progress of the spooling
tubing. A manual override facility allows minor adjustments
to be made to the position of the levelwind head when
required. In addition, some vertical adjustment of the
levelwind assembly is necessary to allow the fleet angle of
tubing to suit the equipment rig-up.
2.2.5 Tubing Measurement Accessories
The levelwind travelling head provides an ideal mounting
position for friction wheel depth counters or encoders.
Back-up mechanical counters that display large-sized
digits can, in most cases, be read from the operator’s
console. The travelling head also provides the mounting
position for tubing monitoring equipment such as the Dowell
Universal Tubing Integrity Monitor (UTIM) device.
2.2.6 Tubing Lubrication Equipment
Current reel designs include a fixed tubing lubrication/
inhibition system, part of which is permanently mounted on
the reel chassis, with the control system located on the
operator’s console.
2.2.7 Crash Protection Frame
The degree of protection required depends on anticipated
application and use of the CTU (e.g. offshore skid-mounted
or truck-mounted reel). In addition to the practical efficiency
of the crash frame, consideration must be given to the
requirements of certifying or regulatory authorities. For
example, a DNV certified unit for offshore use must have
a fitted reel roof, coated with a non-slip material, to assist
the seamen in attaching the load to the crane hook.
2.2.8 Wireline Reels
Wireline reels are used in CT logging operations and
incorporate a logging cable installed inside the CT string
Section 210
Rev A - 98
which is used to transmit power and data between the BHA
and surface equipment.
The following items are required to complete the surface
equipment hook-up associated with the CT reels to be used
on coiled tubing logging operations:
Pressure Bulkhead (PBH)
The pressure bulkhead is used to allow electrical connec-
tion of the reel mounted electrical components to the
logging cable inside the CT string. This must be achieved
while maintaining the pressure integrity of the reel manifold.
Reel Collector
The reel connector is used to allow an electrical connection
to be made between the cable in the rotating reel core and
the surface electrical equipment.
3 CT POWER PACK
3.1 Description
The function of the power pack may be simply stated as
providing the hydraulic power to operate the coiled tubing
unit (CTU) and pressure control equipment, e.g., BOP
system. To perform this function satisfactorily under var-
ied conditions and for the duration of any coiled tubing (CT)
operation, current generation power packs are designed to
operate independently of exterior power or air supplies once
started.
In addition to the hydraulic power supplied when running,
the power pack incorporates an accumulator facility to
allow limited operation of pressure control equipment fol-
lowing engine shutdown.
A compressor mounted on the engine provides an air
supply for operation of the engine controls and pneumatic
systems on the CTU, e.g., the stripper air-operated pump,
injector-head chain lubrication, lights and transfer pumps.
The power-pack air receiver will provide sufficient storage
to allow an engine restart shortly after shutdown, provided
the unit pneumatic systems are isolated.
The environment in which the CTU is to operate will
determine the engine protection facilities required by the
relevant local and national authorities. For example, off-
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Rev A - 98 COILED TUBING UNIT Dow ell

Lay er 1 High Exhau st Low Oil Lo ss of

TemhpCoola
Hig eratu re
nt Tem pe ratu re Pre ssure C oola nt

Coo lant Oil

Te mper atur e Pr essu re

En gine
Tach omet er
Per missive
star t

St art
Eng ine Em ergen cy
Air
Kill Kill Pr essur e

Figure 28. CT power pack.

shore skid units operating in the North Sea are required to
be fitted with an engine (and electrical, where fitted)
protection package that allows the unit to be operated in
Zone II areas, hence the designation of Zone II unit.
The CTU configuration will determine the location of the
power pack and corresponding control equipment.
• Truck or trailer mounted using the truck engine as a power
source.
• Truck or trailer mounted with an independent power
source.
• Skid mounted with the control cab and power pack
incorporated on one skid, designated a three-piece unit,
i.e., control cab/power pack, reel and injector-head/BOP
transport basket.
• Skid mounted with the control cab mounted separately
from the power pack, designated as a four piece unit.
continuing satisfactory operation of all CTU functions. The
importance of the relevant power-pack checks being thor-
oughly and regularly completed is obvious. In addition the
completion of the required reports will provide a useful
record of the power unit performance, identifying possible
problems before the operation of the CTU is affected.
3.2 Features
The majority of CTUs in use are assembled by Hydra-Rig.
The evolution of CTU design to the current standards has
resulted in several different designs of the power pack
being supplied. Figure 28 shows the power pack/control
cab skid from a three-piece Hydra-Rig CTU.
In general, all power packs will include the following major
components:
• Engine
• Hydraulic pumps

Regardless of the type of unit to which the power pack is • Pressure Control Valves
fitted, the function and facilities contained within the power
pack will be similar. • Hydraulic Reservoir

Successful operation of the CTU requires the delivery of • Filters and Strainers
precisely controlled hydraulic power on demand. Mainte-
nance checks performed on the CTU, such as those • Hydraulic Fluid
identified in the CT STEM program, are designed to ensure

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• Heat Exchanger and Thermostatic Valve
• Accumulator
Operation, or even start-up of the CTU power pack, must
not be attempted until a series of maintenance and opera-
tional checks has been completed. Failure to follow the
prestart-up procedure may expose equipment and person-
nel to unacceptable risks.
The prestart-up operational checks will vary with the
location and application of the CTU but should include the
following points as a minimum requirement.
• Ensure any location requirements, such as a permit to
work systems, are complied with fully and that actions
need for such requirements have been completed, e.g.,
positioning of gas detecting and fire-fighting equipment.
• Ensure operating and associated personnel are aware of
the above requirements, and that only qualified personnel
are authorized to operate the equipment.
3.2.1 Power-Pack Engine
Almost all engines fitted to CTU power packs are of the
General Motors Detroit series. They may be of 8V, 6V or
(more recently), six cylinder, in-line configuration. Coiled
tubing units manufactured after 1990 are likely to be fitted
with Caterpillar engines. This is primarily due to the superior
engine noise and emission control specifications achieved
by the Caterpillar engine.
Engine controls are likely to be remotely operated from the
control console and from the engine control panel located
on the power pack. Some three-piece units may only be
equipped for single-station operation, i.e., all engine con-
trols are located on the operator’s console.
The following engine controls are found on standard engine
sets.
• Engine Start
• Engine Stop
• Emergency Kill
• Engine Throttle
Section 210
Rev A - 98
Engine instrumentation will generally include the following.
• Oil Pressure Gauge
• Coolant Temperature Gauge
• Air Pressure Gauge
• Ammeter (where applicable)
3.2.2 Hazardous Area Designation
Engines and electrical equipment are often required to be
specially protected or isolated before their use is permitted
in certain environments.
The identification of designated hazardous areas or zones
in and around wellhead and process plant areas is the
principal basis upon which equipment suitability is as-
sessed. The extent of the zoned area is generally deter-
mined by the relevant national authorities. Consequently,
international variations exist both in terminology of areas
and in the extent to which they apply; however, zoned areas
will generally be based on relevant API guidelines.
The inspection and certification of equipment as being in
compliance with the operator’s standards are often con-
ducted by third-party inspection companies. Examples are
Det Norske Veritas (DNV) and the American Bureau of
Shipping (ABS).
3.2.3 Zone II Engine Protection Equipment
Diesel engine driven equipment that is intended for use
within Zone II areas and which is in compliance with the
most rigorous standards set by operating companies will
typically be fitted with the following engine protection
equipment.
• Air-inlet shutoff valve - designed to shut down the engine
when an overspeed condition is detected by increased
airflow through the shutdown valve or by the overspeed
governor, where fitted.
• Liquid-cooled exhaust gas manifold/heat exchanger.
Designed to maintain engine surface temperatures below
392°F (200°C)
• Exhaust gas spark arrestor and flame trap
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Open loop: Return flow to reservoir Directional,

pressure and Load holding
flow control (counterbalance)
valves valves
Injector head
Fixed
drive motors
displacement
pump

Closed loop:

Directional Crossover
control relief
valves valve
Injector head
Variable
drive motors
displacement
pump

Figure 29. Open and closed loop hydraulic systems.

• Engine breather and air-box breather flame traps Balanced vane-type hydraulic pumps for this application
are commonly supplied by Abex Denison. Most of the
• Screw-secured oil-filler cap and dipstick models used are high-performance double pumps, thereby
allowing two separate hydraulic systems to be run from one
• Heavy-duty radiator pump assembly. In this case, the pump contains two
separate pump cartridges supplied by a common suction
• Plastic blade fan line but having separate discharge ports. The construction
of the pump body allows cartridges of a different size, and
The protection package will initiate engine shutdown in two therefore output, to be fitted. Consequently, the output
ways. capability of the hydraulic pump array is tailor made to the
requirement of the system it supplies.
• In the case of engine overspeed, by closing the air-inlet
shutoff valve. 3.2.5 Pressure Control Valves

• In the case of high exhaust temperature, high water Each hydraulic circuit must be fitted with a device to control
temperature and low engine oil pressure, by cutting off the the maximum pressure within the system. On Hydra-Rig
fuel supply, generally by an actuator moving the engine CTU hydraulic circuits, this is achieved in several ways.
fuel rack.
• Preset relief valves
3.2.4 Hydraulic Pumps
• Pilot-operated relief valves
The hydraulic pump array will vary with the model and
manufacturer of the CTU. The hydraulic systems on most • Unloader valves
CTUs consist of balanced vane type pumps operating in an
open-loop system (Figure 29).

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Preset Relief Valves
This type of valve is manually adjusted and set to the
maximum desired pressure in the system. Once this
pressure is reached, the relief valve lifts allowing excess
flow to be directed back to the hydraulic reservoir. This
action imparts considerable energy to the hydraulic fluid,
causing the system temperature to rise if the valve relieves
over a prolonged period.
Pilot-Operated Relief Valves
Pilot operated relief valves are similar to preset relief
valves, but have the additional facility of allowing the relief
pressure to be remotely controlled by a pilot control valve
connected to the relief valve by a pilot control line. The
pressure may be remotely varied up to the preset maximum
setting of the relief valve.
Unloader Valve
Unloader valves are similar to relief valves, but differ in that
when the preset maximum pressure is reached, the valve
reacts to isolate the system and direct the flow to the
reservoir under no load. When the system pressure is
reduced, the valve opens to recharge the system, closing
again when the desired pressure is reached. Unloader
valves are commonly fitted to systems that require little
flow during operation and that are also fitted with accumu-
lators. Hydraulic circuits that supply BOP operating pres-
sure are generally fitted with an unloader-type valve.
3.2.6 Hydraulic Fluid Reservoir
The hydraulic fluid reservoir performs several functions.
• Stores the hydraulic fluid
• Allows the fluid to cool
• Allows settling of dirt and metal particles
• Allows entrained air to be released.
The reservoir is generally mounted high in the power pack
to provide a positive head of pressure at the hydraulic pump
suction port. Suction lines from the reservoir to the pumps
are commonly fitted with strainers and isolation valves.
Section 210
Rev A - 98
3.2.7 Filters and Strainers
The hydraulic fluid and system are kept clean by passing
the fluid through filters and strainers as it flows through the
circuits.
A strainer is a coarse filter, commonly made from wire
mesh, which is generally fitted to the suction line inside the
reservoir. The strainer is generally specified by a mesh
number or standard sieve number.
Filters retain much smaller particle sizes than strainers and
are commonly located on the reservoir return lines. Filters
are generally specified by a micron number and as being
either nominal or absolute. A nominal filter rated at 10
micron will trap most of the particles of that size; however,
an absolute filter will trap all particles of that size and
greater.
In addition to the filters placed in the reservoir return lines,
some circuits have an in-line filter installed upstream of the
valve gear, particularly where there is a limited flow through
the system, e.g., on the priority supply line to the Monsun
Tison valve, the main control valve of the injector head.
Many filter assemblies incorporate a filter condition indica-
tor. This simply gives some indication of the differential
pressure being applied across the filter. A filter which is
partially plugged will create a larger differential, the indica-
tion of which is commonly displayed by a colored indicator
system. A green display during operation is normal; a red
display indicates the filter requires changing. In addition to
this feature, or as an alternative, a bypass system may also
be incorporated into the filter assembly. This allows fluid to
bypass the filter should the back pressure caused by a
blocked, or partially blocked filter, become too severe.
3.2.8 Hydraulic Fluid
The hydraulic fluid has four main functions
• Power Transmission - to transmit power efficiently, the
fluid must flow easily through lines and components.
Resistance to flow caused by friction will result in power
loss. The fluid should also be as incompressible as
possible to transmit power immediately on start-up.
• Lubrication - most hydraulic components are lubricated by
the fluid; therefore, for a long component life, the fluid
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Rev A - 98 COILED TUBING UNIT
should contain the necessary additives to ensure high
antiwear characteristics.
• Sealing - in many cases, the close mechanical fit and
hydraulic fluid provide the only seal against leakage
within the hydraulic component. Therefore, the mechani-
cal fit and fluid viscosity will determine the leakage rate.
• Cooling - heat generated by the components in the system
is dissipated by the fluid as it passes through the lines and
reservoir.
In addition to the four main functions of the fluid, a number
of other quality requirements are desirable.
• Prevent rust, corrosion or pitting.
• Prevent sludge formation.
• Depress foaming.
• Maintain stability over a wide temperature range.
• Separate out water.
• Be compatible with seal and gasket materials.
The excess generation of heat and associated problems is
a relatively common problem in incorrectly designed or
operated hydraulic systems. To combat this potential
problem and to assist with heat dissipation during periods
of high load or high ambient temperature, most CTUs are
equipped with a heat exchanger.
Heat exchangers may rely on air or water to cool the fluid,
and are generally located on a main reservoir return line.
This ensures that the majority of the fluid passing through
the system goes through the heat exchanger.
3.2.9 Accumulator
Hydraulic systems that operate at a static pressure and
have a low fluid flow rate are commonly fitted with accumu-
lators. In this application, the accumulator performs two
functions.
• Energy storage (e.g., BOP accumulator)
• Shock absorption (e.g., tensioner circuit accumulator).
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Accumulators fitted to the power pack generally contain an
internal bladder which is precharged with nitrogen. The
precharge pressure is dependent on the application and
volume of the accumulator. For example, the BOP circuit
is fitted with a large-capacity accumulator which, when fully
charged, will allow limited operation of the BOP following
shutdown of the power pack.
4 CONTROL CABIN
4.1 Description
The control cabin contains all of the controls and instru-
ments necessary to allow the CT operation to be run from
one control station. The location of the control cabin will
vary depending on the configuration and type of the coiled
tubing unit; however, the cabin is generally situated behind
the CT reel, in line with the wellhead/injector head. To help
achieve maximum visibility from the control station, the
cabin is commonly elevated.
The level of control and instrumentation fitted will greatly
depend on the model and version of the CTU. However,
typical design objectives include ability to:
• Control and monitor the operation of all of the CTU
operating functions.
• Control and monitor the operation of well pressure control
equipment.
• Monitor and record the principal well and CT string
parameters of wellhead pressure, circulating pressure,
tubing weight at the injector head and tubing depth.
The principal benefit of this comprehensive control and
instrument package is that it provides the operator with an
increased awareness of the CTU operating conditions. This
in turn provides three important prerequisites that are
crucial to achieving adequate service quality:
• The CTU can be operated safely and efficiently.
• Potential problems can be identified and rectified before
they interfere with the operation of the CTU.
• An accurate CT string work record is developed, based
on the primary factors which influence the useful life of the
tubing.
 COILED TUBING SERVICES MANUAL Section 210
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Dowell
COILED TUBING UNIT Rev A - 98

EMERGENCY
SHEAR RAM BLIND RAM TRACTION SUPPLY
CLOSE OPEN CLOSE OPEN INJECTOR OUTSIDE
TENSION PRESSURE CLOSE OPEN
150 PSI MAX

INSIDE TRACTION
PRESSURE DRAIN AIP SUPPLY
INJECTOR INSIDE PRESSURE
TRACTION PRESSURE ENGINE EMERGENCY
B 1500 PSI MAX STOP STOP
O ON
SLIP RAM P PIPE RAM
30 GPM
CLOSE OPEN CLOSE OPEN OFF PUMP

PRESSURE BLEED
ON
60 GPM
TOP OFF PUMP
TUBING WEIGHT INDICATOR
ON PRESSURE
OFF OFF THROTTLE
ON CIRCULATING PRESSURE WELLHEAD PRESSURE
REEL BRAKE
OFF
INSIDE TRACTION
BOP SUPPLY SUPPLY PRESSURE
AIR HORN
BOP PRESSURE BOP SUPPLY PRESSURE
MIDDLE INSIDE TRACTION
PRIORITY PRESSURE INJECTOR DIRECTIONAL
Schlumberger
ON PRESSURE 2,000 PSI MAX CONTROL VALVE
STRIPPER STRIPPER PILOT PRESSURE Dowell
#2 #1 OFF PRESSURE ADJUST
REEL PRESSURE

IN INJECTOR CHAIN
LUBRICATION
RETRACT NEUTRAL PACK RETRACT NEUTRAL PACK

UP HIGH

STRIPPER SYSTEM PRESSURE BOTTOM

5000 PSI MAX LEVELWIND INJECTOR OUT
ARM SPEED INJECTOR INJECTOR MOTOR
#2 #1 ON PRESSURE MOTOR PRESSURE PRESSURE ADJUST REEL PRESSURE REEL TUBING
STRIPPER STRIPPER INJECTOR ADJUST
OFF LUBRICATION
DOWN LOW CONTROL LEVELWIND REEL CONTROL
STRIPPER OVERRIDE
PRESSURE ADJUST
AIR REG. CONTROL

Figure 30. Typical control panel layout - flat panel.

CLOSE OPEN

INSIDE TRACTION
PRESSURE DRAIN
BOP PRESSURE STRIPPER #1 STRIPPER SYSTEM STRIPPER SYSTEM SYSTEM
PRESSURE PRESSURE PRESSURE AIR PRESSURE

TUBING WEIGHT INDICATOR

STRIPPER PRESSURE BLEED
BOP SYSTEM STRIPPER #2 BLEED INSIDE TRACTION CHARGE PRIORITY
PRESSURE PRESSURE SUPPLY PRESSURE PRESSURE DEPTH SYSTEM PRESSURE
OUTSIDE TENSION
INJECTOR WELLHEAD PRESSURE CIRCULATING PRESSURE

SHEAR RAM BLIND RAM NEUTRAL INSIDE TRACTION

EMERGENCY
CLOSE OPEN CLOSE OPEN RETRACT PACK TRACTION SUPPLY

ON OFF
STRIPPER PRESSURE ADJUST
#1 INJECTOR LUBE REEL LUBE

HIGH LOW ON OFF

B INJECTOR
O CONTROL
SLIP RAM P PIPE RAM ON OFF
INJECTOR REEL BRAKE ENGINE EMERGENCY
CLOSE OPEN CLOSE OPEN STOP
TOP TRACTION 2 SPEED STOP
INJECTOR TOP IN REEL BRAKE
TRACTION CYL. PRESSURE Schlumberger
Dowell
NEUTRAL
RETRACT PACK
ON OFF

STRIPPER MIDDLE TRACTION

#2 OUT
BOP SUPPLY INJECTOR MIDDLE INJECTOR REEL PRESSURE
AUX BOP TRACTION CYL. PRESSURE ADJUST ADJUST
ON
CLOSE OPEN
OFF INJECTOR SLOW THROTTLE
SPEED CONTROL
ON OFF

BOTTOM TRACTION LEVELWIND LEVELWIND REEL CONTROL

STRIPPER
PRESSURE ADJUST INJECTOR BOTTOM INJECTOR CONTROL INJECTOR MOTOR REEL PRESSURE OVERRIDE ARM
TRACTION CYL. PILOT PRESSURE PRESSURE AIR HORN

Figure 31. Typical control panel layout - split panel.

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Rev A - 98 COILED TUBING UNIT Dow ell

4.2 Features Inside Traction Pressure Adjust

Controls and instruments can be grouped by function as This is a pressure reducing valve used to adjust the
follows. hydraulic pressure to the cylinders (increase and decrease
pressure). The hydraulic supply is from the priority circuit
• Injector chain inside tension (2,000 psi); the maximum chain tension pressure should
not exceed 1,500 psi.
• Injector chain outside tension
Inside Traction Supply Pressure Gauge
• Injector-head drive
Displays system pressure as determined by the pressure
• Reel adjust valve.
·
• Lubrication controls Control Valve (3)

• Power unit May be used to isolate each of the three inside chain
tension cylinder sets.
• BOP
· Pressure Gauges (3)
• Stripper
· Displays the hydraulic pressure downstream of the control
• Principal gauges valves.
·
• Emergency hydraulic supply equipment Inside Traction Pressure Drain
·
• Electronic equipment This valve is used to bleed pressure from the system when
the control valves are open. Caution must be exercised
The illustrations in Figure 30 and Figure 31 show typical when opening this valve when tubing is suspended in the
console layouts. injector chains because a sudden drop in the cylinder
pressure will result. Fine pressure adjustment should be
The explanations given below summarize the function of made by the pressure adjust valve.
each control or instrument group.
4.2.2 Injector Outside Chain Tension
4.2.1 Injector Inside Chain Tension
This system is served by the following controls and
This system is served by the following controls and instruments.
instruments.
Injector Outside Tension Pressure Gauge
Emergency Traction Supply
Displays the current hydraulic pressure within the outside
A three-way valve that is used to apply full priority pressure tension cylinders.
in the event of an emergency (runaway) situation. In the
normal operating position, the pressure to each of the three Pressure Valve
tensioner cylinder ram sets is determined by the pressure
adjust valve. A needle valve which isolates the supply pressure from the
system.

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Bleed Valve 4.2.4 Reel Controls

A needle valve used to bleed pressure from the system.
4.2.3 Injector-Head Drive
This system is served by the following controls and
instruments.
Injector Motor Pressure Adjust Valve
A remote pilot valve used to control the injector drive
pressure.
Injector Control Pilot Pressure Gauge
Displays the pilot control pressure, which is equal to the
discharge pressure of the Husco valve.
This system is served by the following controls and
instruments.
Reel Control
The reel directional control valve. Should be locked in the
out-hole direction for all normal operations.
Reel Pressure Adjust
A remote pilot valve used to adjust the reel drive system
relief valve from zero to the preset maximum.
Reel Pressure Gauge
Displays the hydraulic pressure to the reel motor.

Injector Control Valve Reel Brake

Provides directional and speed control of the injector- head A valve used to apply/release the reel brake.
motors by controlling the output of the Husco valve. Pulling
the valve handle backward selects the out-hole direction; Levelwind Override
pushing the handle forward selects an in-hole direction.
Advances or retards the position of the levelwind traveling
Injector Speed High/Low head.

Valve used to control injector-head motor speed selection. Levelwind Raise/Lower

Injector Motor Pressure Control to raise or lower the levelwind assembly.

Displays the injector motor hydraulic pressure. 4.2.5 Lubrication Controls

30-GPM Pump/60-GPM Pump This system is served by the following controls and
instruments.
These two valves are used to control the injector-head
motor speed. One or more of the pumps must be selected Reel Tubing Lubrication
in order to operate the injector head. For high injector head
speeds both pumps may be selected. A pilot valve used to control (on/off) the reel tubing
lubrication system.
Priority Pressure Gauge
Injector Chain Lubrication
Displays the priority system pressure. The priority system
pressure is used to operate several of the remote pilot A pilot valve used to control (on/off) the injector-head chain
functions associated with the other controls. lubrication system.

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4.2.6 Engine Controls 4.2.8 Strippers

This system is served by the following controls and This system is served by the following controls and
instruments. instruments.

Emergency Stop Stripper Selection Valve

A valve which operates the engine’s air inlet shutoff valve. Three-way valve which directs the hydraulic supply to the
Should only be used in an emergency. The shutoff valve appropriate stripper.
must be manually reset at the power pack to allow further
operation. Stripper-System Pressure Gauge

Engine Stop Displays the discharge pressure of the stripper supply

pump.
A valve which remotely shuts off the diesel fuel supply to
the engine. Stripper Pressure Adjust

Throttle Air regulator control which controls the operation of the

stripper supply pump. Stripper pressure decrease cannot
Used to control the engine speed. be achieved by this control.

Air-Supply Pressure Gauge Retract/Neutral/Pack Valve (2)

Displays the pneumatic system pressure. Control valve for each stripper selecting the desired func-
tion. The neutral position bleeds stripper pressure.
4.2.7 Blowout Preventers (BOP)
Stripper Pressure Gauge (2)
This system is served by the following controls and
instruments. Displays the hydraulic pressure of the selected function, as
selected by the retract/neutral/retract valve.
BOP-Supply Pressure Gauge
4.2.9 Principal Gauges
Displays the BOP’s hydraulic supply pressure.
Wellhead Pressure Gauge
BOP Pressure
Displays wellhead pressure at the BOP pressure port,
Displays the hydraulic pressure in the BOP circuit down- generally located at the center of the BOP stack.
stream of the BOP supply valve.
Circulating Pressure Gauge
BOP Supply Valve
Displays pressure at the reel-manifold pressure sensor.
Valve used to isolate the BOP circuit from the hydraulic
supply. Weight Indicator

Ram Control Valve (4) Displays the weight exerted by the tubing on the injector
head.
Used to open/close each of the four ram sets (blind, shear,
slip and pipe rams).

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COILED TUBING UNIT
4.2.10 Emergency Hydraulic Supply
The emergency pump console contains the pressure gauge
and valves to allow the selection and monitoring of emer-
gency hydraulic supply to the stripper, BOP and chain
tensioner systems, as selected. Control of pressure is then
by manual effort.
4.2.11 Electronic Equipment
The following electronic equipment may be fitted or in-
stalled to monitor and record the CTU, tubing, and well data.
• Electronic Depth Sensors
• Electronic Pressure Sensors
• Tubing Monitoring Equipment
4.3 Operating Technique
The controls and systems of any CTU must be operated in
a manner which ensures that the following general require-
ments are met:
• The safety of personnel associated with the operation and
maintenance of the CTU and ancillary equipment must
not be jeopardized by the actions of the CT operator.
• Operation or maintenance of any controls or system of the
CTU must not compromise the efficiency of the well
control barriers. The operation of primary, secondary and
tertiary (where required) well control barriers must be
understood. In addition, the consequences of their opera-
tion must be understood.
• The operating limits of key components and systems
associated with the CTU or ancillary equipment should
not be exceeded.
• The operating limits defined by appropriate CT software
models should not be exceeded. In the event that this
information is not available, the operation should be
conducted within the operating limits identified during the
job design phase.
• Applicable safety and environmental policies must be
understood and complied with.
Section 210
Rev A - 98
The equipment operator should coordinate the control and
instrumentation functions to affect a high level of control
over the CTU. Good control, together with smooth operation
will help to improve the reliability and longevity of the
components, system controls, tools and tubing used.
During operation, consideration must be given to the speed
and levels of force applied to the CT. These must be
consistent with the well conditions and equipment limita-
tions.
Starting/Stopping
The process of starting and stopping the movement of the
CT must be conducted by applying or reducing the driving
force slowly and smoothly. Sudden changes may exert
unacceptably high forces to the tubing, reel, injector head,
power pack and pressure control equipment components.
NOTE: If any of the defined operating limits are met, or
exceeded, the injector-head drive must be disengaged as
quickly as possible. Operation may commence only when
the appropriate course of action has been determined.
Changes in the injector head direction must only be
attempted after the tubing has been brought to a complete
halt.
Several precautions must be taken when the injector-head
drive is to be engaged. These may include, but not be
limited to:
• Check that the BOP rams and wellhead valves are open
(including the subsurface safety valve, where appli-
cable). Ensure that all pressure control systems are
appropriately energized.
• Ensure that parking devices such as BOP slips, reel
brakes, etc., are released and that the appropriate reel
back tension is applied.
• Note (reset if applicable) the depth system readout.
• The weight indicator reading at the maximum allowable
tension (Tmax), as determined during the job planning
phase, must be known and noted by the operator prior to
commencing the operation.
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Running the CT The control and operation of the CTU should be consistent
with any conditions, known or suspected, which may affect
The location of the CT BHA in relation to the wellbore the CT operation.
tubulars and restrictions should be a constant consider-
ation. Appropriate precautions must be taken as the CT The following instruments and gauges are generally vari-
BHA passes restrictions or variations in the wellbore able throughout a CT operation and are assigned an “A”
diameter. These may include, but not be limited to, the priority.
following.
• Weight indicator display
• Close observation of the weight indicator display.
• Wellhead pressure gauge
• A reduction in the running speed.
• Circulating pressure gauge
• Coordination with operators of a specialist tool string, e.g., In addition, the following locations are assigned an “A”
CT Logging company. priority.

• Checking the actual vs predicted weight/depth plots. • Injector head and wellhead area

• The operator must, at all times, be prepared to quickly • CT reel

disengage the injector-head drive should abnormal condi-
tions be observed. The following instruments and gauges are generally less
likely to change rapidly and are assigned a “B” priority.
Pressure Control Equipment
• Depth measurement system
With the exception of strippers and equipment designed to
be operated while the tubing is in motion, operation of • Stripper pack pressure
pressure control equipment must only be attempted when
the tubing is stationary. • Inside chain tensioner system

The operation of BOP functions which may damage the CT, In addition, the following locations are assigned a “B”
e.g., the blind rams or shear rams, must only be attempted priority.
after considering the implications of such action. Lockout
devices should be fitted to all BOP controls that may initiate • Pump and choke parameters
severe damage to the CT if unintentionally actuated.
• Auxiliary equipment
4.4 Instrument Scanning
The following instruments are generally static throughout
To ensure that unusual circumstances during a CT opera- the operation. They do not normally require adjustment and
tion are detected as early as possible, it is necessary for the are assigned a "C" priority.
operator to constantly scan the CTU instrument array.
• Power-Pack Engine Gauges
The priorities assigned to each instrument group are
intended to initiate a regular scanning sequence which • Priority Circuit Pressure Gauge
should become habitual to the operator during normal
operations. However, during special or emergency opera- • BOP Circuit Pressure Gauge
tions, some instrument groups may require extra attention.
• Stripper System Supply Pressure Gauge

• Injector Motor Pressure and Direction Pressure Gauges

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• Outside Chain Tension Pressure Gauge 5 CTU COMPONENTS - APPOROXIMATE SIZES

• Inside Chain Tension Supply Pressure Gauge Figure 32 shows approximate sizes for the following CTU
components:
• Reel Back Tension Pressure Gauge
• Injector head
The frequency of scanning should ensure that all of the
systems and locations are checked every four to five • Reel
minutes.
• Control cabin
The B priority items should be checked every two to three
minutes. • Power pack.

Attention should be maintained on the A priority items at all

times other than when B and C items are being checked.

Width Length Height Weight

(ft) (ft) (ft) (tons)

Injector Head 4 4 10 7
Reel (Small) 8 8 10 20-30
Reel (Large) 9-10 9-10 12 40-50
Control Cabin 8 8 8 7
Power Pack 8 12 8 12
Control Cabin/Power 8 16 8 16
Pack Combined

Figure 32. Approximate sizes of CTU components.

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