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PHONE 403-362-7044 FAX 403-362-7011 CELL 403-501-1180

MAILING ADDRESS: BOX 89 RAINIER, AB T0J 2M0 SHOP: LOT 5, MARTIN WAY, MARTIN INDUSTRIAL PARK, BROOKS, AB

Celtic Rod Injector Operators Manual

Introduction:

The Celtic Rod Injector is designed to be mounted in the mast of a Service Rig, Flushby, Rod Rig or on
a stand-alone TMI unit.

On a service rig the Injector is normally powered on its own by an independent PTO with a Linde
pump and charge pump attached. This circuit normally has its’ own separate hydraulic tank and
filtration system. The skates, safety ram and annular bag are tied into the rig accumulator system. An
isolation valve is installed between the BOP circuit and injector circuit. With two 11 gallon
accumulator bottles the safety brake can be functioned approximately 30 times.

On a Flushby, Rod Rig or TMI unit the Linde Injector pump, Linde charge pump and accumulator
pump are powered by an Omsi transfer case. A five gallon accumulator bottle is plumbed into to the
Skates, Annular bag and Safety Brake circuit, in the event of hydraulic failure there should always be
between 2200 and 2400 psi reserve to function these controls.

Specifications:

The injector is driven by two MSE-11-1 Poclain motors. These motors have a working pressure range
of up to 5800 psi. The motors direct drive the 120-4 main drive sprockets via a 2½” hardened splined
shaft with a 1¾” flange bearing supporting the other end of the drive sprocket.

Main Chain Tension

The lower 120-4 idler sprockets have sealed long life roller bearings for ease of maintenance. The
lower idlers can be hydraulically adjusted to the required chain tension. The whole lower cylinder and
idler can be easily removed via eight ½” bolts for maintenance or repairs. The usual required chain
tension pressure is 300 psi, although more could be required especially when pushing in-hole.

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Skates

Traction between the rod and the injector dies comes from the skates. The process works via eight
3 1/2” bore skate cylinders with a maximum pressure of 3000 psi, pushing on eight 2” 4140 pins that
run through the skates.
The skates are the new re-circulating ball bearing style. These will be three rows of chrome molly ball
bearings encased in a 4140 through hardened track. At the maximum 200,000lbs compression force the
pressure on each ball would be 666lbs. We have tested the balls to 220,000lbs each. This means no
skate chain or skate rollers to break and longer skate life.

Injector Brakes

The injector motor brakes are a pressure release multi disc brake, in the event of hydraulic failure the
brakes will automatically apply as the charge pressure drops below 180 psi. When fully applied the
Poclain brakes will hold approx. twice whatever the motors can pull.
In the event of hydraulic failure it is still recommended to apply the brake leaver instead of waiting for
the charge pressure to bleed down as the response will be a lot quicker.

TR Valves

The TR valves that function the safety brake, annular and skates are zero leak, in the event of hydraulic
failure the skate’s cylinders holding the rod will not bleed off allowing the operator plenty of time to
install a rod clamp.

The skate TR valve should always be run in the closed position as they have reducing relieving
cartridges which if the pressure is set for example to 1000psi it will always maintain that pressure even
if a larger object is run through the Injector. Note this will only maintain the pressure at low speed, if a
large object is run through at high speed the cartridge is likely to lock and the Skate pressure will spike.
The Annular bag TR valve should but functioned to the closed position, the relief set to the desired
pressure and then functioned back to the neutral or lock position. If the TR Valve is left in the closed
position and there is a hole in the Annular bag the oil from the tank can be pumped down the well. In
the neutral position if the gauge bleeds down the operator knows the bag has a hole.

The TR Valve for the safety should be left in the open position until needed then closed. If the brake
needs to be left closed for a longer period of time or the unit needs to be turned off it is recommended
to move the safety TR valve to the neutral or lock position.

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The Celtic Rod Injector has a 48,000 lb. push/pull capacity, weighs approx. 3600 lbs. and is equipped
with:

 2 x MSE 11-1 Poclain motors

 2” 4140 skate pins
 46 ½ ” Long ball bearing style skate
 38” length of skate contact area per side
 Triple wide, ¾” ball bearings, 150 contact points per side
 120-4 Diamond chain and machined steel dies
 8 x 3 ½ ” bore skate cylinders
 At 3000psi skate pressure, max compression force of 200,000lbs
 Max. force per ball bearing 666lbs
 Max. force per steel die 4000lbs
 Fourteen tooth sprockets with sealed bearings
 Hydraulic independent main chain tension
 Electro sensor electronic counter and magnetic pick-up
 Six inch safety brake with 80,000 lb. cylinder
 Swivel arch head mounted to the injector
 Ten piece arch with second swivel section
 Injector - 2.5” through opening
 Hydraulic Safety brake -3” through opening

Gauges for:

 In-hole pressure
 Out-hole pressure
 Annular bag pressure
 Skate pressure
 Chain tension pressure
 Charge pressure
 Accumulator pressure

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Controls in panel (engraved stainless steel face):

 2 speed injector control

 Injector brake
 In hole relief valve
 Out hole relief valve
 Annular bag relief valve
 Skate pressure relief valve
 Chain tension pressure relief valve
 TR Safety ram open/close
 TR Annular bag open/close
 TR Skates open/close
 TR Chain tension apply/release
 Injector joy stick
 Electronic counter display
 Emergency kill

This injector design allows 26 dies per side on the skate at any time, compared to the usual 12. This
feature reduces the amount of skate pressure required, resulting in a longer life expectancy of dies, pins
and cylinders.

The Injector has seven lifting points built around a cage to protect the motors. A two legged lifting
sling is supplied. The unit is capable of vertical or slant wells.

On the top of the injector is the rotating guide-head that allows the guide sections to be turned in any
direction. The first guide section is permanently attached to this head. There are ten guide sections in
total. Each one is labelled 1 to 10 in order of hook-up. Each section has two lift handles for ease of
carrying and storage. These handles are also the Engineered safety sling points and lift points rated to
2500lbs.

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Safety Brake

NOTE: The safety brake was tested and held rod with 40,000 lbs. pull against the brake

 6” cylinder with a closing force of 80,000 lbs.

 cylinder is designed for 3000 psi maximum inlet pressure
 movable steel saddle
 fixed steel saddle
 movable aluminum brake pad
 fixed aluminum brake pad
o Weight – 140 lbs.
o length – 24”
o width – 8”
o height – 14”

Guide Sections:

 1 x injector head swivel

 1 x section #1
 1 x section 2 (slant hammer swivel)
 4 x section # 3, 4, 5, 6
 1 x section #7 (main swivel)
 2 x section #8 & 9 reverse curve
 1 x section 10 flared end
 1 x guide sections stand

Hydraulics:

 LINDE HPV 55 hydraulic pump (injector)

 Linde charge pump
 Prince accumulator pump
 1 x return filter
 2 x high pressure filters
 1 x hot oil shuttle
 1 x 1 quart skate accumulator bottle

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Control Panel – Operating the Injector:

The HUSCO joystick is designed in such a way that the further forward or backward you move the
joystick, the faster the chains will turn. The joystick has a detent kit that will hold it at whatever speed
is selected. The joystick only controls the speed, not the force pulling. The injector will stop once the
joystick is returned to neutral.

When not in use, always engage the injector brakes and return joystick to neutral.

The in-hole relief valve is set to a maximum of 4000 psi. However, this pressure is high for normal
operations as too much in-hole pressure can cause the rod to be damaged or bent if a collar or
obstruction is hit going in-hole.

The out-hole relief is set to use the full capacity of the LINDE hydraulic pump. If required, a full 6000
psi can be dialed in. As a quick guide, in low speed at 6000psi relief pressure the Injector can pull
48,000lb. In high speed at 6000psi it can pull 24,000lb.

When running rod in-hole the operator must ensure there is enough out-hole pressure on the relief
valve to hold the string weight from running away. For example, a rod string of 12,000lb would need at
least 1500psi relief pressure in low speed and 3000psi in high speed.

When running in-hole, if desired, the operator can dial the out-hole relief in completely to ensure he
will always have enough back pressure holding the rod.

When re-surfacing the rod it is important to dial down the out-hole relief to ensure you do not damage
the rod in the event it were to get caught up in the guide sections.

The two speed can be changed on the fly, but it is advisable to slow down before switching speeds from
high to low or vice versa.

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The skates, annular and safety brake are tied into the rig accumulator system, in the event of losing
hydraulic pressure the operator will still have these three functions. If pressure on the accumulator
circuit is available, the skates can handle up to 3000 psi for short periods. For most operating
procedures, pressures of up to 1000 psi will be more than sufficient. The rule of thumb is to use as
little pressure as required to grip to the rod without slipping. This can vary depending on the depth of
the well, obstructions in the well, the condition of the co-rod and the condition of the dies. The lower
the skate pressure, the better the wear life you will get out of the dies, skate pins, cylinders, etc.

The injector brakes work via a pressure release system. This safety feature means that if you lose
hydraulic pressure, the brakes will automatically activate. This can be manually over-rode if required.

CAUTION: DO NOT use more skate pressure than required

DO NOT switch high/low speed without slowing down
ENSURE both relief valves are not dialed in/out any more than required
ALWAYS activate injector brakes when not in use

Assembling the Guide Arch:

Each section of the guide arch is numbered from 1 – 10 and are to be assembled in order accordingly.
ENSURE that the “R” pins are installed in the connecting pins and safety slings are attached to the 'D'
rings, NOT the lift handles.
The winch line should be attached to the fifth guide section.
WATCH for pinch hazards when hooking sections together.
DO NOT walk under raised guide sections.

Rod Injector Maintenance Guideline Chart

See Appendix I

Rod Injector Pre Job Guidelines

See Appendix II

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QUICK CONNECT HOSE CONFIGERATION

A six port hydraulic quick connect bank is installed onto the Injector for easy disconnect to perform
service and repairs. With this system iot should be impossible to hook lines up wrong and damage the
motors.

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A destructive test was performed on the skate ball bearings and steel machined dies. Using C1045
material the ball bearings and steel machined dies had a force of 220,000lb applied which still did not
damage them.
The machined steel dies which are hardened to approx. 54 Rockwell, with these dies only a third of the
normal skate pressure is required compared to the aluminum inserts.

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 Rod Injector

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Circulating Ball-Bearing Skates have two grease zerks on the bottom of the skates. The upper
zerks on either side greases the centre track and the lower zerks greases each outside track. The
skates should be greased at least once a week.

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Rod Unit

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 Control Panel

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 CONTROL PANEL GUAGE PRESSURES AND PART NUMBERS

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 INJECTOR BREAKDOWN AND PART NUMBERS

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 CRI 50 ROD INJECTOR DIMENSIONS

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 SLANT GUIDE LAYOUT AT 45 DEGREES

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 VERTICAL GUIDE LAYOUT

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Each section has two lift handles for ease of carrying and storage. These handles are also the
Engineered safety sling points and lift points rated to 2500lbs. Although the handles are rated for
2500lbs each it is advisable to sling the guides as per the picture.

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