HYDRA RIG INJECTOR MAINTENANCE AND TROUBLESHOOTING

Measuring Injector Chain Elongation or Wear

There are two ways in which “chain elongation” or wear can be measured. The first
means can be used to measure the chains while they are still in the injector. The second
means requires that the chains be removed from the injector and disassembled.
Chain elongation is calculated as the total amount of elongation caused by wear on the
pin and bushing. Remaining chain life can be estimated by measuring chain elongation.
The first means of measuring “chain elongation”: Tools needed to measure the chains
while they are in the injector are:
1. 24 inch Vernier Caliper
2. Calculator
Step one
Wash the injector to ensure that there are no foreign materials built up on the chains. You
will be dealing with precise measurement and any buildup on the chains will greatly
affect the accuracy of the measurements.
Step two
Leave the injector connected to the coiled tubing unit and apply enough pressure to the
chain tension system to ensure that all slack is removed from the chains.

• HR240.......................................................................................................................80 psi
• HR260.......................................................................................................................80 psi
• HR440.......................................................................................................................40 psi
• HR480.......................................................................................................................40 psi
• HR5100...................................................................................................................100 psi
• HR5200...................................................................................................................100 psi
Step three
Close the injector brake isolation valve to ensure safety or take another measure to ensure
that the injector chains cannot be moved while you are measuring them.

CAUTION THIS STEP IS IMPORTANT. A LOCK-OUT TAG-OUT PROCEDURE

MUST BE FOLLOWED TO INSURE THE CHAINS CANNOT MOVE WHILE
MEASUREMENTS ARE BEING TAKEN. IF THERE IS ANY QUESTION THAT
THE INJECTOR IS NOT DISABLED, CONSULT WITH THE HYDRA RIG
SERVICE DEPARTMENT (24 HOUR: 817-457-1521).

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 HYDRA RIG INJECTOR MAINTENANCE AND TROUBLESHOOTING

Step four
Measure the outside of seven chain roller bushings as shown in Fig. 3-1, and that
measurement will be called L2.
Step five
Measure the inside of six of seven chain roller bushings as shown in Fig. 3-1, and that
measurement will be called L1.
Step six
Add L1 to L2 then divide their sum by two. L1+L2 divided by 2= ML (measured
length).
Step seven
Find the standard length of the size chain you are measuring in the original length line on
the chain length table on page 3-4. Subtract the original length from the measured length
(ML) and divide that number by the original length, then multiply that number by 100.
The number you come up with will be the percentage of “chain elongation” that you have
for that particular chain.
Measured Length – Original Length
Original Length X 100= Percentage of “chain elongation”

Step eight
Repeat this procedure in two different locations on the injector chain to ensure that the
percent of “chain elongation” is accurate and that there is no localized area wear.
The maximum allowable “chain elongation” for Hydra Rig injector chains is three
percent (3 %).

CAUTION ANY ELONGATION GREATER THAN 3% CAN RESULT IN:

• CHAIN FAILURE
•THE TENSIONING SYSTEM “BOTTOMING OUT” RENDERING CHAIN
TENSION ADJUSTMENT USELESS CAUSING A POTENTIAL HAZARDOUS
CONDITION IN THE SNUB MODE.
•ACCELERATED WEAR ON THE DRIVE SPROCKETS, IDLER SPROCKETS,
AND SKATES.

Remember that a coiled tubing injector is a machine that wears and requires maintenance.
The better it is maintained, the longer it will provide service. Please refer to operating and
maintenance instructions in the manual.

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 HYDRA RIG INJECTOR MAINTENANCE AND TROUBLESHOOTING

The second means of measuring “chain elongation” requires that the chains be removed
from the injector and partially disassembled.
The tools required to measure “chain elongation” in this manner are:
1. 12 or 24-inch Vernier caliper, depending on chain size. (RS140 can be measured with
12-inch caliper. RS160 and larger must be measured using 24-inch caliper.)
2. Calculator
Step one
Remove the chains from the injector and wash them to ensure accurate measurements.
Lay the chains on a flat surface with the chain bearings up.
Step two
Remove the finish plates from a six-link section of the chain.
Step three
Remove the roller links from that section of chain and continue disassembling that
section of chain until there is only the pin links and the roller link next to them still
assembled.
Step four
Reassemble the roller links that were removed back on to the pin links to ensure that the
pin links are not spread or collapsed. By hand, pull the chains to their greatest length.
Step five
Measure across six pin links, from the inside of first one to the outside of the sixth one.
This length will equal the center of the first pin to the center of the sixth pin.
Refer to the chain length table below to determine the percentage of wear that is present
in a particular chain.
Again, as in the first method of measuring “chain elongation”, the maximum allowable is
three percent (3%).

CAUTION
ANY ELONGATION GREATER THAN 3% CAN RESULT IN:
• CHAIN FAILURE
• THE TENSIONING SYSTEM “BOTTOMING OUT” RENDERING CHAIN
TENSION ADJUSTMENT USELESS CAUSING A POTENTIAL HAZARDOUS
CONDITION IN THE SNUB MODE.
• ACCELERATED WEAR ON THE DRIVE SPROCKETS, IDLER SPROCKETS,
AND SKATES.

Remember that a coiled tubing injector is a machine that wears and requires maintenance.
The better it is maintained, the longer it will provide service. Please refer to operating and
maintenance instructions in the manual.

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 HYDRA RIG INJECTOR MAINTENANCE AND TROUBLESHOOTING

CHAIN LENGTHS

RS140 RS160 RS180 RS200 RS240

Original mm 266.7 304.8 342.9 381 457.2

inches 10.5 12 13.5 15 18

1.50% mm 270.7 309.37 348.04 386.72 464.06

inches 10.66 12.18 13.7 15.23 18.27

2.00% mm 272.03 310.89 349.75 388.62 466.34

inches 10.71 12.24 13.77 15.3 18.38

2.50% mm 273.36 312.42 351.47 390.53 468.83

inches 10.76 12.3 13.83 15.38 18.45

3.00% mm 274.7 313.94 353.18 392.43 470.91

inches 10.81 12.36 13.9 15.45 18.54

Fig. 3-1, Measuring Chain Elongation

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