© 2003 Stewart & Stevenson Services, Inc.

Chapter 1

CHAPTER 1
DESCRIPTION AND SPECIFICATIONS

1.1 GENERAL INFORMATION

The purpose of the coiled tubing injector head is to supply the force and traction required to
snub and hoist the tubing into and out of the well. The injector head consists of several hydrau-
lic systems and components designed to provide the unit operator with a high degree of control.
The following MUST be CHECKED BEFORE OPERATION of Injector:

1. Chain traction and chain tension valves must be closed.

2. Chains and blocks should be in place.
3. All injector hydraulic hoses should be properly connected to the bulkhead panel.
4. If the tubing guide isn’t properly aligned, follow this chapter’s adjustment procedure.
5. Secure all cables and pins for lifting the injector head.
6. Check the stripper assembly and change the pack off rubber if required.
7. Check the O-ring and Teflon ring on the Bowen cap and pin assembly.
8. If the gap between the hydraulic loadcell and the mounting plate is not 3/16″ to 1/4″
then follow the adjustment procedures later in this chapter.
Motor Side Loadcell Side

Rigid Crash Easy-Access

Frame Drive Motors

Easy-Access
Drive Motors

Fold-Down
Workboards

Fold-Down Adjustable
Workboards Legs

The 400 Series Injector has one (1) drive motor,

while the 800 Series (shown) has two (2) drive motors.

NOTE: All hoses are numbered to correspond with the connection

panel on the injector head. Always connect the case drain first and
disconnect it last if hoses need disconnecting.

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1.2 DESCRIPTION AND SPECIFICATIONS

1.2.1 INJECTOR COMPONENTS

1.2.1.1 HYDRAULIC MOTOR

The hydraulic motor is a variable displacement type and can be used in closed loop or open
loop systems. The motor is variable in range from 25 to 5 degrees. The variable displacement
motor has two control modes: a two-stage control providing two speeds, or a variable control
mode. The speeds provided by the two-stage control are low speed when the motor is at
maximum displacement or high speed at minimum displacement. The variable control mode
provides an infinite adjustment from maximum to minimum displacement. The minimum dis-
placement, Swivel Angle, adjustment screw is located on top of the motor.

1.2.1.2 GEARBOX

The gearbox is a power transfer product that utilizes a planetary gear drive with a double
reduction feature. These drives are of a rugged compact design which saves space and
provides for long service life. The gearbox is fully reversible. Reverse is easily obtained
simply by reversing the direction of the input. The drive delivers the power required for
smooth operation and precise control.

1.2.1.3 ACCUMULATORS

The accumulators are bottle-like cylinders that store hydraulic pressure. They are pre-charged
to 500 psi (3447.5 kPa) with nitrogen gas at Stewart & Stevenson Services. Pre-charging
maintains the hydraulic pressure applied to the accumulators. The accumulators on the injector
head help maintain hydraulic pressure in the chain traction system.

Use only dry nitrogen gas to pre-charge the accumulator bottles.

1.2.1.4 FLUID FILTER

Each injector head is equipped with two hydraulic fluid filters; one to filter incoming hydraulic
fluid for the forward direction, and one to filter incoming hydraulic fluid for the reverse direction.
To accommodate the forward and reverse flow of hydraulic fluid, the filter head has a bypass
valve allowing the reverse flow of hydraulic fluid. Each filter also has a visual indicator to signal
when the filter element needs changing.

1.2.1.5 CHAINS

The hydraulic motor(s)/gearbox combination drives two endless chains, on which are mounted
a series of gripper blocks and inserts. The inserts are the part of the chain that is in contact
with the flexible tubing. The inserts can easily be changed to switch from one tubing size to

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another with minimum time down. The chain does not have to be removed from the injector
head to change the inserts. If need be, the chains, themselves, can also be easily changed.
The amount of pressure (traction) the inserts apply to the flexible tubing is hydraulically
controlled. This allows the operator to adjust the amount of traction the inserts apply to the
tubing. The amount of tension on the chain is also hydraulically controlled to prevent exces-
sive wear to the chain.

A hose MUST be connected to the RETURN Connector before any

system is operated; failure to do so could cause damage to the
equipment (blown seals, etc.).

Check the insert locking pins for damaged, worn, loose, and miss-
ing locking pins before and after every job.

There are two sizes of inserts; the Standard Insert and the Extended
Insert. Intermixing the two sizes on the Injector Head can damage
the tubing and/or the chains.

1.2.2 INJECTOR SPECIFICATIONS

GEN ER AL:
MEASU R EMEN TS: MOD EL 800

HEIGHT (wi thout extensi on legs) 102 i n (2590.8mm)

WID TH 54.50 i n (1384.3 mm)

D EPTH 71.24 i n (1809.5 mm)

C OILED TU B IN G R AN GE

VARI BLOC K II 0.75 i n to 3.5 i n (19.1 mm to 88.9 mm)

VARI BLOC K III 0.75 i n to 2.375 i n (19.1 mm to 60.3 mm)

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1.2.3 INJECTOR RATINGS

Model 800
WEIG HT (w it hout t ubing guide) 6125 lbs (2, 774. 6 kg)

O PERAT ING PRESSURE:

3, 000 psi (20, 685 kPa)
Maximum gpm (L/ m) 110 (416. 3)

RAT ED SPEED & PULL

speed 177 f t / min (53. 9 m/ min)

HI G H
pull 26, 000 lbs (11, 778 kg)

speed 54 f t / min (16. 5 m/ min)

LO W
pull 80, 000 lbs (36, 240 kg)

3, 500 psi (24, 132. 5 kPa)

Maximum gpm (L/ m) 100 (378. 5)

RAT ED SPEED & PULL

speed 200 f t / min (61 m/ min)

HI G H
pull 25, 000 lbs (11, 325 kg)

speed 59 f t / min (18 m/ min)

LO W
pull 80, 000 lbs (36, 240 kg)

4, 800 psi (33, 096 kPa)

Maximum gpm (L/ m) 64 (242. 2)

RAT ED SPEED & PULL

speed 210 f t / min (64 m/ min)

HI G H
pull 22, 000 lbs (9, 966 kg)

speed 59 f t / min (18 m/ min)

LO W
pull 80, 000 lbs (36, 240 kg)

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1.2.4 INJECTOR FORMULAS

LOW PRESSURE (3500 psi)

Maximum Motor Displacement

Speed 0.568 X Hydraulic Fluid Flow (gpm)

Pull 28.165 X Hydraulic Pressure (psi)

Minimum Motor Displacement

Speed 1.967 X Hydraulic Fluid Flow (gpm)

Pull 8.135 X Hydraulic Pressure (psi)

HIGH PRESSURE (5000 psi)

Maximum Motor Displacement

Speed 0.849 X Hydraulic Fluid Flow (gpm)

Pull 18.844 X Hydraulic Pressure (psi)

Minimum Motor Displacement

Speed 3.081 X Hydraulic Fluid Flow (gpm)

Pull 5.194 X Hydraulic Pressure (psi)

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1.2.5 INJECTOR HEAD ODOMETER CONVERSION TABLE

Stewart and Stevenson’s new injector head odometer reads one mile for every 567 revolutions
of the drive shaft. This, however, does not correspond to one mile of injector usage. The
following conversion table should be used to determine actual injector usage:

CONVERSION ACTUAL INJECTOR

FACTOR USAGE

1334.18 F eet

ODOMETER
MILEAGE X 0.2527 = Miles

406.66 Meters

0.4067 Kilometers

As an example, consider an odometer reading of 100 miles. To convert to feet, multiply by

1334.18. This results in a total injector usage of 133,418′. Similarly, multiply by 406.66 to
convert to 40,666 m.

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