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TEXVEN ENERGY SERVICES LLC TS-80-SS2 SKID-MOUNTED

COILED TUBING UNIT CONTROL CABIN AND POWER PACK
OPERATION & MAINTENANCE MANUAL
TABLE OF CONTENTS
SECTION II – DESCRIPTION & OPERATION
1. Unit Description.............................................................................................. 3
1.1 Introduction ......................................................................................................... 3
1.2 Unit Dimensions .................................................................................................. 3
1.3 Assembly ............................................................................................................ 3
1.3.1 Master Skid .................................................................................................. 3
1.3.2 Control Cabin ............................................................................................... 4
1.3.3 Standard Control Console ........................................................................... 4
1.4 Jumper Hose Bundles ........................................................................................ 6
1.5 Power Pack ......................................................................................................... 6
1.5.1 Diesel Engine .............................................................................................. 6
1.5.2 Fuel System ................................................................................................. 7
1.5.3 Hydraulic System ......................................................................................... 7
1.5.4 Accumulator System .................................................................................... 7
1.5.5 Hydraulic Oil Filtration and Cooling ............................................................. 7
2. Control Operation........................................................................................... 9
2.1 Control Panel Assembly ..................................................................................... 9
2.2 Engine Controls ................................................................................................ 10
2.3 BOP Controls .................................................................................................... 11
2.4 Reel Controls .................................................................................................... 12
2.5 Miscellaneous Controls ..................................................................................... 14
2.5.1 Injector Controls ........................................................................................ 15
2.5.2 Stripper Controls ........................................................................................ 16
2.5.3 Chain Tension Controls ............................................................................. 17
2.5.4 Chain Traction Controls ............................................................................. 18
2.5.6 Gauge Panel Assembly ............................................................................. 19
2.5.7 Engine Gauges .......................................................................................... 19
2.5.8 Control System and Air Pressure Gauges ................................................. 20
2.5.9 Circulation, Wellhead Pressure, and Weight Indicator Gauges ................. 21
2.6 Stripper Pressure and Traction Pressure Gauges ............................................ 22
3. Operation ..................................................................................................... 23
3.1 Pre-Start Checks .............................................................................................. 23
Rev 0 Section II – Description & Operation Page 1
3.1.1 Injector Head ............................................................................................. 23

3.1.2 Fluid Connections Operation ..................................................................... 23
3.1.3 Power Pack (Wet Kit) (If Applicable) ......................................................... 26
3.2 Coiled Tubing Reel ........................................................................................... 27
3.2.1 Levelwind Up and Down Circuit ................................................................ 27
3.2.2 Tubing Size Adjustments ........................................................................... 27
3.2.3 Levelwind Synchronizing Sprockets .......................................................... 28
3.2.4 Counter Assembly ..................................................................................... 29
3.2.5 Corrosion Inhibitor ..................................................................................... 30
3.3 Hose Reel ......................................................................................................... 31
3.3.1 Pre-Start Check for Trailer-Mounted Units (If Applicable) ......................... 31
3.3.2 After Operation Check for Skid-Mounted Units ......................................... 31
3.3.3 Stripper Pack-Off ....................................................................................... 32
3.3.4 Blowout Preventer (BOP) .......................................................................... 32
3.3.5 Mobilization ............................................................................................... 32
3.4 Spotting the Unit on Location ........................................................................... 33
Page 2 Section II – Description & Operation Rev 0

1. Unit Description
1.1 Introduction
The Stewart & Stevenson Model TS-80-SS2 (space saver) skid-mounted coiled tubing
unit and power pack.
The coiled tubing unit is fully operational from the control cabin via mechanical, hydrau-
lic, and pneumatic controls. The cabin lift system and power hose reel controls are oper-
ated from appropriately located local controls.
The Model TS-80-SS2 is equipped with a total of 350 BHP.
While delivering full horsepower at any speed within the speed range of the engine in
any gear, there shall be no components which vibrate with excessive amplitudes in res-
onance with the forcing vibrations of the engines or pumps. Also, there shall be no ex-
cessive rotational vibrations of the engine-transmission or pumps due to transmitted
torque and the flexibility of the frame and mounting systems.
The Unit is capable of operating in ambient temperatures up to 115 ºF (46 ºC).
1.2 Unit Dimensions

Table 1, Unit Dimensions
UNIT DIMENSIONS
Length 16' (4.9 m)
Width 8'6" (2.6 m)
Height 8'6" (2.6 m)
Weight 18,300 lbs. (8,300 kg)
NOTE: Sections in this manual describe typical components, assemblies, and

functions. For further information about your equipment, refer to the Engineer-
ing Drawings in Section V of this manual.
1.3 Assembly
1.3.1 Master Skid
The control cabin and power pack are installed on a single heavy-duty steel master skid
assembly. This skid features a lifting/crash frame with four point lift system. Other fea-
tures include:
• Heavy-duty square tube crash frame mounted to skid base
• Skid base constructed of heavy-duty rectangular tube sections
• Skid base features, two 6-inch tall by 12-inch tall wide forklift slots
• Welded drip pan integral to skid base for pollution control with 2 inch con-
nection for draining fluids

• Ladders will be included to access the cabin while in the raised position
All connections to and from this skid terminate within the skid frame at a reasonable dis-
tance from the exterior of the skid.
All hoses (where applicable) will be separated from the drip pans with support clamps to
facilitate skid cleaning.
1.3.2 Control Cabin

The control cabin is approximately 7' wide by 8' deep by 6'-6" high. This cabin is a sin-
gle piece cabin and includes a structural frame. This cabin has a aluminum outer cover
and is lined and insulated. The cabin has two side locking doors with windows, and a
large front window with protective attack-proof glass.
Four hydraulic lift cylinders with a minimum telescoping height of 30' are installed, one at
each corner of the enclosure. The control valve for the lift cylinders is located below the
cabin on the side of the chassis for easy access during job rig up. Mechanical locking
devices are included at each corner post to ensure the cabin is locked in place for opera-
tion.
Standard equipment in the control cabin includes:
• Stainless steel, permanently etched control panel

• Air conditioning unit power from power pack
• Internal lighting system
• Fold down operator chairs
• Air horn
• Two externally mounted work lights (adjustable from inside cabin)
All hydraulic connections to and from the control cabin are via a removable hydraulic
bulkhead. This manifold is stainless steel and features permanently engraved labeling
of connection number.
The cabin includes a large removable panel below the front window, which allows ac-
cess to all hydraulic connections in the control panel.
NOTE: Sections in this manual describe typical compo-

nents, assemblies, and functions. Some sections may not
apply to your unit.
1.3.3 Standard Control Console

A control panel is installed in this cabin. This panel is stainless steel and fully labeled
with all gauge and control information. The panel is mounted on an engineered fabricat-
ed housing that includes the backup pump, hydraulic valves, interface, and other neces-
sary devices. Gauges are liquid filled. All labeling is permanently engraved.

The following controls and gauges are installed in the control console:
• Engine Controls
o Engine throttle
o Engine information display module (oil pressure, water temperature, tachom-
eter)
o Engine stop button
o Engine emergency kill
• Injector Controls
o In/out control valve (direction) joystick type
o Speed control pressure reducing/relieving
o Variable speed control
o Chain traction pressure control valves with individual pressure gauge
o Chain traction “Pressure, Run, Dump” selector valve
o Chain tension pressure control valve with individual pressure indication
o Injector drive pressure gauge – fluid filled
• Auxiliary system hydraulic pressure gauge – fluid filled
• BOP hydraulically actuated ram control valves (quantity of 6)

o Blind
o Shear
o Seal
o Slip
o Auxiliary
o Auxiliary
• BOP safety control valve, spring return
• Stripper packer hydraulic pressure control valve
• Stripper packer directional control valve (equipped for dual)
• Well head pressure gauge
• Circulation pressure gauge
• Tubing weight indicator for pipe light/pipe heavy
• Tubing reel tension (speed) pressure reducing valve with pressure gauge
• Tubing reel direction control
• Tubing reel brake control
• Manual levelwind override control valve
• Levelwind raise/lower control valve
• Inhibitor control
• Injector load cell fluid reservoir with hand pump
• Plus other miscellaneous gauges and controls for full operation of the unit

• Backup Control
o Auxiliary hand pump with reservoir for BOP pressure circuit
o Air driven fluid pump to deliver up to 3,000 PSI to the stripper in case of
emergency. Pump equipped with handle for manual back up
o Auxiliary hand pump for injector traction circuit
1.4 Jumper Hose Bundles

The following jumper hoses are included:
Table 2, Jumper Hose Connections

JUMPER HOSE CONNECTIONS
From To Length
Cabin BOP Hose Reel 50' (15m)
Cabin Injector Hose Reel 50' (15m)
Cabin Tubing Reel 50' (15m)
The jumper hoses are protected by a Cordura covering and can be stored on Figure 8
hose racks. Power Pack
1.5 Power Pack

1.5.1 Diesel Engine
Installed on this skid behind the control cabin is a diesel engine rated as follows:
• Detroit Diesel Series 60, turbocharged diesel engine rated at 375 BHP at
2100 RPM
• Electronic engine management system
• Lube oil pump and distribution system with engine oil pan being provided with an
drain and valve to the edge of the skid
• Fuel pump
• Heavy-duty dry-type air cleaner assembly with filter element restriction indicators
and stainless steel moisture eliminators
• Dipstick and oil filler cap
• Fuel filtration system
• Air start system
• Alternator
• Engine governor - electronic
• Fan assembly
• Exhaust muffler assembly
• Exhaust blankets
• Engine lift brackets
A 12 CFM air compressor with a 30-gallon capacity air receiver and all ancillary air items
and fittings, including a lubricator group is installed between the air receiver and starter.
Other accessories include an air dryer, isolator valves, filters, filters and regulator. The

air compressor is designed to maintain 120 psi in air receiver. In addition, a connection
is provided for remote charging of the air receiver.
A heavy-duty radiator is vertically-mounted with fan, fan belts, and a surge tank.
Dual-output hydraulic drive is mounted on the rear of this diesel engine.
Shutdowns are included for: engine over speed, low oil pressure, and high coolant
temperature.
1.5.2 Fuel System

A 90-gallon fuel tank complete with fuel level indicator, air breather cap, suction filters
and return filters is mounted on the skid. This fuel system is equipped with all necessary
valves and filters including an external fuel source hook up.
1.5.3 Hydraulic System

Mounted on the rear of the engine is a pump-drive assembly designed to provide hy-
draulic power. The injector is powered by a bi-directional, axial piston, pressure com-
pensated, closed-loop hydraulic pump mounted on the output pad of the hydraulic pump-
drive.
An axial piston, pressure compensated, hydraulic pump mounted on the second pad of
the pump-drive provides power for the following:
• Tubing reel hydraulic motor
• Levelwind override hydraulic motor
• Levelwind lift control hydraulic cylinders
• Hose reel hydraulic motors
• Control cabin lift cylinders
• BOP Rams
• Stripper/packer
• Injector chain traction system
The hydraulic systems above are controlled by proportional control valves with built-in
directional and flow control functional and inlet relief valves.
1.5.4 Accumulator System

A high-pressure accumulator system with three 10-gallon accumulators are supplied and
installed to provide a constant backup hydraulic pressure to the hand pump system. This
accumulator system is charged to 1,500 psig from the main hydraulic system.
1.5.5 Hydraulic Oil Filtration and Cooling

All hydraulic oil circuits include suction line filters with stainless steel 100 mesh elements
to remove particles. The elements can be removed for inspection and cleaning. Filtration
of returning oil flows from injector and reel circuits immediately prior to entering main hy-
draulic tank is carried out with the required filter assemblies. Filter size will not be less
than 10 microns and will be spin-on type. High-pressure filters are installed to protect
injector motors and pump. All filters are fitted with a self-activating bypass valve and an
indicator to show relative condition of the element.
Other main components for the hydraulic system which are supplied include:
• A hydraulic oil reservoir with a sight level gauge, filter breather cap, return fil-
ters, and a drain lock
• A hydraulic oil cooler
• All necessary hydraulic valves, gauges, hoses and piping

2. Control Operation
2.1 Control Panel Assembly
NOTE: The following sections describe the control panel by functional part.
Panels shown are typical; others are similar. For your particular control
panel assembly layout, consult the control panel and control console draw-
ings in Section V, Engineering Drawings, of this manual.
The unit is fully operational from the control panel via mechanical, hydraulic, and pneu-
matic controls. For better visibility, the control cabin can be raised.
Figure 1, Typical Control Panel

2.2 Engine Controls
Use the emergency stop control only under emergency conditions

such as an over speed condition. Activating the emergency stop
can cause serious engine damage.
1. Emergency Stop Switch – stops the engine in emergency situations

2. Throttle Engine – controls engine speed by rotating to right (increase), or left (de-
crease)
3. Stop Switch – stops the engine in non-emergency situations.
Figure 2, Engine Controls (Lower Control Panel)

2.3 BOP Controls

1. Hand Pump ON/OFF Switch – used to turn the 3000 psi hand pump on and off.
2. BOP Pressure Gauge – displays BOP pressure, which is the pressure applied to the
BOP circuit.
3. Accumulator Pressure Gauge – displays accumulator pressure, which is the pres-
sure available to the BOP circuit.
Figure 3, BOP Controls

2.4 Reel Controls

1. Reel – Pivot Left/ Right Lever– Pivots reel left or right.
2. Reel – Lift Down/Up lever –Moves the level wind mechanism up or down.
3. Reel - Brake On/Off lever – sets brake in ON position (no pressure) and disengages
brake in OFF position (normally 1100 psi).
4. Reel – In/Out lever – controls the reel direction in-hole or out-hole. The locked rear
position is the out-hole position, and the tubing winds onto the reel toward the control
cabin.
NOTE: Reel is always in “outhole” position.
5. Reel – Levelwind lever – overrides the automatic levelwind function.

6. Reel – Regulate Pressure knob – adjusts pressure to achieve proper tension when
going in-hole and out-hole.
7. Reel – Inhibitor Spray button – controls the application of rust-inhibiting spray on the
tubing as it is reeled in.
Figure 4, Reel Controls

Inhibitor
Levelwind
Mechanism
Figure 5, Reel Levelwind Assembly

2.5 Miscellaneous Controls
1. Control Panel Switch – controls power to the control panel

2. Cabin Lights Switch – controls power to the control cabin’s lights
3. Work Lights On/Off Switch – turns the exterior lights on and off
4. Wiper Switch – activates the control cabin’s windshield wipers (air actuated)
5. Horn Switch – activates the unit’s air horn
Figure 6, Miscellaneous Controls

2.5.1 Injector Controls

1. Injector Lube spring-loaded button – press to apply lubricant on the injector chains
and release button to stop.
2. Pressure Regulator valve – controls the pressure applied to the injector head motor.
When 500 psi is applied, the brakes begin to release. At 700 psi, the brakes are fully
open.
3. Injector In/Out joystick – adjust the injector joystick to the “IN” position to move tubing
into the well bore; adjust the injector joystick to the “OUT” position to move the tubing
out of the well bore. Center or neutral position activates the injector brake.
4. Normal Speed control – controls speed of injector motor(s); turn clockwise to in-
crease speed.
Figure 7, Injector Head Controls (Lower Control Panel)

2.5.2 Stripper Controls

For the Stripper Controls described below, refer to Figure 7, Stripper Controls.
1. Stripper Retract/Pack valves – controls the operation of the stripper. Normally in the
NEUTRAL position. To compress the stripper around tubing, place in the PACK posi-
tion. To release the stripper from around tubing, place in the RETRACT position.
2. Stripper Select valve – controls which stripper is receiving hydraulic pressure.
3. Bleed System valve – In the “system” position, it sends system pressure to the strip-
per (pack-off) circuit; in the bleed position, it bleeds pressure from the stripper (pack-
off) circuit.
4. Pressure Regulator valve – adjusts the hydraulic pressure applied to the stripper.
Turns counterclockwise to reduce the pressure; turn clockwise to increase the pres-
sure.
5. Stripper Hand Pump On/Off valve – turn valve to the “On” position to provide pres-
sure to the stripper (pack-off) circuit to allow operation of the hand pump.
Figure 8, Stripper Controls

2.5.3 Chain Tension Controls
1. The chain tension control can be placed in three different positions:
• Pressure – when pressure valve is placed in this position, it allows

tension pressure to be increased.
• Run – the valve must be placed in this position after tension has been
adjusted to recommended pressure.
• Dump – this position can be used to lower and or dump tension pres-
sure.
2. Regulate Pressure control – controls pressure to chain tension circuit.
Figure 9, Chain Tension Controls (Lower Control Panel)

2.5.4 Chain Traction Controls
Traction valves must be placed in the “run” position. Failure to

place traction valves in the “run” position can lead to a loss of tub-
ing in case of hydraulic malfunction.
1. End Traction Pressure/Run/Dump valve – valve is placed in “pressure” position to

adjust pressure in this circuit, supplying pressure to top and bottom traction cylin-
ders. The “run” position is required when the desired pressure setting is achieved.
This position keeps pressure locked in case of loss of hydraulic power. The “dump”
position allows operation to release all pressure from this circuit.
2. Middle Traction Pressure Run/Dump valve – valve is placed in “pressure” position to
adjust pressure in this circuit, supplying pressure to the middle traction cylinders.
The “run” position is required when the desired pressure setting is achieved. This
position keeps pressure locked in case of loss of hydraulic power. The “dump” posi-
tion allows operation to release all pressure from this circuit.
3. Regulate Pressure control – controls the increase and decrease of pressure to chain
traction circuit.
4. Hand Pump On/Off valve – turn valve to the “On” position to allow manual operation
of the inside traction cylinders.
5. Regulate Pressure control – controls the increase and decrease of pressure to chain
traction circuit.
Figure 10, Chain Traction Controls

2.5.6 Gauge Panel Assembly
Figure 11, Typical Gauge Panel
2.5.7 Engine Gauges

1. Engine display – displays engine conditions via an EDM (Electronic Display Module)
2. Throttle – controls speed of engine, increase by rotating clockwise.
3. Start – used to start the engine
4. Stop – used to stop the engine under regular operating conditions (non emergency)
5. Emergency Stop – used to stop the engine only under EMERGENCY CONDITIONS
6. Remote/Local – used to toggle between remote and local control
7. Air Pressure – gauge to display current air pressure
Figure 12, Engine Gauge

2.5.8 Control System and Air Pressure Gauges

1. Air Pressure gauge – displays pressure of air supply (normally 120 psi)
2. System Pressure gauge – displays the pressure for the system (normally 2800 psi to
3000 psi)
3. Control Pressure gauge – displays the pressure to reel stack valve and joy stick
(normally 1100-1300 psi)
4. Injector Pressure gauge – displays the pressure applied to the injector
5. Speed Pressure gauge – displays the pressure applied to shifting injector motor(s)
from low to high (operating range)
6. Reel Pressure gauge – displays the reel motor pressure. Pressure will vary due to
different factors such as pipe size, injector speed running in-hole or out-hole
Figure 13, Control System and Air Pressure Gauges (Upper Control Panel)

2.5.9 Circulation, Wellhead Pressure, and Weight Indicator Gauges

1. Circulation Pressure gauge – displays pressure of circulating fluids through the coil
tubing.
2. Weight Indicator gauge – displays the positive and negative tubing weight.
3. Wellhead Pressure gauge – displays the static pressure at the wellhead.
Figure 14, Circulation, Wellhead Pressure, and Weight Indicator Gauges

(Upper Control Panel)

2.6 Stripper Pressure and Traction Pressure Gauges

1. Stripper Pressure #1 gauge – measures and displays the hydraulic pressure to the
#1 stripper.
2. Stripper Pressure #2 gauge – measures and displays the hydraulic pressure to the
#2 stripper.
3. Stripper System Pressure gauge – measures and displays the hydraulic pressure of
the stripper system.
4. Chain Tension Pressure gauge – displays tension pressure.
5. Chain Traction Pressure, End gauge – displays traction pressure at the top and bot-
tom traction cylinders.
6. Chain Traction Pressure, Middle gauge – displays traction pressure at the middle
traction cylinders
Figure 15, Stripper Pressure & Transaction Gauges (Upper Control Panel)

3. Operation
3.1 Pre-Start Checks
Sections 3.1.1 through 3.1.8 explain the pre-start checks for the coiled tubing unit and its
components.
Before operating this equipment, operator should carefully read

the operation instructions in this section, review the safety sum-
mary, and conduct a pre-operation safety inspection of the
equipment.
3.1.1 Injector Head

Perform the following preliminary checks before operating equipment:
1. Check all operating fluids, such as engine oil and coolant.
2. Grease all bearings and drivelines.
3. Check all connections. Make sure all fittings are tight, and ensure all hoses are con-
nected properly. If any leaks are found, repair immediately.
3.1.2 Fluid Connections Operation

Perform the following preliminary checks before operating equipment:
1. Hydraulic input forward direction connector – allows input of hydraulic fluid to mo-
tor(s) for forward direction (into well) (refer to Figure 16).
2. Hydraulic input reverse direction connector – allows input of hydraulic fluid to mo-
tor(s) for reverse direction (out of well).
3. Spare connectors – connects hoses from the hose reel to the injector head (refer to
Figure 16)
4. Speed connector – controls motor displacement, which increases and decreases

speed (refer to Figure 16).
5. Oiler connector – allows input of chain lubricant to chain oiler nipples in top of frame
over chains (refer to Figure 16).
6. Chain tension connector – controls of amount of tension applied to chain to keep
chain tight (refer to Figure 16).
7. Traction end connector – controls of amount of pressure that chain (gripper blocks)
applies to tubing at ends of chain (refer to Figure 16)

Figure 16, Hydraulic Input Connectors
Always connect return connector first and disconnect last.
8. Stripper pack connector – energizes packing element to prevent well pressure from
venting past tubing (Refer to Figure 17).
9. Traction middle connector – controls of amount of pressure that chain (gripper

blocks) applies to tubing in middle of chain (Refer to Error! Reference source not
found.).
10. Stripper retract connector – removes pressure from packing element to facilitate
changing of packing elements (Refer to Figure 17).
11. Well pressure connector – connects to optional debooster (Refer to Figure 17) .
12. Return connector – allows hydraulic fluid to return to tank (Refer to Figure 17).
13. Weight indicator connector – connects to load cell (Refer to Figure 17)
Spare Connectors
Brake
Speed
Oiler
Chain Tension
Traction End
Stripper Pack
Traction Middle
Stripper Retract
Well Pressure
Weight Indicator
Return Connector
Figure 17, Injector Head Connection Panel

3.1.3 Power Pack (Wet Kit) (If Applicable)
Only use factory specified fluids for the unit.
Never idle engine for a long period of time. Idle at a maximum of

1100 rpm while the unit is not in operation.
Never close any hydraulic suction valves while the power pack is
operating. If a problem occurs, shut down the power unit.
Never use a wrench to make adjustments.
Before operating the power pack, check the following to ensure:

• Proper oil level
• Proper coolant level
• Proper diesel tank level
• Fan and alternator belts are in good condition
• Accumulator valve is closed
• All suction valves to pump are opened
• Accumulator valve is open so unit is not starting under hydraulic load. Close this
valve after engine is warmed up
• Proper hydraulic oil level (bleed off 11 gallons (42 liter) accumulator first)
• Reel and injector head oilers are 50/50 of oil/diesel in summer and diesel only in
Winter
• Correct adjustment of reel and levelwind chains and free of any link damage

• Crane winch block and cable for damage

• All pressure and control valve controls are in neutral position and pressures for
reel and injector head are dialed OFF
3.2 Coiled Tubing Reel

3.2.1 Levelwind Up and Down Circuit
The levelwind circuit is operated by the control pressure. Shifting the control valve to the
“UP” position sends hydraulic pressure through the load holding valves, check valves,
and to the hydraulic cylinders which lift the mechanism.
Shifting the control valve to the “LOWER” position opens the holding valves and allows
hydraulic fluid to return to the hydraulic supply reservoir. The weight of the levelwind as-
sembly assists with this function.
3.2.2 Tubing Size Adjustments

All CTU reels are capable of operating with a range of tubing sizes. When the tubing siz-
es are changed on the reel, make modifications if necessary to accommodate larger and
smaller tubing sizes. Five main areas are affected by a tubing size change:
• Tubing reel capacity
• Levelwind synchronizing sprockets (refer to Figure 18 and Figure 19)

• Counter wheels
• Inhibitor injector guides (lubricator)
• Injector chain inserts
Care should be taken to ensure that operators have completed all changes to compo-
nents and are aware of changes in reel capacity before operating the unit.
Sprocket
Figure 18, Levelwind Synchronizing Sprocket (1)

3.2.3 Levelwind Synchronizing Sprockets

Specific sprocket combinations are required to maintain drum and levelwind synchroni-
zation during operation. Custom combinations can be provided for non-standard tubing.
Verify the CTU reel design assembly type. They are either an internal or an external reel
motor design. Sprocket locations change on internal and external reel assemblies.
The table that follows provides levelwind assembly timing sprockets for different sized
tubing.
Table 3, Levelwind Assembly Timing Sprockets Table

LEVELWIND ASSEMBLY TIMING SPROCKETS FOR DIFFERENT SIZED TUBING
OD OF TIMING SMALL DRIVER SPROCKET* LARGE SLAVE SPROCKET*
1.000 in. 12 44
1.250 in. 15 44
1.500 in. 18 44
1.750 in. 21 44
2.000 in. 24 44
2.375 in. 22 34
2.875 in. 29 37
* Slave and driver sprocket locations vary. Be sure to identify reel design type and proper sprocket
location.
Sprocket
Sprocket
Figure 19, Levelwind Synchronizing Sprocket (2)

3.2.4 Counter Assembly

The counter is located inside the upper portion of the counter assembly. The assembly
contains four guide wheels that cannot function properly unless the wheels are meas-
ured to specific tubing sizes.
When preparing equipment to run a different tubing size, attention should be given to
both the installation of the new wheel size and the lubrication of the new wheels before
any operation of the new configuration.
NOTE: Guide wheels are matched to the tubing size; therefore, if the tubing
size changes, the guide wheels will need to be changed.
Encoder
Counter Assembly
Mechanical Counter
Assembly
Guide Wheels
Figure 20, Counter Assembly

3.2.5 Corrosion Inhibitor

The corrosion inhibitor is mounted on the back of the counter and is attached by a link-
age on the reel side of the counter assembly. The inhibitor has bushings on both ends to
be changed with tubing sizing and is attached between tubing guide and reel.
When changing out the bushings, the oiler must be repacked with Scotch-Brite™. Check
to ensure that the new assembly is fully charged and ready to be put into service.
NOTE: The Scotch-Brite™ absorbent material (PN# TS960411) should be

changed monthly.
Figure 21, Corrosion Inhibitor

3.3 Hose Reel
Figure 22, Typical Trailer-Mounted Coiled Tubing Unit
3.3.1 Pre-Start Check for Trailer-Mounted Units (If Applicable)
NOTE: The hose reel power hoses for the truck-mounted units are con-
nected at the factory.
Before operating equipment, complete the following procedures:

1. Check all connections.
2. Follow manufacturer’s recommended procedures or your company’s standard oper-
ating practices for operating the hose reel.
3.3.2 After Operation Check for Skid-Mounted Units

To rig-down the hose reel, complete the following procedures:
1. Move the handle to the spring return position to reel in the hoses.
2. Adjust knob clockwise on speed control valve to increase reel speed and out coun-
terclockwise to decrease reel speed.
3. Monitor slack in hose bundles as hoses are recoiled (reeled-in).
4. Disconnect hoses from injector/BOP/stripper.
5. Disconnect reel power hoses from power unit.

3.3.3 Stripper Pack-Off

Complete the following procedures to rig-up the stripper/pack-off:
1. Hoist (crane operator) the injector upward and over toward the wellhead after per-
forming the pre-operation procedures for the injector head.
2. Lubricate the bottom of the injector head.
3. Connect the stripper/pack-off to the injector head.
3.3.4 Blowout Preventer (BOP)

Before operating the blowout preventer, perform the following procedures:
1. Inspect the blowout preventer and determine if ready to be placed into service.
2. Follow the manufacturer’s recommended operating procedures or your company’s
standard operating practices for operating this equipment.
Figure 23, Blowout Preventer (BOP) on CTU
3.3.5 Mobilization
Given the size and weight of the unit, travel routes must be chosen carefully. Bridges,
sharp corners, rough roadways, uneven shoulders, and overhead obstacles must be
taken into consideration.
NOTE: DOT routing certifications may be necessary.

3.4 Spotting the Unit on Location
Use spotter when backing the unit or when moving the unit at all
times on and off location.
A pre-trip inspection is recommended to confirm location layout and well condition. The
area immediately around the wellhead where the unit is to be positioned must be level to
aid in the safe operation of the crane and ensure that the reel operates correctly.
For truck mounted units, under the guidance of the supervisor position the unit upwind or
crosswind of wellhead, if possible, so that the coiled tubing operation is not hindered by
the coiled tubing unit. Positioning the unit up to 3 meters at the back and 3 meters to the
left from the well center may serve as a general guideline; depending on site guidelines
and wellhead height, position the unit that will work best for that well site. With the unit
in this position, set the parking brakes and insert chock blocks behind and in front of the
trailer/truck tires.
NOTE: Be sure to check wind speed during coiled tubing operation: wind
gusting, sudden direction shifts, debris, sand, or heavy rain can alter opera-
tional conditions.
Positioning of unit varies depending on type of unit you are operat-

ing, some units may line up off center or center, follow guidelines
set prior to initial testing of familiarization of unit.
Complete the following inspection procedures:

1. After unit is spotted in place on location, walk around the unit inspecting all hydraulic
hoses, connections, headers, filters, and any equipment for evidence of leaks or
loose hoses due to transporting to location. Check hydraulic fluid level prior to en-
gaging PTO hydraulics.
2. Correct any problems that are found before proceeding to engage hydraulics to begin
rig-up.
3. Follow in cab instructions on engaging PTO; ensure proper gear is selected. Refer
to Stewart & Stevenson operation manual or tag on dash.

Fluid Level With

Accumulator Bottles
Dessicant Dumped
Cap
Thermometer
Figure 24, Sight Gauge on Hydraulic Tank

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TEXVEN ENERGY SERVICES LLC TS-80-SS2 SKID-MOUNTED

3.1.1 Injector Head ............................................................................................. 23

Page 2 Section II – Description & Operation Rev 0

1.2 Unit Dimensions

NOTE: Sections in this manual describe typical components, assemblies, and

Rev 0 Section II – Description & Operation Page 3

1.3.2 Control Cabin

Standard equipment in the control cabin includes:

• Stainless steel, permanently etched control panel

NOTE: Sections in this manual describe typical compo-

1.3.3 Standard Control Console

Page 4 Section II – Description & Operation Rev 0

• Auxiliary system hydraulic pressure gauge – fluid filled

• BOP hydraulically actuated ram control valves (quantity of 6)

Rev 0 Section II – Description & Operation Page 5

1.4 Jumper Hose Bundles

Table 2, Jumper Hose Connections

1.5 Power Pack

Page 6 Section II – Description & Operation Rev 0

Dual-output hydraulic drive is mounted on the rear of this diesel engine.

1.5.2 Fuel System

1.5.3 Hydraulic System

1.5.4 Accumulator System

1.5.5 Hydraulic Oil Filtration and Cooling

Page 8 Section II – Description & Operation Rev 0

Figure 1, Typical Control Panel

Rev 0 Section II – Description & Operation Page 9

2.2 Engine Controls

Use the emergency stop control only under emergency conditions

1. Emergency Stop Switch – stops the engine in emergency situations

Figure 2, Engine Controls (Lower Control Panel)

Page 10 Section II – Description & Operation Rev 0

2.3 BOP Controls

Figure 3, BOP Controls

Rev 0 Section II – Description & Operation Page 11

2.4 Reel Controls

NOTE: Reel is always in “outhole” position.

5. Reel – Levelwind lever – overrides the automatic levelwind function.

Figure 4, Reel Controls

Page 12 Section II – Description & Operation Rev 0

Figure 5, Reel Levelwind Assembly

Rev 0 Section II – Description & Operation Page 13

2.5 Miscellaneous Controls

1. Control Panel Switch – controls power to the control panel

Figure 6, Miscellaneous Controls

Page 14 Section II – Description & Operation Rev 0

2.5.1 Injector Controls

Figure 7, Injector Head Controls (Lower Control Panel)

Rev 0 Section II – Description & Operation Page 15

2.5.2 Stripper Controls

Figure 8, Stripper Controls

Page 16 Section II – Description & Operation Rev 0

2.5.3 Chain Tension Controls

1. The chain tension control can be placed in three different positions:

• Pressure – when pressure valve is placed in this position, it allows

Figure 9, Chain Tension Controls (Lower Control Panel)

Rev 0 Section II – Description & Operation Page 17

2.5.4 Chain Traction Controls

Traction valves must be placed in the “run” position. Failure to

1. End Traction Pressure/Run/Dump valve – valve is placed in “pressure” position to

Figure 10, Chain Traction Controls

Page 18 Section II – Description & Operation Rev 0

2.5.6 Gauge Panel Assembly