Module CT04

Objectives
 After attending this presentation you will be able to:
 Explain all major components of the Hydra-Rig CT reels.
 Calculate the capacity of a reel drum.
 Identify and understand all reel controls.
 Explain in full detail all the hydraulic system functions.
 Troubleshoot the Reel system
 Side View of CT Reel
Crash protection frame
 Side view of current generation Reel drum
Hydra-Rig CT Reel

– Reel Drum
– Reel drive and brake system
– Crash protection frame

Reel drive and brake system

 Front View of CT Reel
 Front view of current generation Tubing measurement accessories
Hydra-Rig CT reel
– Tubing measurement accessories
– Levelwind assembly
– Reel swivel and manifold
– Tubing lubrication equipment

Reel
Levelwind swivel
assembly and
manifold

Tubing lubrication equipment

 Reel Drum
Levelwind
drive
sprocket
Reel drum
securing
points

Tubing access &

Reel drum guide to reel core
drive
motor/sprocket
Reel drum
Reel
drive sprocket
drum
Reel drum
lifting
lifting point
point
Drive chain tension adjustment
Levelwind
drive Swivel
sprocket flange
on
Reel drum axle
drive
sprocket
 Calculating Reel Capacity
 L= (A+C) (A) (B) (K), Freeboard
– Where
L = Tubing capacity (ft)
A = Tubing stack height A
(in)
B = Width between flanges (in)
C = Reel drum core diameter (in)
K = K value for different tubing sizes
Tubing OD (in) K Value C
1.00 0.262
1.25 0.168
1.50 0.116
1.75 0.086
2.00 0.066

MINIMUM RECOMMENDED FREEBOARD

Tubing OD (in) Freeboard (in)
B
1.00 and 1.25 1.5
1.50 and 1.75 2.0 Reel Drum Capacity
2.00 3.0
 Example of Calculating Reel Capacity
Freeboard
 Tubing OD = 1.50 in; therefore
the freeboard is 2.0 in
A
– A = 22 in (24 in drum rim height
minus 2 in freeboard)
– B =72 in C

– C = 72 in
– K = 0.116

 L = (22 + 72)(22) (72) (0.116)

B
 L = 17,272 ft of 1.5 in tubing
Reel Drum Capacity
 Tension
 Reel drive back pressure adjusted to provide suitable
tension between injector head and reel

INCORRECT

INSUFFICIENT BACK
TENSION ALLOWING
TUBING TO SAG

CORRECT SUFFICIENT BACK

TENSION APPLIED TO
KEEP TUBING STRAIGHT
 Schematic of Hydra-Rig Reel Drive & Brake System
3

2
CT REEL 1

Priority 7
supply

9 Levelwind
8
Supply
CONTROL
CABIN 6

11 10

14
12 13
POWER
PACK 16

17
15

18
 Blank Diagram
3

2
CT REEL 1

Priority 7
supply

9 Levelwind
8
Supply
CONTROL
CABIN

11 10 6

14
12 13
POWER
PACK 16

17
15

18
 4-Way Detail in POOH position
3

2
CT REEL 1

Reel
Drive
4 Hoses

Priority 7
supply

Levelwind
9 8 Levelwind
Supply
supply
CONTROL
CABIN

11 10 6

14
12 13
POWER
PACK 16

17
15

18
 POOH Animation
3

2
CT REEL 1

Pump provides pressurized fluid,

4 causing Reel Drive motor to spin
5
Return line carries the fluid back to
Priority 7
supply the tank

9 Levelwind
8
Supply
CONTROL
CABIN

11 10 6

14
12 13
POWER
PACK 16

17
15

18
 RIH animation
3

2 Normal POOH motor spin

CT REEL 1

Actual spin while RIH

4
Pushes fluid backward
5 towards the 4-way valve
Priority 7 up to the Relief Valve
supply

9 Levelwind
8
CONTROL
Supply
Pump provides fluid
CABIN up to the relief valve
11 10 6

BOTH flows get vented

by the relief valve
14
12 13
POWER The backpressure (80psi)
PACK 16

17
on the return line feeds the motor
15

18
 Reel Drive/Brake Systems
 General
Engine
– Hydraulically driven
– In hole-out hole positions
– Tension on tubing
– Reel drive motor Auxiliary

– Reel brake system BOP

Injector
(Low Flow) Injector
(High Flow)
Levelwind
Reel
Priority

Typical Hydra-rig hydraulic pump arrangement

 Hydra-Rig Reel Drive System
 Typical control panel
layout of reel controls
(Hydra-Rig)

UP
LEVELWIND
ARM

DOWN
 Uniflex Reel Drive System
 1. Reel drive motor
Hydraulic
– (Charlynn Fluid
Reservoir

reversible high
torque low speed
motor) Floodline

 2. Four way control 2

valve (out hole, 1

in hole)
 3. Wabco valve Hydraulic pump

Air

 4. Relief valve Supply

3 5
4

 5. Pilot relief valve

• Uniflex Reel brake System

– Reel brakes on Uniflex reels will be operated either hydraulically or pneumatically
and act on the rim of the reel drum
 Hydra-Rig Brake Systems
 Current models Reel drum rim

– Hydraulic brake Caliper secured

to reel chassis
 Earlier models
– Pneumatic brake)

Actuator
push rod
Air Actuator
HYDRA -RIG PNEUMATIC BRAKE
 Reel Swivel and Manifold
Grease point (may be connected) to
central lubrication station)

 Latest design
– Integral SLP 11
– Full bore balls
darts
 Earlier design
Face seal
– Threaded between
connections swivel and
reel shaft
– Small OD holes
Swivel secured to reel shaft
by studs, lock washers and nuts

2 in 1502 union
 Hydra-Rig Reel Swivel and Manifold
1. Swivel Housing
2. Mandrel
3. Grease seal
4. Extrusion ring
5. Bearings
6. Mandrel retainer
7. Packing assembly
8. Backup ring
9. Face seal 2

10. O-ring 10 11
11. O-ring 12

12. O-ring
13. Set screw
14. Grease Nipple
15. Wing half 1502 Hydra-Rig Reel Swivel (Type 4)
16. Bearing housing
Hydra-Rig Reel Manifold
 Uniflex Reel Swivel and Manifold
Threaded treating Outer assembly
line connection secured to mandrel
by capscrew
 Threaded connection
 Obstructed bore

Outer assembly
secured to mandrel Chevron packing
by capscrew
 Hydra-Rig Levelwind Assembly
Tubing measurement accessories
mounted on Levelwind travelling head
Levelwind leadscrew
drive sprocket and
override clutch

Levelwind travelling
head/yoke assembly
driven by lead screw

Levelwind travelling
head/yoke assembly
Levelwind pivot Levelwind driven by lead screw
points override
motor

Levelwind leadscrew drive sprocket and

override clutch
Levelwind driven by sprocket on reel axle
 Levelwind Assembly
Benefits

 Cross spooled pipe = damaged pipe

 Maximizes the capacity of reel; Poorly spooled tubing may not

fit back into the reel

 Frees up the operator’s attention

 Corrosion protection: Well spooled pipe has less exposed area.

 Uniflex Levelwind Assembly
 Powered by reel’s axle chain sprocket

 Endless chain (no lead screw)

 Over ride system

– Hydraulic motor and clutch

 Height Adjustment

– Hydraulic rams

 Tubing guide

– Vertical slot of urethane

 Tubing Measurement Accessories
Counter Slide mount for Mechanical
 Friction wheel depth wheel mechanical counter counter drive
counters/encoders Spring
forces
 Mechanical counters counter
wheel
(backup to electronic Counter
against
wheel
counters) tubing
assembly
pivot
 UTIM point

Counter head hinged

to assist with
installation over-centre
catches secure
Mechanical
counter drive
 Tubing Lubrication Equipment
3 7
CT REEL

4
6
To lubricator 9 5
block

CONTROL CAB

Permanently mounted tubing lubrication equipment schematic

 Warning - pressurized tank

 Levelwind Clutch Adjustment
 Caution Friction facings

 Procedure Disk spring

Setscrew and key
Adjustment
bolts (3)

Levelwind shaft

Adjustment nut
Clutch hub screwed onto
Sprocket clutch hub
 Maintenance-Reel Drive & Brake Systems
 Check general condition of hoses, connections and components

 Ensure motor drive mounts etc are secure and that general alignment
of drive chains etc have not been disrupted in transit.

 Check drive chain tension

 Function test brake and drive systems, note operating pressures

where applicable.

 Grease main bearings with general purpose grease and lubricate drive
chain.
Maintenance-Reel Drive & Brake Systems
STEM II

 Check efficiency of brake and motor

 Check retaining bolts and set screws

 Remove and inspect drive chain

 Check operation and setting of system relief valves and

pop-off valves (where fitted)
 Reel Swivel and Manifold
 Stem 1
– General condition
– Grease bearings
– Grease valves
– Check debooster
– P-Test swivel and manifold
5000 psi

 Stem II
– Replace gears and packing
– Check operation of
debooster
 Levelwind Assembly and Circuit
 Stem 1
– General condition
– Mounts and chain alignment
– Lubrication
– Hydraulic function

 Stem II
– Condition of chains and sprockets
– Yoke
– Levelwind trolley
– Levelwind raise
 Levelwind Trolley Adjustment
 Free trolley

 Lead screw collar cover

 Roller and roller bearing

 Free movement of trolley

 Grease
 Depth Measurement Accessories
 Stem 1
– Lubricate bearings, chains and pinions on the counter head
– Check operation and lubricate the spring mechanism which maintains
counter wheel contact with tubing
– Check mount and alignment of depth counters or sensors

 Stem II
– Check condition of all bearings on the counter head
– Remove measuring wheel from counter heads, check for wear on the
running surface by accurately measuring wheel diameter. Check
against manufacturer’s specifications and replace as required.
– Check for excessive wear or play in the counterhead chains pinions.
 Tubing Lubrication System

 Stem I
– Check reservoir level
– Function test system and adjust flow as required

 Stem II
– Check operation and setting of pressure regulators and relief valves
– Inspect pressure vessel (pressure vessel and associated safety
valves ,any required periodic certification. Check local
requirements).
 Chain Identification
 To determine the number Master link or
connecting
of pitches in a chain, link
several methods may be Pitch
used:
– If the chain is in service and
complete, count the link External
pins. The number of link Linkplate Internal
pins equals the number of Linkplate
pitches.
Connecting link Alternative
cotter pin connecting
– If the chain is broken and
link assembly
laid out, ignore the last link using spring
plate hole lock
 Troubleshooting
 Caution
– Attempt to operate the system or circuit to ensure that a problem does
exist

– Check all controls, valves etc are positioned correctly and that
corresponding pressure gauges display the anticipated system pressures.

– Check that all hoses are connected and that no gross leaks are evident.
Incorrectly fitted hoses and malfunctioning connector check valves are
a relatively common problem source.

– Check components for evidence of leaks binding or obvious damage.

– Follow the troubleshooting guidelines contained in the appropriate

manual section.
 Reel Drive System
Reel Drum will not rotate

Reel system pressure

gauge responds
as expected
Yes
No
Reel, brake
control off

Yes Check main relief valve

bypass and hose
Air brake Hydraulic brake connections to power pack
Air system Priority system
pressure OK Pressure OK

No Yes Yes No

Troubleshoot Check main

Air system Check for obstruction on reel drum relief valve
bypass

Check hydraulic Troubleshoot

Air brake pads released pressure at brake priority circuit/supply
(see hydraulic system
troubleshooting)
No Yes

Air Pressure Possible Causes

at brake actuator
 Hydraulic pump or main relief valve malfunction.
Yes No Troubleshoot the supply circuit (see power-pack troubleshooting)
Check/service  Crossover relief valve located on the reel is passing
Troubleshoot
brake actuator control system Check for noise and vibration
 Internal damage to drive motor allowing fluid to pass
Check for noise and vibration
Possible Causes  Faulty pilot valve
 Internal damage to motor preventing rotation. Check for back off the main relief valve, disconnect the pilot adjust hose
the take up of the chain slack when the motor is engaged and attempt to increase the pressure at main relief valve (maximum 2,500 psi)
 
Blockage or malfunction of the console directional control If pressure increases, the panel pilot valve is faulty
valve. Check the control circuit lines. If there is no pressure, the main relief valve is faulty
 Reel Levelwind System
System pressure gauge
OVERRIDE MOTOR WILL increases to 2,500 psi
when override control
NOT ROTATE is neutral

Yes No

Check hoses and System pressure gauge

connections increases to 2,500 psi
when override is selected

No Yes

Check main relief Override chain slack

valve hoses and is taken up when override
connections is selected
No Yes
Check for internal
leakage in override motor
(noise and vibration) Check hoses and Check for mechanical
connections to reel binding or damage to
Levelwind assembly
Check hydraulic Troubleshoot
pump operation control system

LEADSCREW WILL NOT Leadscrew turns

TURN WITH REEL DRUM with override selected

No Yes

Check hoses and connections Check override clutch adjustment. More

Levelwind motor should be able to idle when in compression may be required
neutral and reel is turning

Check for mechanical binding on chains,

sprockets, bearings, leadscrew and pawl.
Lubricator Block Internal Detail
Upper split-half with
fitted brass bearings
Rope Type Felt Packing

Lower split-half
with
fitted brass
bushings
Strut mounting to
counter head Quick connector and
fluid supply hose
Counter Head Assembly
Lubricator Block Mounting Position

Block mounted
“Outboard” of
Spooler/Counter Levelwind assembly
Head Assembly

Fluid Hose
Routed to reservoir

Levelwind
Drive System
Hydra Rig Depth Counter
Mechanical Display
Friction Wheel

Tubing
Tubing Guide

Spooler Head Assembly