Coiled tubing control consoles may vary in appearance from one unit to another because of the age
and type of the unit. Check that the console control functions are standardized and meet the
requirements outlined in the design specifications for coiled tubing unit control consoles.
6 0 K Con t r o l Cons o l e
The oper a t or can control and monitor all of the CTU’s functions (including the
stripp e r and the BOP) from the control console. Figure 1 shows the seve n
major are a s of the control console pan el.
Figure 1—Control console panel
The consol e oper a t or can control the following functions:
• engin e start
• engin e stop
• engin e spe e d
• engin e eme r g e n c y kill
• injector- gripper pres s ur e
• injector- gripper direction
(grip or retra c t)
• reel direction
• reel holding brake
• reel tension (pre s s u r e )
• levelwind override direction
• levelwind boo m direction
• injector holding brake
• injector direction (in or out)
• injector pres s u r e
• injector- mot or displac e m e n t
• stripp e r position (strip or retr a c t)
• stripp e r pres s ur e
• stripp e r hand- pump pres s u r e
• auxiliary BOP ra ms (thre e)
• BOP blind ra m
• BOP cutt e r ra m
• BOP tubing ra m
• BOP slips ra m
• accu m ul a t or pre s s ur e
The consol e oper a t or can monitor the following para m e t e r s :
• wellhe a d pres s ur e
• tubing pres s ur e
• weight indicat or
• console oper a tin g pres s ur e
• console pilot control pres s ur e
• power- pack a g e engine tacho m e t e r
• injector grippe r pres s ur e
• reel pump pres s ur e
• injector pump pres s ur e
• injector pump torqu e / s p e e d pres s ur e
• strippe r hydr a ulic pres s ur e
• strippe r hydr a ulic supply (oper a tin g) pres s u r e
• BOP hydr a ulic supply pres s u r e
• alter n a t or char ging for both the power pack
and the hous e
The consol e cont ains ma n u a l hydr a ulic pu mp s that can supply e me r g e n c y
pres s u r e for the control of vital functions if the main pump fails. All
control valves are close d when the knob or lever is cent e r e d .
The engin e controls are locat e d in the uppe r left are a of the control console
(Figur e 1) The engine control are a of the control console pan el is
shown in Figure 2.
Figure 2—Engine control area of the console
The START , s TOP , and EMERGENCY KILL push button s start and stop the engine . All
engin e controls are pne u m a t i c ally oper a t e d . The AIR THROTTLE regula ting valve
controls the engine spe e d. Clockwis e rota tion of the valve incre a s e s engin e
spe e d. The tacho m e t e r at the far left side of the control consol e pan el shows
engin e spe e d .
Note If you use the EMERGENCY KILL, you mus t res e t the kill cylinder
before the engin e will rest a r t.
The controls for the outsid e flood lights, the air condition e r, and the hea t e r
also in this are a . Undern e a t h the tacho m e t e r controls are the volt me t e r s
desig- nat e d
for both the power pack and the hous e alter n a t o r s .
The PRIMARY INJECTOR or “gripp er” controls are locat e d on the left side of the
consol e (Figur e 1). The grippe r control are a of the control- console
pan el is shown in Figure 3.
Figure 3 – Primar y Injector or Gripper control are a of the consol e
The GRIPPER POSITION lever controls the eng a g e m e n t of the grip cylinde r s and the
gripper blocks. The lever has two positions: GRIP and RETRACT. Once it is place d
in the require d position, the lever locks in place. Positioning the gripper
lever to the GRIP or RETRACT position direct s hydr a ulic pres s u r e to the linearbe a m
grip cylinder s . In the grip position, applied pres s ur e to the grip cylinder s
caus e s
the linear be a m s to exert pres s u r e on the tubing OD throug h the grippe r
Sufficient pres s ur e prev e n t s the tubing from sliding in the gripper blocks as
tubing is inject e d into or re mov e d from the well.
Turning the GRIPPER PRESSURE ADJUST knob clockwis e incre a s e s the grippe r
pres s u r e . The gripper pres s ur e mus t be adjust e d to a level high enoug h to
preve n t slippa g e of the tubing at oper a ting loads.
Although pres s ur e can be incre a s e d from the consol e, the oper a t or mus t first
adjus t the pres s ur e to the require d value and the n open the blee d valve at
injector' s accu m ul a t or until the pres s ur e is stabilize d at the requir e d value.
proc e s s is nec e s s a r y bec a u s e of a safet y pilot- oper a t e d check- valve that
preve n t s
the loss of be a m pres s u r e whe n hydr a ulic pres s ur e is lost.
The OPEN FOR GRIPPER HAND PUMP valve should be close d und er nor mal oper a tin g
conditions. If, howev e r, hydr a ulic pres s u r e is lost, the accu m ul a t or on the
injector should hold grippe r pres s u r e . If this accu m ul a t or pres s ur e start s
ope n the OPEN FOR GRIPPER HAND PUMP valve by turning the valve count e r- clockwis e.
Then use the ma n u al hand pu mp locat e d und er the console to hold
pres s u r e on the gripper blocks until the BOP can be activat e d or until the
is sta ble.
To maint ain control of the coiled tubing workstring, you mus t apply sufficient
linear be a m pres s u r e to the tubing to prev e n t slippa g e betw e e n the tubing
gripper blocks. The reco m m e n d e d linear be a m pres s u r e for a given hoisting
for the 60k injector is define d by the following equ a tion s:
p = 200 psi (whe n Q < 10,00 0 lb)
p = Q ÷ 50 psi (whe n Q > 10,000 lb)
wher e p is the hydr a ulic pres s u r e (psi) applied to the linear be a m cylinder s
(indica t e d by the oper a t or control cons ol e gaug e labele d GRIPPER PRESSURE ) and
is the axial hoisting load (lb) on the tubing.
Note Thes e reco m m e n d e d value s are bas e d on cons e rv a tiv e ass u m p - tions.
Many factor s affect the gripping efficiency of the gripper
blocks. Therefor e , differe n t be a m pres s u r e s ma y be use d bas e d
on the conditions pres e n t .
Exces sive gripper pres s ur e plac e s unn e c e s s a r y stre s s on the tubing and can
in decr e a s e d tubing life and da ma g e to the tubing. See the Gripper Block for
Coiled Tubing Injectors Manual (Part No. 70.51 1 4 0) for reco m m e n d e d gripper
pres s u r e s for various tubing sizes and wall thickne s s e s .
The GRIPPER PRESSURE gaug e indicat e s the pres s ur e applied to the grippe r.
The reel and levelwind controls are locat e d in the REEL are a at the botto m of
control consol e (Figur e 1). The reel control are a of the control- consol e
pan el is shown in Figure 4
Figure 4—Reel control area of the console
The REEL TORQUE LEVER controls the direction and winding force of the tubing
reel. The lever oper a t e s the direction al valve to the main reel mot or. The
(spool- off) position caus e s the reel to rota t e in a direction that unwinds the
Cauti o n Car e sh o u l d be tak e n to pre v e n t th e tubi n g fro m un w r a p pin g
an d birdn e s t i n g w h e n th e re e l is in th e sla c k mo d e .
Unwr a p p i n g coul d re s u l t in tubi n g da m a g e .
The TENSION (spool- on) position caus e s the reel to rota t e in a direction that
rewinds the coiled tubing. During nor mal oper a tion s , the reel is kept in the
TENSION position all the time to ens ur e that the coiled tubing re mai n s tightly
wound on the reel.
The MAX PRESS ADJUST knob controls the hydr a ulic pres s u r e to the reel drive
mot or. This knob is conn e c t e d to the high- and low- set pres s ur e- relief valves
locat e d on the reel’s power pack ma nifold block. Turning the knob clockwis e
incre a s e s the torqu e of the reel drive mot or. Monitor the reel pres s u r e during
job and adjust it as nec e s s a r y to maint ain a consist e n t coiled tubing wrap on
The PUMP pres s u r e gaug e indicat e s the reel pu mp pres s u r e whe n the REEL TORQUE
valve is in the TENSION position.
The HOLDING BRAKE knob set s and rele a s e s the brake on the reel. The reel
brake is locat e d inside the reel plan e t a r y ge ar box. The brake is a fail-safe,
spring- set/pr e s s u r e - rele a s e brak e. In the SET position, the hydr a ulic pres- sure
is du mp e d off the brak e piston, and the springs set the brak e. In the RELEASE
position, pre s s ur e is applied to the brak e piston and the brak e is rele a s e d to
Cauti o n Do no t s e t th e re e l hol di n g brak e w hil e th e re e l is turni n g .
The re e l hol di n g brak e is a parki n g brak e onl y .
Occasion al interru ption of the auto- levelwind ma y be nec e s s a r y to ens ur e
the tubing wraps are unifor m. The LEVELWIND OVERRIDE knob allows the oper a t or
to interru pt the auto m a ti c levelwind me c h a ni s m on the reel to adjus t the
tubing. The knob is spring- bias e d to the cent e r (neutr al) position. When the
is relea s e d , it stops the override function and re- eng a g e s the auto m a t ic
The LEVELWIND BOOM knob allows the levelwind tubing guide to be raise d ( UP ) or
lower e d ( DOWN ) so that the correct relations hi p betw e e n the reel and the
tubing guide can be ma d e for optimu m oper a tion. The valve is also springbias e d
to the cent e r position.
The injector pu mp and motor controls are locat e d at the botto m cent e r of the
consol e (Figur e 1). The injector control are a of the control console
pan el is shown in Figure 4.
Figure 4 –Injector control area of the console
The INJECTOR SPEED lever (Munson- Tyson valve) controls the spe e d and direction
of the injector. Specifically, it direct s pilot pres s ur e to the injector direction al
control, which both est a blish e s the direction of the injector and functions as a
flow- control valve that controls the a mo u n t of fluid to the motor s . The
spe e d is controlled relative to how far from the cent e r position the lever is
place d. The injector is station a r y when the lever is cent e r e d , and the injector
full spe e d when the lever is positione d in either of the extre m e positions.
The MAX PRESS ADJUST knob controls the hydr a ulic pres s u r e at the injector drive
mot or s. The knob oper a t e s by venting the main relief valve on the power
pack a g e’ s injector ma nifold. Turning the MAX PRESS ADJUST knob clockwis e
incre a s e s the power of the injector mot or s. The MAX PRESS ADJUST knob should be
adjus t e d to the mini mu m a mo u n t of pres s ur e nec e s s a r y to overco m e the
load- induc e d
resist a n c e .
The PUMP pres s u r e gaug e indicat e s the injector mot or pres s ur e regar dl e s s of
direction of rota tion. The gaug e also acts as a spar e weight indicator by
the pres s u r e shown and multiplying by a factor of 12.
Note The weight indicator is a mor e accur a t e device for me a s u ri ng the
actu al injector forces.
The LOW SPEED / HI TORQUE / VAR knob allows the oper a t or to select the injector
mot or’s mod e of oper a tion. In the LOW SPEED / HI TORQUE mod e , the motor s oper a t e
at ma xi mu m displac e m e n t (low spe e d) for maxi mu m torqu e . In the VAR (variable)
mod e , the oper a t or can cha ng e the mot or displac e m e n t , and ther efor e,
affect the injector motor spe e d and torqu e in speci al applications .
Note When the injector is in variabl e mod e , the backpr e s s u r e on the
syst e m can caus e the injector spe e d to cha ng e . For exa m pl e ,
oper a ti ng the levelwind override caus e s the return pres s u r e to
incre a s e ; the incre a s e in retur n pres s u r e caus e s the injector
spe e d control pres s u r e to incre a s e , which caus e s the injector
spe e d to incre a s e .
The ADJUST knob to the right of the LOW SPEED / HI TORQUE / VAR knob controls the
spe e d and torqu e of the motor s in the VAR mod e . Clockwis e rota tion of the
incre a s e s mot or spe e d and caus e s a corre s p o n di n g decr e a s e in availabl e
torqu e .
The pres s u r e gaug e next to the ADJUST knob indicat e s the injector mot or
pres s u r e .
The HOLDING BRAKE knob controls the injector holding brake s inside the plan e t a r y
ge ar boxe s that drive the injector. The brak e s are fail-safe, disc- type, springset/
pres s u r e- relea s e brake s . In the SET position, the hydr a ulic pres s u r e is
re mov e d
from the brake piston, and the springs set the brake . In the RELEASE position,
pres s u r e is applied to the brak e piston, and the brake is rele a s e d to allow
of the motor s .
The valves and gaug e s controlling and displa ying the oper a tin g conditions of
BOPs are locat e d on the right side of the console. (See Figure 1) The
BOP control are a of the control cons ol e is shown in Figure 5.
Figure 5—BOP control area of the console
The BLIND, CUTTER , SLIPS , and TUBING levers control the ra ms on the qua d blowout
preve n t e r . The thre e spar e levers allow the oper a t or to control additional
BOPs. For all BOP ra ms , the control- valve levers are locke d in both the open
close position to prev e n t inadve r t e n t selection of either mod e . The BOPs are
nor mally eng a g e d whe n the tubing is station a r y. Closing the BOP ra ms while
running tubing can interfer e with tubing oper a tion s and da m a g e the tubing.
Dyna mic well- pres s ur e control is maint ain e d with the strippe r. To activat e
ra ms , disen g a g e the locks, place the valve in the CLOSE position, and eng a g e
locks. To retra c t the ra ms , plac e the valve in the OPEN position.
If a syst e m hydr a ulic failure occur s, a check valve on the supply side of the
control ma nifold isolat e s the BOP controls. The hous e’s accu m ul a t or pack a g e
supply power to oper a t e the BOPs if the main syst e m pre s s ur e is lost. A hand
pu mp is also available as a final e me r g e n c y supply.
The SUPPLY pres s u r e gaug e indicat e s the hydr a ulic pre s s ur e available for
oper a t- ing
the BOPs. The gaug e doe s not indicat e the pres s u r e available from the
accu m ul a t or s .
In the eve nt of power loss from the power pack a g e , the accu m ul a t or s store
ener g y in the form of fluid pres s ur e . The accu m ul a t or s store enoug h ener g y
close all BOP ra ms 1.5 time s or to close, open, and close all the ra ms unde r
“worst cas e ” conditions.
The OPEN FOR BOP HAND PUMP valve should be close d unde r nor m al oper a ti ng
conditions. If hydr a ulic power is lost, the accu m ul a t or s should supply power
activa t e the BOPs. If, howe v e r , accu m ul a t or pres s ur e is lost, open the OPEN FOR
BOP HAND PUMP valve by turning the valve count e r clockwis e . To activat e the BOP,
eng a g e the BOP ra m knob and use the ma n u a l hand pump.
The ACCUMULATOR lever control rele a s e s pres s ur e stor e d in the accu m ul a t o r s
a job. All pres s u r e should be relea s e d befor e any hos e s are disconn e c t e d .
The valves and gaug e s controlling and displa ying the oper a tin g conditions of
stripp e r are locat e d at the lower right side of the consol e (Figure 1).
The stripp e r controls are a of the control consol e is shown in Figure 6.
Figure 6—Stripper control area of the console
The STRIPPER POSITION lever direct s hydr a ulic pres s u r e to the strippe r. Moving the
lever to the STRIP position applies pres s ur e to the port which squ e e z e s the
stripp e r
aroun d the tubing. This action provide s a seal aroun d the tubing to control
wellhe a d pres s ur e . The RETRACT position re mov e s pres s ur e from the stripp e r.
The STRIPPER PRESSURE ADJUST knob controls the a mo u n t of pres s u r e (sque e z e )
place d on the tubing. Turning the knob clockwis e incre a s e s the pres s ur e .
The HYDRAULIC SUPPLY pres s u r e gaug e indicat e s the pres s u r e available for
oper a ti ng
the stripp e r.
The STRIPPER PRESSURE gaug e indicat e s the pres s ur e being applied to the strippe r.
The OPEN FOR STRIPPER HAND PUMP valve should be close d und er nor mal oper a tin g
conditions. If, howev e r, hydr a ulic pres s u r e is lost, ope n the OPEN FOR STRIPPER
HAND PUMP valve by turning the knob count e r clockwis e . Make sure that the
STRIPPER POSITION valve is in the correct position and use the hand pu mp locat e d
und er the console.
To rele a s e the hand pump pres s ur e to the stripp e r, open the valve labele d
STRIP - PER
DUMP . The STRIPPER DUMP valve can also be use d to reduc e the strippe r
pres s u r e without moving the STRIPPER POSITION lever into its RETRACT position.
Miscellaneous Instrumen ts
Miscellan e o u s gaug e s and instru m e n t s are locat e d in the upp er cent e r, upp er
and uppe r right of the control console pan el (Figure 1). Thes e are a s of the
control consol e pan el are shown in figure 7.
Figure 7 – Miscellaneous instruments area of the control console.
The CONSOLE PRESSURE gaug e indicat e s the oper a tin g pres s ur e of the main
hydr a ulic
syst e m.
The PILOT PRESSURE gaug e indicat e s the console pres s ur e provide d (500 psi or
3400 kPa) to oper a t e other cons ol e valve s.
The WELLHEAD PRESSURE gaug e indicat e s the wellhe a d pres s ur e . The gaug e is
isolat e d from the well fluids by a pres s ur e deboos t e r .
The TUBING PRESSURE gaug e indicat e s the pres s u r e on the tubing. The gaug e is
isolat e d from the well fluids by a pres s ur e deboos t e r .
Cauti o n The WELLHEAD PRESSURE ga u g e and th e TUBING PRESSURE ga u g e
ar e sp e c i a l ga u g e s wit h a 1:4 s e n s i n g - to- indi c a t i n g rati o . If
repl a c e d , th e s e ga u g e s mu s t be re pl a c e d wit h ide n t i c a l
ga u g e s . Failur e to do so will re s ul t in pr e s s u r e re a d i n g s tha t
ar e onl y 25% of th e ac t u a l w ell h e a d or tubi n g pr e s s u r e .
The digital and analog weight indicat or s indicat e the weight being suppor t e d
the load pins locat e d at the botto m of the injector. If prope rly “zeroe d, ” the s e
weight indicator s will indicat e the tubing loads, such as tubing weight and
Both weight indicat or s are a part of the dat a acquisition syst e m (DAS). See
Section 10, 60k CTU Data- Acquisition Syst e m and the DAS ma n u a l s (Part No.
516.9 9 0 0 6 and Part No. 516.9 9 0 0 7) for mor e infor ma tio n.
3 0 K/ 3 8 K Con t r o l Con so l e
The operator can control and monitor all of the CTU’s functions from the control console. Figure 8 shows
the controls for a standard 30/38K coil tubing unit.
Figure 8 -
D T I L C.
E AL O
SCA E F L
6 PA S
59 56 55
CO SO E
56 57 62
I J CO
P E UR
R SS E
NE T R
ST I P R
A J ST
NE T R
I J CO
A J ST
R E MT R
R E A JU
E L D ST
R G A OR
E UL T
ST I P R
SE CU D T I
E T E AL
F RH N L S
O A DE
CU H N L S A D
T A DE N
T R A 1/2 - 13N
CU H N L S A D
T A DE N
T R A 1/2 - 13N
56 59 8
SE D T I
E E AL
CU H N L S A D
T A DE N
T R A 1/2 - 13N
H N L CUT O F D T I
F E AL
The console operator can control the following functions:
- engine start
- engine stop
- engine speed
- engine emergency kill
- injector gripper pressure
- injector gripper direction
- reel direction
- reel tension
- levelwind override direction
- injector direction(in or out)
- injector speed
- injector speed selector (high and low)
- stripper pressure
- stripper position
- BOP blind rams
- BOP cutter rams
- BOP tubing rams
- BOP slip rams
- auxiliary BOP rams (three)
- accumulator pressure
The console operator can monitor the following parameters:
- wellhead pressure
CU H N L S A D
T A DE N
T R A 1/2 - 13N
T R TL
HO T E
996 494- C
ST I P R
55 56 59
L VL I D
WI H I DCA O
EG T N I T R
I ST N M
N L- I
- H USE O E A O O - PRTR
COL T I G T AL R
I UBN R I E
I B 03- 03- 97
console operating pressure
injector gripper pressure
reel tension pressure
stripper hydraulic pressure
BOP supply pressure
The console contains manual hydraulic pumps that can supply emergency pressure for the control
of vital functions if the main pump fails. All directional control valves are closed when the knob or
lever is centered.
The START, STOP, and EMERGENCY KILL push buttons start and stop the engine. All engine
controls are pneumatically operated. The AIR THROTTLE regulating valve controls the engine
NOTE: If you use the EMERGENCY KILL, you must reset the kill switch on the power pack
before the engine will restart.
Injector “In – Out” (Directional Control)
The injector direction is selected manually by positioning the lever to the “in” or “out” position.
This valve directs pilot pressure to the main directional control valve located on the power pack
and causes the valve to supply power to the injector drive motor ports.
Injector Adjust (Pressure Control)
The hydraulic pressure at the injector drive motors can be limited by adjusting the “injector
pressure control” valve. This valve is an adjustable relief valve that is connected by a hose to the
vent port on the main relief valve on the injector manifold block of the power pack. Turning the
injector adjustment valve knob counterclockwise causes the maximum pressure directed to the
injector motors to decrease. The adjusted pressure is the maximum pressure that is available to do
work. It is a good operating practice to adjust this control only high enough to overcome the load
Injector ‘In – Out” Pressure Gauges
Two pressure gauges are mounted to the panel. One indicates the actual injector motor pressure in
the “in” direction and the other in the “out” direction. By monitoring the pressure on the gauge and
using the pressure factor found in the Injector section of the manual for the injector in use the
operator may calculate the approximate load.
NOTE: The weight indicator is a more accurate device for measuring the actual injector forces.
Beam Pressure (Injector Gripper Control)
Positioning the Beam Pressure control lever to the “on” or “off” position directs hydraulic
pressure to the linear beam cylinders. Application of pressure to the “on” cylinder ports causes
force to be exerted on the tubing OD by the linear beams. The force then generates the frictional
reaction force necessary to grip the tubing without sliding the gripper blocks on the tubing.
NOTE: This control should have a “Weevil lock” on it to keep it from being accidentally moved to
the “off” position while pipe is in the hole.
Beam Pressure Adjust (Injector Gripper Pressure Control)
The magnitude of the tubing frictional force is proportional to the amount of lateral force generated
by the gripper cylinders. The gripper pressure must be adjusted to a level high enough to prevent
slippage of the tubing at the operating loads. Too high a setting, however, places unnecessary
stresses on the tubing. Higher stresses cause the life of the tubing to decrease. High gripper
pressures also accelerate the wear rate on the injector chain components. A nominal setting of 1000
psi is recommended. Turning the knob clockwise increases the gripper pressure.
Gripper pressure is isolated at the injector by a pilot operated check valve. Reducing the pressure
on the house gauge will not reduce the pressure on the gripper beams. If the pressure needs to be
reduced there is a bleed off valve on the injector where this may be done. The operator must first
adjust the pressure to the required setting and then open the bleed off valve until the pressure is
stabilized. Extreme care should be taken when doing this.
NOTE: Refer to the “Gripper Block for Coiled Tubing Injectors Manual” (Part # 70.51140) for
recommended gripper pressures for various tubing sizes and wall thickness.
If hydraulic pressure is lost on the console, the beam pressure has a check valve, which isolates it
and allows pressure to be maintained on the beams. If this pressure starts dropping or needs to be
raised the Auxiliary Beam two-way valve should be switched from the “Off” position to the “On”
position. There is an emergency hand pump, located below the console, that will allow the operator
to supply pressure to the beams when this valve is in the “On” position
Beam Pressure gauge
The gauge “Beam Pressure” indicates the amount of hydraulic pressure that is being applied to the
gripper cylinders on the injector.
Speed Control “High – Low”
The injector speed selector has a pre-set pressure on most units and only needs to be shifted to high
or low to be activated. On some older units this control has a pressure control adjustment which
needs manually set. This should be set at 1500 psi.
When running in the hole the 30K injector should be shifted from high to low when the weight
reaches approximately 10,000 lbs. When pulling out of the hole it may be shifted back into high
when the weight reaches approximately 10,000 lbs. The injector should be stopped and put in
neutral to carry out this operation.
The 38K injector may be shifted at 12,000 lbs.
The chain oiler air operated button provides the operator with a means of lubricating the chains
while tripping in and out of the hole. The chains should be oiled approximately every 10,000
running feet. Refer to the Injector section of this manual for types of acceptable lubricating oil.
Pump “A”, “B”, “C”
Three two-way ball valves mounted on the panel permit the operator to selectively engage the main
injector drive pumps on the power pack. Setting the dump valve to the “vent” position causes the
pump unloader to vent, thus diverting the entire pump flow to the tank. Venting all three valves will
unload all three pumps. This is a convenient method of selecting injector speed by diverting some
of the excess flow to the tank at a low pressure drop. The other method of controlling injector
speed is to reduce the injector pressure until the relief valve bypasses some of the fluid flow. The
excess pump flow will then be dumped across the main pressure relief valve, reducing the flow to
the motors and causing the speed to decrease. A disadvantage of this speed control method is the
wasted energy that is evident by the heat input into the hydraulic oil.
Reel “In – Out” (Directional Control)
The Reel directional control valve is used to select the direction that the reel turns. Positioning the
lever to either the “In” or “Out” position causes a pilot signal to shift the main reel motor
directional valve (on the power pack) in the direction to power the reel motor to the “in” or “out”
direction. In most normal operations, the reel will always be in the “out” mode, whether going in or
pulling out of the hole. It is necessary to maintain tension on the reel to prevent birdnesting.
The Reel Adjust valve allows the operator to adjust the pressure that is powering the reel drive
motor. Turning the knob counterclockwise decreases the pressure at the motor port. This valve is
connected to the high and low set pressure reducing relief valves located on the power pack reel
manifold block. The reel pressure should be monitored during the job and adjusted as necessary to
maintain a consistent wrap on the reel.
Reel Motor Pressure gauge
The reel pressure gauge located on the panel permits the operator to monitor the hydraulic pressure
to the reel drive motor that is producing the tension on the tubing.
Occasional interruption of the auto-levelwind may be necessary to ensure that the tubing wraps are
uniform. The “Levelwind” directional control knob allows the operator to override the autolevelwind when necessary. The operator should observe the direction that the levelwind carriage
moves when the valve is selected.
BOP & Stripper Controls
BOP Control Valves
The Blind, Cutter, Slips and Tubing levers control the rams on the quad blowout preventer. The
three spare levers allow the operator to control additional safety BOP’s. For all BOP rams, the
control valve levers are locked in the open position to prevent accidental closing. The BOP’s are
normally engaged when the tubing is stationary. Closing the BOP rams while running tubing can
interfere with tubing operations and damage the tubing. To activate the BOP rams, disengage the
locks and place the valve in the CLOSE position. To retract the rams, place the valve in the OPEN
BOP Pressure gauge
The BOP Pressure gauge allows the operator to see the hydraulic pressure available for the BOP
If a system hydraulic failure occurs, a check valve on the supply side of the BOP control manifold
isolates the BOP controls. The house’s accumulator package can supply power to operate the
BOPs if the main system pressure is lost. The Auxiliary BOP two-way valve should be switched
from the “Off” position to the “On” position and the desired BOP valve selected.
A hand pump, located below the console, is also available as a final emergency supply.
The stripper valve is a two way valve that allows the operator to select the “Dump” position for
decreasing or bleeding off the pressure on the stripper or select the “Off” position to maintain the
required hydraulic pressure on the stripper.
The Air Regulator allows the operator to adjust the amount of air pressure needed to activate the
pneumatically powered pump mounted underneath the console. This pump supplies the pressure to
hydraulically energize the stripper packoff.
Air Pressure gauge
The air pressure gauge located on the console lets the operator see how much air pressure is being
applied to the pneumatic powered pump.
Stripper Pressure gauge
The stripper pressure gauge allows the operator to see how much hydraulic pressure is being
applied to the stripper packoff.
In the event of a system hydraulic failure or loss of air supply, a check valve on the supply side of
the stripper isolates the stripper to prevent loss of pressure. The auxiliary stripper two-way valve
may be switched from the “Off” position to the “On” position and pressure may be supplied with
the emergency hand pump, located below the console.
The Console Pressure gauge indicates the console pressure available to operate the console valves.
This pressure should normally be at 1500 psi.
The Wellhead and Tubing Pressure gauges read the pressures on the wellhead and tubing. These
gauges are each isolated from well fluids by pressure deboosters.
NOTE: On some units these gauges are special gauges with a 1:4 sensing to indicating ratio. If
replaced, these gauges must be replaced with identical gauges. Failure to do so will result in
pressure readings that are only 25% of the actual pressure.
Weight Indicators may be digital, analog or bladder type.
The digital and analog weight indicators indicate the weight being supported by the load pins
located at the bottom of the injector. If properly “zeroed,” these weight indicators will indicate the
tubing loads, such as tubing weight and snubbing force. Both indicators are a part of the Data
Acquisition System (DAS). See the DAS manual (part # 516.99007) for more information.
The bladder type (Martin-Decker) weight indicator only indicates tubing weight and will not
measure snubbing forces.
There are toggle switches located on the console for operation of lights, heater, air conditioner and
crane on most units.