Section 9

Tubing Reel Assembly

Table of Contents
Halliburton Tubing Reel Assembly........................................................................................................9-3
Reel Skid and Drive Unit ...................................................................................................................9-3
Tubing Reel.......................................................................................................................................9-4
Automatic Levelwind.........................................................................................................................9-4
DNV 60k CTU Reel..............................................................................................................................9-5
ReelSpool..........................................................................................................................................9-5
Offshore Lift Frame...........................................................................................................................9-6
Lift Bar .............................................................................................................................................9-6
Hydraulic Drive Mechanism ..............................................................................................................9-6
Cems Pre – Job Inspection Checklist ...................................................................................................9-10
Cems Post – Job Maintenance Checklist ..............................................................................................9-11
Test Your Knowledge..........................................................................................................................9-12

Halliburton 9•1 Coiled Tubing Essentials

© 2000, Halliburton
 Tubing Reel Assembly

Halliburton 9•2 Coiled Tubing Essentials

© 2000, Halliburton

Halliburton Tubing Reel
Assembly
The reel assembly is a large steel storage drum
suspended on a shaft and mounted onto a skid frame.
The reel is powered by a bi-directional hydraulic
motor directly driving the reel through roller chain
Fig. 1: Major components of coiled tubing reel assembly.
Reel Skid and Drive Unit
The reel skid is a heavy-duty oilfield type skid
complete with drip pan and designed to give rigid
support to the tubing reel. The pedestal mounted
bearings are anti-friction pillow block bearings
designed to take the full load of the reel, tubing and
any fluid in the tubing. The reel skid is complete
with the hydraulic drive motor for the tubing reel,
which is bearing mounted and which can be adjusted
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© 2000, Halliburton
Tubing Reel Assembly
and sprockets. A fail-safe spring applied parking
brake is installed between the motor and drive
sprocket to prevent unintentional reel motion.
Following are the major components:
• Reel skid and drive unit
• Tubing reel
• Automatic levelwind
for proper tension of the drive sprocket and chain.
The reel skid also contains the drive sprockets for
mechanically driving the levelwind assembly and a
hydraulic motor for overriding the mechanical drive,
should the levelwind get out of phase with the reel.
Four lift eyes are welded to the skid main structural
uprights, and are designed to support the reel
assembly weight plus the tubing weight. The lift eyes
are sized to maintain a 5.0 minimum safety factor.
9•3 Coiled Tubing Essentials
 Tubing Reel Assembly

Tubing Reel Automatic Levelwind

The tubing reel is a fabricated steel spool capable of
handling up to 25,000 ft of 1 1/4-in. tubing. The
main shaft is hollow on one end to provide a
passageway for fluids pumped into the coiled tubing.
The inboard end of the tubing is connected through
the hollow end of the reel shaft to a rotating joint
which is flange mounted to the reel shaft. The
rotating joint stationary section is connected to the
fluid or gas circulation pump system, thus,
circulation can be maintained continuously as the
tubing is injected or retrieved from the well. A
10,000 psi shutoff valve is provided between the
tubing and the reel shaft for emergency use.
The automatic levelwind is attached to the reel
assembly frame and is adjusted to suit field
conditions with a floating tubing guide. The
levelwind mechanism is a gimbal mounted guide
bushing, through which the tubing is run on an
adjustable leadscrew powered by rotation of the reel
itself. The leadscrew automatically positions the
tubing laterally on the reel to ensure smooth wraps
on the core. A mechanical differential device in the
levelwind drive mechanism permits manual override
adjustments of the levelwind to compensate for
winding errors.

Table 1: Primary Coiled Tubing Reel Assemblies

Shaft Style 996.16074 996.16076 996.15871 997.02400 997.02104 997.02407 997.02102 996.16786
Shaftless Style 997.02128 997.02104 997.02138 997.02142 80K
60K
Approx. Weight (lb) 5,500 7,000 9,600 7,800 8,500 9,900 9,000 14,000
Height (in.) 118.75 118.75 118.75 129.52 98 138.75 142 154
Width (in.) 94 94 98.38 93.88 96 95.5 81 102
Length (in.) 128.75 128.75 149.25 139.75 126 139.75 173 168
Core Diameter (in.) 72 72 72 80 72 80 84 84
Flange Diameter (in.) 118 118 118 128 104 138 142 144
Drum Width (in.) 54.13 54.13 54.13 54.13 79 54.13 65 76
Tubing OD (in.) 1.25 1.25 1.25 1.5 1.25 1.5 1.25 1.25
1.5 2.375 2.375
Reel Capacity (ft) 17,500 17,500 17,500 15,000 15,000- 1.25 18,000 17,350- 1.75 12,500- 2.375
8,000- 1.5
Working Pressure (psi) 10,000 10,000 10,000 10,000 10,000 10,000 10,000 5,000
Service H2 S H2 S H2 S H2 S H2 S H2 S H2 S H2 S

Halliburton 9•4 Coiled Tubing Essentials

© 2000, Halliburton

DNV 60k CTU Reel
The DNV 60k coiled tubing reel (Figure 7.1) is a
specialized power winch that temporarily stores
large quantities of coiled tubing for transport
between jobs. Tubing is spooled hydraulically on or
off the reel. During coiled tubing operations, the
reel serves as part of the active control system. The
reel assembly can be mounted either in an offshore
lifting frame or an embedded reel trailer. Although
the reel requires a minimum amount of servicing to
remain operational, it is essential that the reel be
well-maintained and handled properly. (See Lift Bar
for information about lifting the reel assembly.)
ReelSpool
The reel spool (Figure 7.4) is supported on both sides
with large radial bearings. The reel spool is bolted
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© 2000, Halliburton
Tubing Reel Assembly
to a flex plate on the outer race of the bearings and
the inner race is bolted to the reel support frame.
Internally mounted fixed-displacement hydraulic
motors rotate the reel with a pinion gear that drives
the reel with external gear teeth located on the large
diameter of the support bearings.
The spool flange is available in 142-in. (3.61-m) and
148-in. (3.76-m) diameters. The core diameter is 84
in. (2.13 m), and the flange width is 65 in. (1.65 m)
for all spool sizes. Table 7.4, Page 7-6, lists the
spooling capacities of the different reel sizes
according to reel flange diameter, height, and
weight.
Note The reel spool is not typically removed from
the reel frame except for maintenance.
All DNV 60k reels are equipped with the E-line
swivel. The E-line swivel allows the remote
manifold close-in valve mounted in the internal
manifolding to be operated hydraulically. A
termination assembly must be installed when the E-
line swivel is used inside the tubing (Figure 7.7).
9•5 Coiled Tubing Essentials

Offshore Lift Frame
The offshore lift frame is a welded assembly of
structural elements that support the weight of the
reel plus the amount of tubing installed on the reel.
Four lift eyes are mounted to the frame for hoisting
the reel. The addition of a lift sling, shackles, and
lift bar allows the unit to lift both the reel and the
tubing. the bottom of the frame is enclosed and
serves as a drip pan that collects leaking fluids and
well fluids accumulated on the outside of the tubing.
Lift Bar
A special lift sling (Figures 7.2 and 7.3) with a
spreader bar is required to hoist a fully loaded reel
assembly safely.
Caution Do not lift the reel assembly without the
lift bar. Damage to the reel assembly may result
and may cause injury to personnel.
All fluids should be purged from the tubing before
hoisting the reel assembly to minimize the weight of
the loaded reel assembly.
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© 2000, Halliburton
Tubing Reel Assembly
Hydraulic Drive Mechanism
The hydraulic power package powers the reel drive
and levelwind-assembly override with a closed-loop
variable displacement pump. Refer to Section 6,
DNV 60k CTU Hydraulic Power Package for
information on the operation and maintenance of
this pump.
The components that control the reel consist of dual-
drive motors that turn the spool, a levelwind override
for accurate wrapping of tubing from side to side,
and a levelwind elevating cylinder.
The dual-drive motor package incorporates a
bidirectional hydraulic motor coupled to a planetary
gear box with a remotely operated, spring-applied,
hydraulically released holding or parking brake. The
overall reduction of the drive package is optimized to
provide a maximum tubing speed of 230 ft/min.
Important: The holding brake on the drive motor
package is a parking brake only. It is used to
lock the reel in one position when the reel is
stopped. There is no dynamic brake.
The continuous tension (mooring) feature is
controlled with the hydraulic pressure to the reel
drive motor. The operator at the control console of
the operator house adjusts the pressure as needed to
maintain smooth wrapping of the tubing on the reel.
'Me controls affect the pump output pressure from
the hydraulic power package.
The reel drive motor (Figure 7.8) operates in
continuous tension mode to maintain tension on the
tubing when the tubing is being spooled onto the reel
or when the tubing is being spooled off the reel. To
spool the tubing onto the reel, the source pressure
must provide enough torque to overcome the
frictional forces and the bending forces needed to
make the tubing conform to the spool diameter. To
avoid unnecessary strains on the unit, the motor
pressure is lower when tubing is spooled off the reel .
When the tubing is being spooled off, the drive
motor operates as a pump. To prevent cavitation at
the output port, the hydraulic system is configured to
provide charge pressure on the offside motor port.
This pressure is always present when the directional
control valve in the operator house is shifted from
the neutral position.
Figures 7.9 and 7.10 show the hydraulic power-
package circuit and operator house control circuit.
9•6 Coiled Tubing Essentials
 Tubing Reel Assembly

Halliburton 9•7 Coiled Tubing Essentials

© 2000, Halliburton
 Tubing Reel Assembly

Loc. Qty. Description

1 2 Screw - Swivel
2 1 End Plate - Swivel
3 2 Whasher - Thrust Bronze
4 2 Bearing -Thrust - Needle
5 6 Screw - Socket Set
6 6 Bolt - Hex Head
7 1 O-Ring - Sour Gas
8 6 Washer - Lock
9 2 Fitting - Grease
10 2 Ring - Back-up Teflon
11 2 O-Ring - Sour Gas
401 1 Housing - Swivel
402 1 Ring - Lantern
403 2 V-Pkg Set
404 1 Shaft - Swivel
405 2 End Cap - Swivel

Halliburton 9•8 Coiled Tubing Essentials

© 2000, Halliburton
 Tubing Reel Assembly

Halliburton 9•9 Coiled Tubing Essentials

© 2000, Halliburton
 Tubing Reel Assembly

Cems Pre – Job Inspection Checklist

(To be performed before every job)
( ) Visually Check for damage.
( ) Visually check for Hydraulic leaks.
( ) Visually check condition of spreader bar. Verify no damage.
( ) Verify spreader bar lifting slings are in good condition.
( ) Verify shackles, nuts and cotter pins are secure and in good condition.
( ) Verify drain plugs are in drip pan.
( ) Verify drip pan is clean and dry.
( ) Check all chains for lubrication.
( ) Check all chains for correct tension and alignment.
( ) Check levelwind bar guide for lubrication.
( ) Check bearings for lubrication and good condition.
( ) Check pump swivel and pump lines condition and secureness.
( ) Check manifold support for damage.
( ) Verify manifold support brackets are not inducing side loads into the swivel housing and that the manifolding
aligns with the swivel.
( ) Check condition of pipe on reel.
( ) Record pipe size: ____________
( ) Record Pipe footage: ____________

Halliburton 9 • 10 Coiled Tubing Essentials

© 2000, Halliburton
 Tubing Reel Assembly

Cems Post – Job Maintenance Checklist

(To be performed within 24 hours after completion of job)
( ) Clean unit and allow to dry.
( ) Remove and lubricate the levelwind lead screw.
( ) Grease the levelwind pawl and guides.
( ) Lubricate the tubing guides.
( ) Lubricate all chains.
( ) Grease all bearings.
( ) Grease all Lo-torc valves.
( ) Visually inspect circulating swivel and manifold support for damage.
( ) Verify manifold support brackets are not inducing side loads into the swivel housing and that the manifold
aligns with the swivel.
( ) Grease the swivel.
( ) Check hoses and quick disconnects to verify no leaks.
( ) Visually check for damage.
( ) Check condition of pipe.
( ) Check condition of spreader bar. Verify no damage.
( ) Verify all lifting slings are in good condition.
( ) Verify all shackles, nuts and cotter pins are in good condition and secure.

Halliburton 9 • 11 Coiled Tubing Essentials

© 2000, Halliburton
 Tubing Reel Assembly

Test Your Knowledge

1. What are the tree major components of the Reel Assembly?
1.
2.
3.
2. The ____________ ____________ makes it possible for continuous circulation while the reel is in motion.
3. What is the purpose of the levelwind assembly?
1.
4. The working press for the tubing reel assemblies is ____________ PSI.
5. All reel chains should be lubricated within ____________ Hours after every Job.

Halliburton 9 • 12 Coiled Tubing Essentials

© 2000, Halliburton