TECHNICAL MANUAL PCE Coiled Tubing Motorhead Assembly

DOCUMENT NUMBER REV

TM – 210.1 C200-025-08 / 1.687” A

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 Technical Manual

PCE Coiled Tubing Motorhead Assembly

This document contains proprietary and confidential information Downhole

which belongs to National-Oilwell Varco, L.P., its affiliates or
subsidiaries (all collectively referred to hereinafter as "NOV"). It is 7909 Parkwood Circle Drive
loaned for limited purposes only and remains the property of NOV. Houston, Texas 77036
Reproduction, in whole or in part, or use of this design or United States
distribution of this information to others is not permitted without the
express written consent of NOV. This document is to be returned to Phone: 713 346 7500
NOV upon request and in any event upon completion of the use for Fax: 713 346 7959
which it was loaned. This document and the information contained
and represented herein is the copyrighted property of NOV.
© National Oilwell Varco

DOCUMENT NUMBER REV

TM – 210.1 C200-025-08 A

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REVISION HISTORY

A 29/05/08 Updated T.Alner

0 22/06/07 Re-formatted into new layout T.Alner
Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

CHANGE DESCRIPTION

Revision Change Description

A

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TABLE OF CONTENTS

1 INTRODUCTION............................................................................................................... 4
2 DESCRIPTION.................................................................................................................. 4
3 ASSEMBLY PROCEDURE (FLAPPER CARTRIDGE) SUB ASSEMBLY....................... 6
4 ASSEMBLY PROCEDURE (HYDRAULIC DISCONNECT) SUB ASSEMBLY ................ 7
5 ASSEMBLY PROCEDURE (CIRCULATION TOOL) SUB ASSEMBLY .......................... 9
6 ASSEMBLY PROCEDURE (MOTORHEAD ASSEMBLY)............................................. 10
7 HYDRAULIC DISCONNECT OPERATION .................................................................... 10
8 MAINTENANCE.............................................................................................................. 11
9 DATA SHEET C165-013 (1.310” FLAPPER CARTRIDGE ASSEMBLY)...................... 12
10 ASSEMBLY DRAWING C165-AS-10 (FLAPPER CARTRIDGE ASSEMBLY).............. 13
11 DATA SHEET C200-025-08 (MOTORHEAD ASSEMBLY)............................................ 14
12 ASSEMBLY DRAWING C200-AS-10 (MOTORHEAD ASSEMBLY) ............................. 15
13 SHEAR PIN VALUES (1-11/16” MOTORHEAD ASSEMBLY)....................................... 16

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1 INTRODUCTION
The PCE Coiled Tubing Motorhead Assembly (MHA) has been developed in recognition
to industry demands for compact, heavy duty, integrated bha components. The (MHA)
combines the Double Flapper Check Valve with the HD Hydraulic Disconnect and the
Dual Circulation Valve, standard components for virtually all toolstring designs. The
tubing connector has been deliberately eliminated to give the added flexibility of
operator choice for the connector type and coil tubing size.

The (MHA) provides the operator with a compact, versatile, upper BHA and offers the
following features:

1) The (MHA)’s compact design gives an overall length saving of approximately

30% over the use of conventional individual components.

2) The high torque capability of the Motor Head Assembly provides the ideal Motor
Head for today’s high demand coiled tubing drilling applications.

3) The choice of tubing connector is not dictated by the Motor Head, therefore
giving the operator the flexibility to choose the most appropriate connector to suit
the application.

4) With a considerable reduction in the number of component parts, seals and

thread connections, the (MHA) is uncomplicated to assemble/disassemble and
inexpensive to redress.

2 DESCRIPTION
Double Flapper Check Valve
The (MHA) incorporates two 17-4PH stainless steel Flapper Cartridge Assemblies. PCE
Flapper Cartridge Assemblies are manufactured to the highest material specification
and include Inconel X750 hinge pins and flapper return springs. Risk of failure is virtually
eliminated through the dual sealing arrangement.

Each Flapper Cartridge incorporates a primary, low pressure PTFE seal, backed up with
a secondary, high pressure metal-to-metal seal. PCE Flapper Cartridge Assemblies
simply ‘drop-in’ to the Double Flapper Check Valve housing, providing ‘ease-of-
assembly’ redressing of the (MHA).

Heavy Duty Hydraulic Disconnect

PCE present their world leading Heavy Duty Hydraulic Disconnect (HDHD), proven to
endure even the most rigorous and demanding coiled tubing applications.

The (HDHD) allows the toolstring to detach at a predetermined point via the deployment
of a suitable drop/trip ball through the coiled tubing.

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The drop ball locates on a piston sleeve creating sufficient back pressure to shear the
pins and disconnect the tool. The piston sleeve pushes the tool apart to ensure a clean
disconnect. Circulation is immediately returned to the toolstring, providing a surface
indication of a positive disconnect. All piston sleeves and drop balls are returned to
surface leaving a standard ‘GS’ internal fish neck for retrieval purposes.

The (HDHD) utilises a heavy duty, one piece, release collet to hold the tool together.
The collet endures higher tensile loading than collet finger type release mechanisms
and is far less susceptible to fatigue. The collet is backed up with a collet sleeve to give
maximum tensile strength to the disconnect during heavy jarring operations.

Only by dropping a ball and shearing the pins can the collet sleeve shift, allowing the
release collet and top sub to part. The piston sleeve is pressure balanced, therefore
internal pressure does not affect the hydraulic configuration and shear values.

High torque capabilities are achieved through positive torque drive teeth between the
top sub and the main body of the tool. The (HDHD) is therefore ideally suited for high
torque, heavy duty coiled tubing drilling operations where maximum performance and
durability is essential.

Shear screws can be supplied in either brass or steel to give a comprehensive pressure
range to suit virtually any coiled tubing application. Shear screws are also integrally
situated to eliminate the possibility of shear screws vibrating free during CT drilling
operations.

The standard configuration consists of the maximum flow through bore available, whilst
maintaining maximum tensile strength in the tool. By interchanging the piston sleeve,
the drop/trip ball size can be varied to suit the desired toolstring requirements. This is a
particularly useful feature when the (HDHD) is situated below jars and accelerators, and
ID restrictions are a considering factor. Running the (HDHD) below jars and accelerators
ensures that if disconnection of the toolstring is necessary, a greater proportion of the
toolstring is safely returned to surface.

A major inherent design consideration is that of simple field redress. The hydraulic
disconnect has been methodically designed to ensure assembly & disassembly of the
tool is trouble free. No special assembly tools are required and all seals are standard ‘O’
rings.

Dual Circulation Valve

The (MHA) also incorporates the unique feature of the PCE Coiled Tubing Dual
Circulation Valve (CTDCV). The (CTDCV) offers the traditional method of returning
circulation of the toolstring through use of a drop ball. In addition, the valve is capable of
operating through internal overpressure within the tubing string. Conventional dual
circulation valves use a burst or rupture disc to facilitate the function of returning
circulation through overpressure. However, the (CTDCV) offers a pressure differential
activated piston.

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The piston activation pressure can be predetermined at surface through shear pins,
offering superior flexibility and considerable savings on redress. As with the other
components of the (MHA), the emphasis is on simplicity and the (CTDCV) has very few
component parts, seals and thread connections

3 ASSEMBLY PROCEDURE (FLAPPER CARTRIDGE) SUB ASSEMBLY

1) Install ‘O’ rings and grease.

2) Insert Flapper (3) into Body (1).

3) Cut Spring Arms (5) to length and place between hinge of Flapper (3).

4) Insert Pin (7) through the holes in Body (1), holes in Flapper (3), Spring (5) and
file flush to outside diameter.

5) Place Seal (4) onto Seat (2).

6) Insert seat (2) with seal (4) uppermost in body (1).

7) Insert 2 x Flapper Cartridge assemblies into Flapper Assembly Housing

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4 ASSEMBLY PROCEDURE (HYDRAULIC DISCONNECT) SUB ASSEMBLY

Dis-assembly and Re-pinning procedure for Disconnect

If the tool has not been released after running in the hole it should be dis-assembled,
inspected and re-assembled with re-dress parts as required. To do this, use the
following procedure.

1) Breakout the Circ Sub Body (12) from the Fish Neck / Body (5) and the Flapper
Housing (1) from Upper Release sub (4).

2) Using a soft drift bar tap the Release Piston (11) downwards into the bore of the
Upper Release Sub (4) so that it moves the Piston (8) with Collet Sleeve (7) and
Shear Collar (9) out from the Fish Neck / Body (5).

3) Remove Shear Screws (31) from Fish Neck / Body (5). The Upper Release Sub
(4) and Fish Neck / Body (5) will then separate with a sharp tap on the bottom of
the Upper Release Sub (4) with a soft drift bar. The Release collet (6) will exit
from the Fish Neck / Body (5) and the Release Piston (11) can be removed from
the Upper Release Sub (4).

4) Remove Shear screws (10) from Shear Collar (9) inspect and replace with new
ones if necessary.

5) O’rings should be replaced as and when required.

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Assembly

1) Place Shear collar (9) over the piston (8) so as the holes in the Shear Collar (9)
line up with the Shear groove in the Piston (8).

2) Load all O-Rings.

3) Install as many Shear pins (10) as necessary to equal the required release
pressure. Refer to individual Data sheet for shear values.

4) Tap Upper Release sub (4) into the Fish Neck Body (5), aligning the castlations
so that they inter-lock.

5) Make up Piston (8) to the Sleeve (7), tighten and fit Grubscrew (25).

6) Place Upper Release sub (4) Fish Neck Body (5) sub assembly on a bench with
Upper Release sub (4) down. Install the serpentine Collet (6) into the Fish Neck
Body (5) over the nose of the Upper Release sub.

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7) Using the Assembly tool knock the serpentine collet down until it butts against the
houlder in the Fish Neck Body.

8) Assemble the Release Sleeve (7) over the serpentine collet. When it is fully
down, the Piston (8) will be level with the bottom of body (5). Note. 2-7/8 model
the Piston is 3/8” below end of body (5).

9) Insert the Circulation Sleeve (11) into the Upper Release sub (4) until it butts up
against the Piston (8).

10) Fit O’ ring (27) and make up the Circ Sub to the bottom of the Fish Neck
Body (5) and tighten.

5 ASSEMBLY PROCEDURE (CIRCULATION TOOL) SUB ASSEMBLY

1) Install 'o'rings and grease.

2) Invert body (12) on bench top and push shear piston (13) into body.

3) Align pin holes with shear pin groove which can be seen through the circulating
ports.

4) Install Shear Screws (14) to value required. See data tables at the end of this
document for shear screw values.

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6 ASSEMBLY PROCEDURE (MOTORHEAD ASSEMBLY)

Once the three sub-assemblies of the (MHA) have been assembled then screw
together, ensuring that ‘o’-ring (18) and flapper seating ring (2) are installed between the
flapper cartridge and heavy duty hydraulic disconnect sub, then tighten.

The tool is now ready for pressure testing

7 HYDRAULIC DISCONNECT OPERATION

Pre-Run Checks
1) Determine the required release pressure and, referring to the data tables
calculate the required number of shear pins (10).

2) Ensure the tool is assembled correctly as described in the assembly section. Use
the number of shear pins as resolved above.

3) Check the ball (the diameter of the ball is stated on the data sheet) will pass
through the upper part of the (MHA).

Disconnect Operation
4) If it becomes necessary to disconnect the release joint drop the correct size ball.

5) Pressure up the coiled tubing to a pressure slightly higher than the release value
of the tool.

6) The shear pins will shear out allowing the shear sleeve to drop.

7) Overpull on the coiled tubing 300 to 500 lbs to separate the tool.

Retrieval Operation
A standard ‘GS’ pulling tool such as a Flow Activated ‘GS’ Pulling tool or an Internal
Fishneck Retrieval Tool can be used to pull the lower half of the tool string. The fishing
neck size is shown on the technical specification sheets.

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8 MAINTENANCE
1) After every run ensure that the tool is disassembled, cleaned and inspected.
Replace all seals.

2) Replace any worn or damaged parts.

3) Lightly oil or grease all parts and seals prior to assembly.

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9 DATA SHEET C165-013 (1.310” FLAPPER CARTRIDGE ASSEMBLY)

____________________________________________________________________________
| Prod No: C165-013 Rev:B (12 Jun 00) Drg No: C165-AS-10 |
| FLAPPER CARTRIDGE ASSEMBLY |
| 1.310" OD x 0.687" ID Size Ref: 1.310" |
|____________________________________________________________________________|
| Max O.D: 1.31 |Fish Neck: |Service: H2S |
| Min I.D: 0.687" | Top Con: |________________|
| Length: 2.566 |Lower Con: | Weight: |
| Other: | Other: | (Kg) |
|__________________________|________________________________|________________|
| W.Press: 5000 PSI |W.Tensile: | Tech Manual |
| T.Press: 5000 PSI |Calc Tens: | |
| |Other P/L: | |
|__________________________|________________________________|________________|
| Notes: |
| |
| |
|____________________________________________________________________________|
____________________________________________________________________________
|Item| Qty| Part No Rev | Description | Spare |
|____|____|______________|______________________________________|____________|
| 1 | 1 |00-12223 B| FLAPPER HOUSING | |
| 2 | 1 |00-12224 A| FLAPPER SEAT | |
| 3 | 1 |00-12222 C| FLAPPER | |
| 4 | 1 |00-12225 A| FLAPPER SEAL | KS |
| 5 | 1 |MSS0-343 C| COIL SPRING | KS |
| 6 | 1 |HV03-032 | O-RING | KS |
| 7 | 1 |00-13614 A| HINGE PIN | KS |
|____|____|______________|______________________________________|____________|
Recommended Spares: KS (General Spares Kit) KR (Other Recommended Spares)

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10 ASSEMBLY DRAWING C165-AS-10 (FLAPPER CARTRIDGE ASSEMBLY)

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11 DATA SHEET C200-025-08 (MOTORHEAD ASSEMBLY)

____________________________________________________________________________
| Prod No: C200-025-08 Rev:A (07 Apr 08) Drg No: C200-AS-10 |
| MOTOR HEAD |
| 1 11/16 HW 1" AMMT B X P Size Ref: 1 11/16 |
|____________________________________________________________________________|
| Max O.D: 1.687 |Fish Neck: 2" INT 'GS' |Service: H2S |
| Min I.D: 0.406 | Top Con: 1" AMMT BOX |________________|
| Length: 27 1/4" |Lower Con: 1" AMMT PIN | Weight: 4.5|
| Other: | Other: | (Kg) |
|__________________________|________________________________|________________|
| W.Press: 5000 PSI |W.Tensile: | Tech Manual |
| T.Press: 6500 PSI |Calc Tens: 34600 LBS CALC | |
| |Other P/L: | TM-210.2 |
|__________________________|________________________________|________________|
| Notes: 7/16 BALL FOR CIRCULATION / 5/8 MIN BALL FOR RELEASE |
| SEE TECHNICAL MANUAL FOR SHEAR PIN INFORMATION |
|____________________________________________________________________________|
____________________________________________________________________________
|Item| Qty| Part No Rev | Description | Spare |
|____|____|______________|______________________________________|____________|
| 1 | 1 |02-31745 0| TOP SUB | |
| 2 | 1 |01-31547 0| FISH NECK / BODY | |
| 3 | 1 |00-31136 A| RELEASE COLLET | |
| 4 | 1 |02-27610-VE 0| COLLET RELEASE SLEEVE | |
| 5 | 1 |02-27611 A| PISTON | |
| 6 | 1 |00-27612 A| SHEAR COLLAR | |
| 7 | 1 |02-31744 0| CIRC SUB BODY | |
| 9 | 1 |HV02-019 | O-RING | KS |
| 10 | 1 |01-31300 0| CIRCULATION SLEEVE | |
| 11 | 1 |MBB9-009 | BALL 5/8" | KS |
| 12 | 3 |HV03-033 | O-RING | KS |
| 13 | 1 |HV03-020 | O-RING | KS |
| 14 | 1 |MBB9-006 | BALL 7/16" | KS |
| 15 | 6 |00-17117 C| SHEAR SCREW SOLID | KS |
| 16 | 0 |SEE ITEM 25 0| INCLUDED IN ITEM 25 | |
| 17 | 1 |HV05-007 | O-RING | KS |
| 18 | 1 |02-31546 0| UPPER RELEASE SUB - 1 11/16 | |
| 19 | 0 |SEE ITEM 12 0| INCLUDED IN ITEM 12 | |
| 20 | 1 |HV04-012 | O-RING | KS |
| 21 | 1 |FSH7-022 | HEX SOCKET SET SCREW | KS |
| 23 | 1 |02-31616 A| FLAPPER ASSEMBLY HOUSING | |
| 24 | 2 |C165-013 B| FLAPPER CARTRIDGE ASSEMBLY | |
| 25 | 3 |HV03-032 | O-RING | KS |
| 26 | 1 |02-27834 0| CIRC SLEEVE | |
| 27 | 1 |HV02-021 | O-RING | KS |
| 28 | 1 |HV02-018 | O-RING | KS |
| 29 | 6 |FZCP1-052 0| SHEAR PIN (CALIBRATED) | KS |
| 30 | 6 |FSH7-032 | HEX SOCKET SET SCREW | KS |
| 31 | 4 |00-29381 B| SHEAR SCREW (BRASS) | KS |
|500 | 1 |00-31234 0| COLLET ASSEMBLY TOOL | |
|____|____|______________|______________________________________|____________|
Recommended Spares: KS (General Spares Kit) KR (Other Recommended Spares)

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12 ASSEMBLY DRAWING C200-AS-10 (MOTORHEAD ASSEMBLY)

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13 SHEAR PIN VALUES (1-11/16” MOTORHEAD ASSEMBLY)

Release Joint
The following table specifies the pressure required to activate the drop ball release joint after the required
ball has been dropped.

Steel Shear Pins

0 1 2 3 4 5 6 7 8
0 1662 2825 3987 5149 6311 7474
Brass Shear Pins

1 1457 2619 3782 4944 6106 7269

2 2414 3577 4739 5901 7063
3 3371 4534 5696 6858
4 4329 5491 6653
5 5286 6448
6 6243
7
8

Drop Ball Circulation Sub

The following table specifies the pressure required to activate the circulation sub after the required ball has
been dropped.

Steel Shear Pins

0 1 2 3 4 5 6 7 8
0 1728 3205 4683 6160 7638 9116
Brass Shear Pins

1 1133 2611 4088 5566 7043 8521

2 2016 3493 4971 6449 7926
3 2899 4376 5854 7332
4 3782 5259 6737
5 4665 6142
6 5548
7

Over Pressure Circulation Sub

The following table specifies the pressure required to activate the circulation sub by pressure alone without a
ball being dropped. The pressures quoted are significantly higher than those specified in the drop ball option.
Care must be taken to ensure that the specified pressure can be achieved.

Steel Shear Pins

0 1 2 3 4 5 6 7 8
0 4126 7751 11377 15002 18628 22253
Brass Shear Pins

1 2666 6292 9917 13543 17168 20794

2 4833 8458 12084 15709 19335
3 6999 10625 14250 17876
4 9166 12791 16417
5 11332 14958
6 13499
7

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