CHAPTER 10 ELECTRIC SYSTEM

10.1 FUNCTION.................................................................................................................... 1

10.2 POWER ON AND OFF .................................................................................................. 1

10.3 LIGHTING SYSTEM ...................................................................................................... 2

10.4 INSTRUMENT SYSTEM ............................................................................................... 2

10.5 CIRCUIT BREAKERS AND FUSES ................................................................................ 2

10.6 CONTROL BOX WORKING CONDITION ................................................................... 3

10.7 ELECTRIC COMPONENTS INTRODUCTION .............................................................. 5

10.7.1 CONTROL BOX ................................................................................................. 5

10.7.2 FLOWMETER .................................................................................................... 6

10.7.3 CIRCULATION PRESSURE SENSOR ................................................................ 8

10.7.4 TUBING DEPTH COUNTER ............................................................................. 9

10.7.5 WELLHEAD PRESSURE SENSOR ..................................................................... 9

10.7.6 TUBING HEAVY INDICATOR ........................................................................ 10

10.8 ELECTRIC SYSTEM PRINCIPLE SCHEMATICS ......................................................... 11

10.8.1 GENERAL SCHEMATIC .................................................................................. 11

10.8.2 ENGINE CONTROL SCHEMATIC .................................................................. 12

10.8.3 CONTROL SCHEMATIC ................................................................................. 13

10.8.4 LIGHT CONTROL SCHEMATIC ..................................................................... 14

10.8.5 LIGHT AND AIR CONDITIONER SCHEMATIC ............................................. 15

10.8.6 PLC SCHEMATIC ............................................................................................ 16

10.8.7 IO SCHEMATIC 1 ............................................................................................ 17

10.8.8 IO SCHEMATIC 2 ............................................................................................ 18

 CHAPTER 10 ELECTRIC SYSTEM

10.1 FUNCTION

a) Start the engine.

b) Handle coiled tubing signals.

c) Supply electric power to all the devices and instrument indicators to ensure they

can work during operation.

d) Supply power to all lights to ensure this unit can work in the night time.

e) The power supply of the unit is provided by two batteries of 195 Ah. The generator

equipped with the engine will charge the battery after the engine is started.

10.2 POWER ON AND OFF

a) Before starting the engine, please make sure that the pneumatic control system

and hydraulic system are normal and all switches on the instrument panel are off.

b) After the engine works normally, turn the computer switch on the panel upward,

then the HMI and PLC will work.

c) Before power off, turn off the switches of the computer and the lights first, then

turn off the power switch on the operation console and then the main power switch

on the battery box finally. The power supply of the engine is only controlled by the

main switch.

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10.3 LIGHTING SYSTEM

There are four light switches on the local control box and they are used to control five

lights and instrument panel lights.

Switch Lighting Object

Left front of the control cabin

Front Light Switch
Right front of the control cabin

Rear Light Switch Engine lights

Wellhead light 1
Wellhead Light Switch
Wellhead light 2

Panel light
Panel Light Switch
Voltmeter, Fuel Level Gauge

10.4 INSTRUMENT SYSTEM

The instrument panel includes the voltmeter, engine display module, fuel level gauge

and hydraulic oil temperature gauge. The voltmeter displays the system voltage. The

EDM module displays engine parameters such as rotary speed, oil pressure, coolant

temperature and load. The four parameters are default to display upon delivery. Users

can choose to display other parameters according to their own requirements.

10.5 CIRCUIT BREAKERS AND FUSES

There are 13 circuit breakers inside the fuse box and the control box. Every fuse is

corresponding to one set of electronic devices. If power is not available, please check

the circuit and replace the fuse according table below:

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Fuse Specification:

Code Model Specification Device

3QF1 Vehicle Breaker 20A Engine ECM Power

3QF2 Vehicle Breaker 6A Engine Control Power

Supply power to hydraulic Oil
4QF1 Vehicle Breaker 6A temperature gauge and fuel level
meter
4QF2 Vehicle Breaker 6A Data Acquisition Port Power

5QF1 Vehicle Breaker 6A Outdoor Light

5QF2 Vehicle Breaker 6A Control Cabin Lights, Panel Light

5QF3 Vehicle Breaker 6A Wiper Motor, Heating Pad

Engine, Wellhead Light, Generator
6QF1 Vehicle Breaker 6A
Solenoid Valve
6QF2 Miniature Breaker 20A Air Conditioner

6QF3 Miniature Breaker 10A Wellhead Light Solenoid Valve

7QF1 Vehicle Breaker 6A PLC, HMI

7QF2 Vehicle Breaker 15A Tablet PC

10.6 CONTROL BOX WORKING CONDITION

a) Altitude shall not be over 2,000 m.

b) Ambient temperature shall not be over 50°C and the average temperature within 24

hours no more than +35°C. The lowest ambient temperature is -30 °C.

c) The relative air humidity under +40°C is no higher than 50%. The relative humidity

can be higher under lower temperature. The average relative humidity for the

highest month is 90%, and the lowest average temperature of this month is +20°C.

Condensation dew on the surface of the equipment should be considered due to

temperature change.

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d) The degree of inclination is no more than 5°.

e) Not much vibration or impulse in the work site.

a) There is no explosive medium in the installation site, and no such

medium in which there are some element that can erode metal or

destroy the insulation and conductive dust.

NOTE

a) Please switch off the main power supply after job; otherwise the battery cannot be

used any more due to serious power loss.

b) Tighten the screws connecting every electric device on the circuit before restarting

the unit after long time no use or before the first start-up.

c) Please check whether the sound of the main components and parameters

displayed on the instruments are normal after start-up.

d) Please keep the control box tidy and clean. Do not put unrelated materials in the

control box, especially conductive materials. Do not put messy objectives on the

control box either.

e) Make sure no rain or snow or water will leak into the electric control box during

usage and storage.

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10.7 ELECTRIC COMPONENTS INTRODUCTION

10.7.1 CONTROL BOX

5 6

7
3

2
8

1 9

Item Name Description

Used to connect the external wiring. The yellow and
1 Terminal
green ones are grounding terminals.
Circuit Breaker
2 Each circuit breaker or fuse protects a certain loop.
and Fuse
3 Heating Pad Used to warm the electric control box in winter.

4 PLC Heart of the control system.

5 Transmitter Used to shift among different kinds of signals.

6 Switchboard Used for communication.

7 Relay Used to convert and control the control signals.

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 Temperature Used to monitor the temperature inside the control box
8
Controller and control the hearing and cooling of the control box.
9 Isolated Gate Used to supply power to the injector encoder.

10.7.2 FLOWMETER

Flow meter is turbine flowmeter with high accuracy, high measure range and without

zero deflection.

Measure Principle: when the measured fluid running through the turbo flow meter

sensor, the impeller rotates and its speed is in positive proportion to the average

pipeline flow rate. Meanwhile, magnetic force line which is produced by impeller

changes the coil magnetic flux. And according to the electromagnetic induction

principle, the electric pulse signal is inducted in the coil. Frequency of this signal is in

positive proportion to the flow rate of the measured fluid. The pulses are calculated by

computer for flow rate measurement.

The flow factor will be bound on the flowmeter. It’s a special data uniquely calibrated

to the flow meter by manufacturer.

Generally flow factor value is around 55 which means every 55 pulses stand for 1 gal of

fluid.
A + [ IN ]
B - [ COMMON ]

C [ OUT ]

PIN OUT
A +Voltage
B -Ground
C Signal Output Square Wave

Flowmeter Schematic Flowmeter Plug Stitch Definition

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 Turbine Structure

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10.7.3 CIRCULATION PRESSURE SENSOR

The circulation pressure sensor is a product of VIATRAN.

Two-wire system instrument

Pressure Range: 0～15,000 psi

Voltage: 9 to 30 VDC

Installation Instruction 1: Pressure Sensor Installation Position

PIN A +Power/Signal
PIN B -Power/Signal
PIN C No Connection
PIN D No Connection
PIN E +Calibration
PIN F -Calibration

Pressure Sensor Schematic Pressure Sensor Wiring Way

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10.7.4 TUBING DEPTH COUNTER

Electronic encoder is installed on the levelwind head of the tubing reel. It is used to

measure the length of the coiled tubing during the levelwind operation.

Encode Cable # 108594-

Functio 6 Pin Single Ended
Pin Wire Color
Sig. A E BRN
Sig. B D ORN
Sig. Z C YEL
Power +V B RED
Com A BLK
Case — —
N/C F —

Encoder Wiring Way Encoder Illustration

10.7.5 WELLHEAD PRESSURE SENSOR

The wellhead pressure sensor is a product of Danfoss.

Wellhead Pressure Sensor Range: 0-250 BAR

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10.7.6 TUBING HEAVY INDICATOR

Tubing Heavy Sensor Range: -40,000—40,000 BLS

Tubing Heavy Sensor Schematic:

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10.8 ELECTRIC SYSTEM PRINCIPLE SCHEMATICS

10.8.1 GENERAL SCHEMATIC

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10.8.2 ENGINE CONTROL SCHEMATIC

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10.8.3 CONTROL SCHEMATIC

Chapter 10 Electric System 13

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10.8.4 LIGHT CONTROL SCHEMATIC

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10.8.5 LIGHT AND AIR CONDITIONER SCHEMATIC

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10.8.6 PLC SCHEMATIC

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10.8.7 IO SCHEMATIC 1

Chapter 10 Electric System 17

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10.8.8 IO SCHEMATIC 2

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