OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD

TECHNICAL MANUAL

OIL

S ystem
Coiled Tubing Equipment Coiled Tubing Equipment

SERIAL NUMBER: OS25K0001 Maintenance Manual for the OS 25K INJECTOR HEAD Address: 9763-62 Avenue, Edmonton, Alberta Canada Office Ph: (780) 483-6415 Fax Ph: (780) 488-3988

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD TABLE OF CONTENTS

TECHNICAL MANUAL

SECTION 1: SAFETY SUMMARY SECTION 2: TROUBLESHOOTING SECTION 3: OVERVIEW SECTION 4: 25K INJECTOR HEAD DRAWINGS 25K INJECTOR SCHEMATIC INJECTOR ASSEMBLY

1-7 1-3 1-12 1-2

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD RECORD OF REVISIONS PROPERTY OF: White Fox Well Services Ltd COMPANY: White Fox Well Services Ltd ADDRESS: Brier Park Way CITY: Medicine Hat PROVINCE: Alberta REVISION DATA

TECHNICAL MANUAL

POSTAL CODE:

CHECK EACH REVISION RECEIVED, AND INSERT THE REVISED AND SUPPLEMTARY PAGES IN YOUR MANUAL DATE OF ORIGINAL PUBLICATION: JUNE 2001-06-26 REVISION 1 2 3 4 5 6 7 DATE ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ ___________________

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD General Information

TECHNICAL MANUAL

Recommended Lubricants and Lubrication points Hydraulic Oil: 32W _______________________ _______________________ _______________________ Gear Lube: Grease: 80/90W _______________________ (Planetary Drives) Lithium Complex NLGI#2 (See illustrations in Manual for exact location) _______________________

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD OILSYSTEMS 25K INJECTOR HEAD

TECHNICAL MANUAL

MANUAL This manual contains information and instructions for the installation, operation, troubleshooting, and preventive maintenance of the Oilsystems Ltd. OS 25K Injector Head. This manual is not intended as a textbook on mechanics, electronics, or hydraulics. Sufficient descriptive material and illustrations are included to enable the operator to understand the basic construction and theory of operation of the OS 25K Injector Head. The intent of this manual is to guide the operators and maintenance personnel in the proper use of the OS 25K Injector Head. Personnel responsible for operation and maintenance should study these sections of the manual pertaining to their particular duties. Similarly, before beginning a repair or overhaul job, the service technician should read the manual carefully to become familiar with the components, parts, or subassemblies of the equipment. Of equal importance is the use of proper tools and procedures during equipment overhaul. Safety is very important. Read the entire information section located in this manual prior to performing any operations or maintenance. OILSYSTEMS DESIGN WORKS LTD Oilsystems Ltd. Established in 2000, base business is the design, manufacturing and repair of Coiled Tubing, Nitrogen, Fluid Pumping and associated equipment. Oilsystems has vast experience in oilfield equipment design, primarily in Coiled Tubing and Nitrogen Equipment. Our team of support personnel has hands on experience in the operation and maintenance of the equipment and is directly involved in the design of Oilsystems built equipment. This integrated team effort has lead to the concept of the OS 25K Injector, being the most dependable and easy to maintain injector on the market today. The OS 25K Injector was designed to be lightweight, durable, dependable, accessible and extremely easy to maintain. The Oilsystems incorporates an innovative and unique tubing traction system, a state of the art yet simple and reliable dual acting weight sensing system and a proven drive system. All of this and more are discussed in detail throughout this manual. The Oilsystems design and drafting team and service professionals are always here to answer any questions you have. Our team members are confident that the Oilsystems 25K will become your injector of choice.

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD SAFETY SUMMARY GENERAL

TECHNICAL MANUAL

Safety is everyones business and must be of primary concern. Knowing the guidelines covered in this manual will help to provide for the safety of the individual, for the safety of the group, and for the proper operation of the machine. SAFETY SYMBOLS Look for these symbols that point out items of importance to the safety of the individual and the group.

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WARNING safety noted MUST be followed. Failure to do so might result in SERIOUS INJURY or DEATH. CAUTIO N CAUTION safety notes are also very important. Failure to follow them could cause damage to the machine. NOTE is used to notify people of information that is IMPORTANT but NOT HAZARDRELATED.

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD SAFETY SUMMARY MAJOR HAZARD AREA UNDERNEATH MACHINE machine HAZARD

TECHNICAL MANUAL

SAFEGUARD

An injector head that falls or swings Keep all people from under while being hoisted or lifted can and around the crush body parts or bodies between during hoisting procedures.

or lifting itself and immovable objects causing irreparable injury or death. CHAIN place A moving chain can cut off fingers and hands. If clothing is caught by a moving chain, the chain can drag the entire arm or body into the chain cavity causing irreparable damage or death HYDRAULIC SYSTEM working in hydraulic oil that can cause injury the manual if punctured or if a fitting is associated with removed while pressurized. accumulators. SAFETY WARNINGS AND PRECAUTIONS These safety warnings and precautions contained here in, and on the following pages, must be observed during all phases of operation. the bleed valves the area, release

keep chain guards in

and keep hands clear of the chain cavity when the chain is in motion.

Hydraulic accumulators contain Do not strike or puncture high pressure nitrogen gas and accumulators. If

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Always use caution when working around moving or rotating equipment. Serious injury to personnel or damage to equipment could occur.

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD

TECHNICAL MANUAL

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Always use caution when working around electrical equipment. Serious injury to personnel or damage to equipment could occur.

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Clean or service only when equipment is shut down, isolated and tagged out of service.

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In case of accident, shut down the unit immediately.

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Always use lifting equipment, supports, and chains with a safe minimum capacity of one and a half times that of the object being lifted or supported. Irreparable injury, or death can result from falling or swinging equipment.

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The fluid and machines surfaces can be very hot. Always wear protective equipment to prevent burn injuries.

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD

TECHNICAL MANUAL

Exercise extreme caution when performing maintenance on the hydraulic system. Fluid escaping under pressure can cause serious personal injury. Face shield and protective clothing must be worn.

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Prior to hoisting the injector head, ensure that no loose bars, tools, parts and the like are lying in or on part of the unit, as they could cause serious injury to personnel and/or damage the unit.

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For your own protection, do not use substitute parts without the approval of Oilsystems.

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Before using this equipment, the operator should carefully read the instructions in this section and become familiar with the connections of the injector head

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OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD

TECHNICAL MANUAL

If the operator has ANY QUESTIONS about the safe use of the injector head, ASK THE SUPERVISOR-NEVER GUESS-ALWAYS CHECK.

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Leaking joints, fittings, and connections must be tightened only under pressure less conditions.

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Do not wear loose clothing, unbuttoned shirts, or neckties while working on moving equipment.

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When cleaning, use only approved solvent to prevent damage and/or deterioration to the equipment. CAUTIO N

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD

TECHNICAL MANUAL

CAUTIO N Follow the manufacturers recommendations to properly maintain equipment. CAUTIO N Use only specified fluid types. Do not mix fluids. CAUTIO N Always wear safety glasses, ear plugs (if necessary), foot wear, and hard hat while working with or around working equipment. CAUTIO N When using Teflon tape, always start the wrap about two threads away from the opening. This will prevent Teflon tape contamination of the hydraulic system. CAUTIO N Use only nitrogen gas to pre-charge the accumulator bottles. CAUTIO N Use CAUTION when tightening brass fittings. They are easily stripped when over-torqued.

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OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD

TECHNICAL MANUAL

FLUID SYSTEM RETURN AND CASE DRAIN RETURN connector MUST be connected before any system is operated; failure to do so could cause damage to the equipment (blown seals, etc.)

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Working with high-pressure gases can be dangerous.

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Do not perform service or maintenance on equipment if you are not qualified. If you are unsure if you are qualified then you are not qualified.

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD Troubleshooting

TECHNICAL MANUAL

When troubleshooting the OS 25K Injector, due to it being a hydraulically driven piece of equipment, the first step in troubleshooting operation should be to check all of the quick union connections. Ensure that all connections are properly made up and free of any contaminants. Quick connections typically have built in check valves; these should be visually inspected before each rig up, for bent or damaged check valve components. A double check of proper hook up should also be done to ensure that the lines are not crossed. The above are a good place to begin most troubleshooting operations. When hydraulic pressure or flow can not be obtained, it may be a good idea to isolate the injector from its power supply and perform a deadened pressure check to isolate and confirm that there is a problem with the injector. PROBLEM: EXCESSIVE NOISE WHEN INJECTOR IS OPERATING. Check #1 : make sure chain has adequate lubrication and chain oiler is supplying lubrication to the drive chains. Check #2 : inspect chain for possible broken links ( these are usually indicated by looking at the keeper pins to see if they have rotated out of their proper alignment; also a good indicator would be the extrusion of a link pin past the others) Check #3 : check to see if outside chain tension is sufficient for coiled tubing operation. Check #4 : check bearings in bearing carrier assembly for broken are damaged bearings (check for proper lubrication of all bearings in the carrier assembly) Check #5 : check accumulators for proper precharge. Check #6 : check for wear on bearing carrier and carrier alignment racks, and check condition of bushings in the bearing carriers. Check #7 : inspect all shafts, shaft bearings and sprockets for wear and proper alignment.

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD

TECHNICAL MANUAL

PROBLEM: INJECTOR LEAVING MARKS ON COILED TUBING. Check # 1: check drive chains for broken pins. Inspect drive chains for wrong size and damaged gripper blocks. Look for trash or debris on back and front of gripper blocks. Check #2 : check-bearing carriers for broken, worn out, or damaged bearings. A good place to begin this inspection is in the base skin of the injector. Check # 3 : inspect the drive shafts for wear and possible bending; also inspect outside tension shaft and bottom idler shaft for alignment, wear , and bending. The bearings for these shafts should also be looked at. Check # 4 : the tubing guide arch assembly should be inspected for proper alignment. Check # 5: be sure that proper outside chain tension is being run for the coiled tubing work being performed. PROBLEM: WEIGHT INDICATOR SYSTEM NOT READING ACCURATELY. Check # 1: check quick connections for proper fit and connection. Check that hoses are connected to proper port. Check # 2 : bleed air out of hoses. Check for prop 9/16 to gap on load cell. Check # 3 : Check preload on accumulator. Check # 4 : check that needle valve in system has been closed to prevent bleeding of the system.

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD

TECHNICAL MANUAL

PROBLEM: INJECTOR PRESSURE INCREASES BUT MOTORS DO NOT TURN. Check # 1: make sure slips in B.O.Ps are not set. Check # 2: check stripper to see if pack off pressure is too high (if tubing is in the hole.) Check # 3: Check main injector hoses for quick connection make up. Also inspect check valve in unions for damage and proper operation. Check # 4: Look at counter balance valve gauges to see that they are getting pressure. If they are not reading pressure, check valve to see that they are adjusted properly (Approximately 1 to 2 turns) Check # 5: Install gauge in pressure input line to pilot operated directional valve. There should be approximately 400-2,000 psi going to this valve. Install gauges in the lines from the directional valve to both brakes; this pressure should be the same or more than the front side of the valve. The brakes need a minimum pressure of 400 psi to release. The 3-way 2-position valve is set to shift at approximately 400 psi. Check # 6: visually inspect chains and sprockets for foreign debris that may be binding the drive mechanism.

PROBLEM: INJECTOR PRESSURE INCREASES BUT MOTORS DO NOT TURN. Check # 1: Make sure slips in B.O.Ps are not set. Check #2: Check stripper to see if pack off pressure is too high ( if tubing is in the hole) Check # 3: Check main injector hoses for quick connection make up. Also inspect check valve in unions for damage and proper operation. Check # 4: Look at counter balance valve gauges to see that they are getting pressure. If they are not reading pressure, check needle valve to see that they are adjusted properly (approximately 1 to 2 turns) Check # 5: Install gauge in pressure input line to pilot operated directional valve. There should be approximately 400 to 2,000 psi going to this valve. Install gauges in the lines from the directional valve to both brakes; this pressure should be the same or more than the front side of the valve. The brakes need a minimum pressure of 400 psi to release. The 3-way 2position valve is set to shift at approximately 400 psi.

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD OILSYSTEMS 25K INJECTOR HEAD OVERVIEW

TECHNICAL MANUAL

This section contains instructions for the care and recommended maintenance of the OS 25K injector head manufactured by OILSYSTEMS. MAINTENANCE BENEFITS

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If the operator has ANY QUESTIONS about the safe use or maintenance of the injector head, ASK THE SUPERVISOR-NEVER GUESS-ALWAYS CHECK. Your injector head is ensured of its best performance and reliability when a scheduled preventive maintenance program is followed. A small cost and effort expended for a preventive maintenance program yields improved performance and efficiency. NATURE OF PREVENTIVE MAINTENANCE Maintenance should be preventive in nature, whereby potential failures are detected and corrected before they cause the equipment to breakdown. The nature of preventive maintenance demands operator awareness of the injector heads operation. Awareness demands consciousness of abnormalities such as leaks, knocks, or smoke. Awareness demands knowing the injector heads equipment capabilities and perceiving the equipments needs, being aware can also be described as being watchful, or being alert. Regardless of the method or manner of detection, the potential failure should be promptly corrected, in order to prevent a shutdown or a breakdown.

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Always use caution when working around moving or rotating equipment. Serious injury to personnel or damage to equipment could occur.

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD OILSYSTEMS 25K INJECTOR HEAD CHAIN INSTALLATION

TECHNICAL MANUAL

Visual inspections of the chain can locate wear and damage to the drive chain or the gripper blocks. By identifying the wear and damage, it can prevent equipment failure. Removing a damaged chain can be accomplished by using the following procedure. PROCEDURE 1) When replacing the old chain with new chain. The old chain should be separated just above the outside chain-tensioning sprocket. The new chain is attached to the old chain above the outside chain-tensioning sprocket. 2) The injectors run in the in-hole direction and the new chain is pulled into the injector by the old chain. 3) Caution should be taken by running the injector very slowly, pulling the old chain out the bottom and guiding the new chain in the top. 4) The unit operator needs full vision of operation to stop the unit/shut the power off in case of a problem or if he sees unsafe conditions.

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In case of an accident, shut down the unit immediately.

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Do not wear loose clothing, unbuttoned shirts, or neckties while working on moving equipment. When a new chain is installed into an injector head without a chain already in it refer to the following procedure.

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD PROCEDURE

TECHNICAL MANUAL

1) Install the chain through the top of the drive box, first around the drive sprocket, then the lower sprocket and finally making the connection in the chain tension area. 2) Tighten and close any open hydraulic lines or valves. 3) Turn on power. 4) Check for leaks. If any leaks are found, repair as necessary. 5) Replace chain guards and any other items removed. 6) Mechanically center chain-tensioning cylinder with both sides equally extended. Then tighten double safety nuts.

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD GRIPPER BLOCK INSTALLATION & REMOVAL

TECHNICAL MANUAL

Gripper blocks are to be installed and removed while chain is off the injector for easy access. When removing or installing refer to the following procedure.

3 2 FIG 3-1

1) Gripper block 2) cotter pin 3) roller link 4) connecting link 1) Remove cotter pin from connecting link. 2) Remove connecting link. 3) Remove old gripper block and replace with a new one. 4) Repeat steps 1-3 to replace any other gripper blocks. 5) Replace all connecting links through roller links and insert new cotter pins.

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD LUBRICATION

TECHNICAL MANUAL

Lubrication is oiling or greasing. These are five areas, which are listed below, on the injector head that require lubrication. Those areas are zerk (grease) Fittings and drive gear box/brake. The grease recommended for use on this injector is lithium complex NLGI#2. The recommended oil is 90-weight gear lube oil. 1) 2) 3) 4) 5) 1) Drive box Lower body Traction system Outside chain tension Guide Arch

Drive Box There are two grease fittings located on the flanged bearings mounted to the drive box. Use only recommended grease. For location of these fittings see Fig 3-2 below. FIG 3-2 Picture of top of the injector

Grease fitting

Fig 3-2

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD 2) LOWER BODY

TECHNICAL MANUAL

The lower body has six grease fittings. Two fittings are located where the body hinged to the base. The other four are located on the flanged bearings for the bottom shafts. Use only recommended grease. For location of these fittings see Fig 3-3 below. Fig 3-3 Bottom of Injector

Grease Fitting

Fig 3-3

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD 3) TRACTION SYSTEM

TECHNICAL MANUAL

The traction system has a total of two individual sets (top and bottom). Each shaft has six grease fittings. The total of both sets contains twenty-four grease fittings. Use only recommended grease for these fittings see Fig 3-4 below. Fig 3-4 Traction System

Skate Slide Grease fitting

Grease fitting

Fig 3-4

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD 4) OUTSIDE CHAIN TENSION

TECHNICAL MANUAL

The outside chain tension has a total of four grease fittings. These fittings are located on the end of the take-up bearings. Use only recommended grease for these fittings. For location of these fittings see Fig 3-5 Fig 3-5 Outside Chain Tension

Grease fittings

Fig 3-5

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD 5) GUIDE ARCH

TECHNICAL MANUAL

The guide arch has twenty-six grease fittings. Each is located on the end of each roller shaft. Use only recommended grease for these fittings. For location of these fittings see Fig 36 below. Fig 3-6 Guide Arch Grease fittings Grease fittings

Adjustment bolt Fig 3-6 Note #1 Keep threaded adjustment bolt lubricated to prevent rusting and to allow free movement of the adjustment nut.

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD ADDING AND CHANGING OIL

TECHNICAL MANUAL

Filler Plug Drain Plug Fig 3-7

CAUTIO N

Use recommended EP-90 to fill planetary gearbox. Do not mix fluids. Adding Oil 1) Remove the planetary oil filler plug as shown in Fig 3-7. 2) Pour oil into the planetary through the filler hole until oil begins to leak out of the filler hole. 3) Replace the planetary oil filler plug.

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD Changing Oil 1) 2) 3) 4) 5) 6)

TECHNICAL MANUAL

Remove the planetary filler plug from as shown in Fig 3-7 Place a container under the planetary drain plug to catch oil. Remove the drain plug. When oil has finished draining, replace the drain plug. Dispose of the dirty oil in accordance with local regulations. Pour new oil into the planetary through the filler hole. Fill until oil begins to leak out of the oil level hole. 7) Replace the planetary oil filler plug.

VISUAL INSPECTION (VERY IMPORTANT) NOTE The following inspections should be done every time BEFORE putting the injector into service. Failure to do so could result in a catastrophic failure. 1) Inspect gripper blocks for excessive wear and replace damaged ones. 2) Inspect guide arch rollers for wear, breakage, or cracks. Replace as needed. 3) Inspect frame base and other welded structures for loose or broken fasteners, cracks, or rust. 4) Inspect skate roller bearings for lubrication, damage, worn or broken needles. Make sure bearings roll freely, if not, supply grease or replace if necessary. NOTE A monthly inspection should be performed on the skate assembly. This would consist of completely disassembling the Traction System and inspecting the carriers for wear. Check the tie-rods for cracks, cuts and damaged threads. Inspect skate cylinder for leaks. This inspection may be more or less frequent depending in the use of the injector.

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD

TECHNICAL MANUAL

5) Inspect the chain for excessive wear. If the chain is bottomed out on the cutout in the channel, then the chain as exceeded its allowable stretch length. The chain must be replaced immediately. 6) Check hydraulic hoses and pipes for leaks, cuts, or wear. Replace if necessary. Check for loose or damaged fittings. Tighten or reseal fittings. 7) Check drive gearbox for proper oil level. Fill if necessary. 8) Check all lubrication points listed previously in this section. Add if necessary.

OILSYSTEMS DESIGN WORKS LTD OS 25K INJECTOR HEAD

TECHNICAL MANUAL

SECTION 4 25K INJECTOR HEAD DRAWING

SECTION 1

SAFETY SUMMARY