CT INJECTOR HEAD

Training/Learning objectives

• Understand and Explain main components of injector head

• Understand and Explain all factors affecting on performance
of IHs
• Understand and Explain Injector head circuit
• Be able to perform basic Troubleshooting
Injector Head – Functions

• Main functions of the injector head or equipment

include:

– Injecting and Retrieving the CT string from the well

– Holding the CT string static
– Keeping IH chains in tension
– Guiding the CT to the reel with gooseneck/arch
– Chains lubrications
– Tension/compression measurement (CT weight indicator)
– Depth measurement (depth system sensor)
– Mounting place for primary pressure barrier (stripper)
 Main Components of Injector Head

• Injector chains
• Inside traction system
• Outside tension
• Drive motors and brakes
• Timing Gears (some IH w/o Timing Gears)
• Gooseneck (with or w/o pipe straightener)
• Inside and outside frames
• Load Cell/Limit bolts
• Lubrication tank
Injector Head - Manufacturers

• Hydra Rig
– Current OS major supplier - 91% of Injector head
– Most units in the field are manufactured by Hydra-Rig

• Stewart & Stevenson

– Simpler construction compare with a hydra-rig with same rating

• HPT
– Very few units in service today

• CT Logic
– Aluminum Injector head design
 HR Injector Head Series
*HR - 125 *HR - 240 *HR - 260 HR - 420 HR - 440 HR - 480 HR - 5100 HR - 5200
Hydraulic Motor H-25 Poclain H-25 Poclain H-30 Poclain MS082 Poclain MS-50 Poclain MS-50 Poclain Rexroth Rexroth
Series Motors Motors Motors Motors Motors Motors AA6VM250 AA6VM250
Large Hydraulic
381 381 599.6 608 1216
Motor Disp.(cu.in.) Variable to 250 Variable to 500
Disp. 114 cu. In.
Small Hydraulic Not
190.5 190.5 299.8 304 608
cc cc
Motor Disp.(cu.in.)
in Gearbox W/66:1 Gearbox W/88:1
Drive System Direct Direct Direct Direct Direct Direct
use Ratio Ratio
Maximum Rate
32,000 40,000 60,000 18,000 60,000 100,000 100,000 200,000
Pull (lbs)
Maximum Snub
10,000 15,000 15,000 5,000 20,000 40,000 60,000 60,000
Capacity
Tubing Size
1" - 1 3/4" 1' - 1 3/4" 1" - 2 3/8" 1" - 1 1/2" 1" - 2 3/8" 1 1/4" - 3 1/2" 1 1/4" - 3 1/2" 2" - 5 1/2"
Capacity
Approx. Weight
7,500 8,000 11,000 3,600 7,200 13,500 17,200 26,000
W/Gooseneck (lbs)
Length (in) 61 61 76 40 55 64 73 86

Width (in) 59 59 72 32 52 60 53 51

Height (in) 93 95 102 60 80 109 121 165

In je c to rH e a d – H R 4 4 0 G

Featured with:
 1 Rexroth Motor
 Timing Gears
 Chain bearings
require greasing
 Vertical Chain
Tensioning system
HR 480 Injector

Featured with:
• 4 Poclain Motor
• Heavy but strong and reliable
• Horizontal Tensioning system
• Chain bearings require
greasing
• Pipe strainer function
available
In je c to rH e a d – H R 5 6 0

Featured with:
 1 Rexroth Motor
 Timing Gears
 Chain bearings
greasing N/A
 Vertical Chain
Tensioning system
HR 480 Injector Head – 4 drive motors

?” Gooseneck Radius

Gooseneck flared end

4 Injector Drive Motor

Front injector chain tensioning sprocket Rear injection chain

tensioning sprocket
Inside chain tension system

Accumulator
Guide Arch ( Gooseneck )

 Larger the goose neck - less fatigue

 Always use gooseneck support struts
 Gooseneck alignment required ( see notes below or manual)
Nov Goosseneck rating
Private & Confidential 12
Gooseneck Alignment

 Alignment to be checked before each job

 Especially important to check when change CT size (OD), Wall
Thickness
 Pipe should go smooth, straight, and be gripped equally by each chain
 Read manual for details
Gooseneck Alignment

1. Apply 100 PSI to the chain tension circuit, set all three traction circuits to
the “Bleed” position
2. Rotate chains ten revolutions and inspect chains visually to ensure smooth
rotation with the proper tension
3. Apply 100 PSI to the traction circuit, insert the tubing into the chains, and
then drive the injector in-hole to pull the tubing through the
injector/stripper
4. Once the tubing is completely through the injector and stripper, increase
traction pressure to 500 PSI
5. Look down into the injector chains from the top of the injector, observing
the area where the tubing first contacts the chains.
6. Loosen the jam nut and adjust the gooseneck by turning the screw at the
top rear of the frame until the tubing is 1/8”-1/4” off center of the area near
the chain, toward the reel
HR580 Gooseneck alignment
Private & Confidential 15
C h a in S y s te mH– R 4 8 0

 Typical chain system includes:

 Drive sprocket/system (1)
 Inside tractioners (2)
 Outside tensioners (3)
 Lower idling sprocket (4)
Injector Chains Tensioning System
“S” Type Injector Chains

• All current IH chains are “S” type

• “S” Advantages
– Easier bearing changes/removal
– Slightly higher pull/psi of injector drive
pressure
– Compatible with smaller injector head
– Performance with one piece skate enhanced
C h a in C o m p o n e n ts – H R 2 4 0 /2 6 0 “ S ” -T y p e

• Gripper Blocks Can Be: Chain link

• Non-Coated pins
• Coated (Tungsten
carbide)

Gripper block
Roller bearing
Split pin

Chain link plate

HR 480 “S” Type Chain

“Clip &
Screws”
holders

Grease Nipples

 Example of Carrier Blocks with Inserts for different size of CT

pipes
HR580 Injector head chain
Private & Confidential 21
HR580 Injector head chain specifications
Private & Confidential 22
Injector Chain Vertical Misalignment

* Misalignment is Damaging CT
Pipe
• Check before each job
• Read manual for proper Gripper block offset
procedure
• Check Timing Gears for wear
• NOV specifies that this
misalignment should not be
higher that 1/4" when the
injector is new
Injector Chain Misalignment Symptoms

• Broken chain bearings on one chain and all

bearings in the other chain look good
• Chains do not run in the center of the skate
• Traction system closes more on one side than
it does on the other
• Excessive chain noise during operation
• Marking or damaging tubing
• Excessive wear on one side of stripper bushing
• Excessive motion of the top or bottom traction
set
Misalignment correction

Minor misalignment can be corrected prior to stabbing the

tubing into the injector head by
• slowly running the chains in the out-hole direction and
outside tension
• applied @ maximum of 150psi, and the inside tension system
drain open.
• At least 10 full rotation of the chains should be made, the
slack will be pulled out by the outside tensioners
 HR 5xx Series Chain Gripper Blocks

• Featured:
• Snap lock retainers
• One piece
• Grooved
• Hard Material
• Sealed Chain Bearings
Gripper Blocks - Coated Vs Non-Coated

Normal (no coating)

Coated Gripper Blocks:
• Better Grip - Less Traction Pressure
required
• Coating does not serve long time
• Currently replaced by Grooved Gripper
Blocks
Not-coated Gripper Blocks
• More Traction Pressure required
Coated with Tungsten
• Slippages more probable Carbide
• Currently replaced by Grooved Gripper
Blocks
Grippers block’s performance
50,000

45,000

INJECTOR PULL (LB) 40,000

35,000

30,000

25,000

20,000 Hydra Rig Coated

Hydra Rig Non-Coated
15,000

10,000 100 200 300 400 500 600 700 800

900
10,000 INSIDE CHAIN TENSIONER HYDRAULIC PRESSURE (psi)

5,000
 Effects of CT shape

Typical Variations in tubing OD Principle gripping area

New CT Oval CT Ballooned

Contacts Contacts on CT
evenly side of gripper Contact on
blocks back of Typical Gripper Block wear and
( most gripper gripping area
common) block
 Gripper Block Performance
Gripper block performance is affected by
• Wear /condition of gripper block
• Shape or distortion of CT ( oval)
• Coatings on CT (well fluid paraffin's, corrosion inhibitors, rust)
• Grease build up on blocks
• Dirt and rust build up on gripper blocks

Combinations of above have severe affect, leads to

• Increased traction pressure
• More oval CT
• More gripper block damage
• Potential runaway

* Clean, lightly oiled gripper blocks and CT provide the best

performance
 Grooved Gripper Blocks

Tech Alert
Injector heads affected - all 440 / 480 / 500 series
 Soft /smooth gripper blocks discontinued
 Replaced by hard/grooved blocks (same as 500 series
 Testing performed, 19,000ft wells, Pulling to 90,000 lbs, HS110CT
 Result - better grip, longer life.
 Note: Hard gripper blocks more potential damage for CT if IH /goose
neck maintenance/adjustment not correct
Depth Encoder Mounting Point

• From lower sprocket (more accurate)

• From Friction wheel with chain drive (less accurate)
• * During Rig-Up Friction Wheel to be secured to avoid damaging
Stripper mounting point

• Bolted (permanent)
• Quick latched
• 2-Lock pinned
 Frames and Load Cell
• Reads loads acting on injector
head
• Loads are combination of:
– Restrictions / Drags
– Buoyancy / WHP
– CT weight with fluids
• Inner and Outer frames:
– Internal - Pivoted frame (affect
on Load Cell)
– External – Stationary frame
(no affect on Load Cell
• Types of Load Cells:
– Dual acting electronic
strain gauge
– Single acting hydraulic
load cell
– Dual hydraulic load cell
• Limiting Bolts
– Limit inner frame upper
movement
– High WHP could cause
CT kinking
– Use Limiting Bolts when
mobilizing CTU
 Weight Indicator Sensor – Load Cell
Electronic Bi-directional strain gauge
• Connected to frame and injector
head
• Info plate – upside down
• Pivot point position determines
actual weight on Load Cell
• Limiting bolts for transport
• Grease periodically

Pivot point
Electronic Load Cell

Pivot Point
Load Cell

 Simply measure distances

 2:1 ratio IH 240/260
 4:1 ratio IH
420/440/480/560/580/5100
Injector Head Systems
Traction System (Skates)

• Maintain gripper block pressure against CT via 3 sets of

hydraulic rams
• “S” type and “R” type skates
• Hydraulics from priority circuit
• Adjustable 100 to 2000psi (up to 2,500 psi on closed loop
system)
• Manual back up (Haskel and Rucker pumps)
• Hydraulic accumulators/pulsation dampeners: 350/400psi.
• Emergency traction full priority pressure
• Recommended skate pressure
• Enough to cope with load with out slipping Use manufacturers
charts.
• Perform pull test curve
Traction Controls
39

• Top, Middle, Bottom cylinders

• May be locked hydraulically
• Emergency Supply from Priority
Traction System (Skates)

HR440G INJECTOR HEAD

TRACTION PRESSURE CHART (NORMAL) TRACTION PRESSURE CHART (SNUBBING)
HR580 Traction pressure Vs Tubing Load
Private & Confidential 41
Traction System Maintenance and Troubleshooting

• Check bearings each SM 1

• Grease bearing (except Series 5xx - full service life)
• Avoid excess of Traction pressure –
– Leads to Bearings damage
– Leads to additional Pipe Ovality
• Do not pressurize the traction cylinders w/o CT between the
gripper blocks
• Air should be periodically bled from the cylinders
– Air can enter the traction cylinder during connection of hoses
– Damaged bladder will lead to N2 contamination in hydraulic system
* If tubing is in the well – secure the tubing
Outside Tension System
• Maintain adequate tension in chain - Depends on WHP and CT
size
• Tensioning cylinders controlled from Control Cabin
• Hydraulically adjustable from priority system pressure
• Max. 450 psi by pressure reducing valve for 2xx, 4xx Series of
Injectors
• Max up to 2100(HR) psi on new units for 5xx Series of Injectors
• Use charts for snubbing loads
• Unnecessarily high hydraulic pressures damages chains, lower
shaft/sprocket efficiency and deteriorates skate’s force
transmission.
• Insufficient pressure may lead to tubing and/or drive chain
assembly damage
• Normal operation : XXX psi (depends on Injector Head type)
• Minimum pressure when no WHP/Snubbing Load
Injector Head Tension System Selector

Selector fitted to new control

cabs to allow running different
model injector heads
• 240, 440/G, 480
– 435psi max
• 500 series
– 2000-2500psi (max priority)
Tension System - Snubbing Load (HR 480)

Tension system 2 types

• Less psi for side-
tensioner
- HR260, HR480
• More psi for vertical
tensioner
- HR440B/G, HR5xx
Tension System - Snubbing Load (HR 480)

TENSION PRESSURE CHART (NORMAL (0 LBS) AND SNUBBING)

Problem: CT=2-3/8”, BHA=2-7/8”, WHP=7000 psi

Question: How many psi required on Outside Tension before opening the WH
Master ?
Tension System - Snubbing Load (HR 480)

TENSION PRESSURE CHART (NORMAL (0 LBS) AND SNUBBING)

370 psi

Problem: CT=2-3/8”, BHA=2-7/8”, WHP=7000 psi

Question: How many psi required on Outside Tension before opening the WH
Master ?
HR580 Snubbing chart
Private & Confidential 48
HR 240/260/440/480 Injector Head Motors

• Make: POCLAIN
• 10 piston radial piston motor
• 2 speed displacement motor
– High speed - Low torque
– Low speed - High torque
• Integral brakes
• Timing Gears
• Multiple motors
– 2 on 240/260/440
– 4 on 480
* No Timing Gears on “Rebound” IH and “Hydra Rig” 6xx series
 High Speed / Low Torque

 12 passages on distribution block :

- 3 under Hi-pressure, from which 1 isolated = 2 total operational
- 6 under Low-pressure (displacing oil to return line)
 10 passages on cylinder block :
- 2 are under Hi-pressure, 6 under Low-pressure, 2 isolated
 Low Speed / High Torque

 12 passages on distribution block :

- 6 under Hi-pressure, from which 2 isolated = 4 total operational
- 6 under Low-pressure (displacing oil to return line)
 10 passages on cylinder block :
- 4 are under Hi-pressure, 4 under Low-pressure, 2 isolated
 Poclain Motor - Inside View
Distribution block

Cylinder block
Cam ring
• Inlet pressure forces
pistons 1, 4, 6, 9, out
Piston
against the cam ring 5 4

causing the cylinder 6 3

block to rotate and 7 2

1
pistons 3,5, 8 and 10 to 8
9 10
detract. Roller
• Pistons 2 and 7 are in
neutral position. Case Drain
• As a cylinder block is Inlet pressure
Outlet pressure
connected to the output
shaft this results in
torque to move the load.
Hydraulic System with Poclain Motor
Injector Head Two Speeds – Poclain Motor

• Motor displacement changes depending on

number of pistons under pressure
• Low speed/High torque
• (120 ft/m - 40,000 lbf: 240IH)
• High speed/Low torque
• (240 ft/m - 20,000 lbf: 240IH)
• Hi/Lo speed actuator disables ports in
distribution block
• All pistons share the load over time
• Hydraulics in change-over spool
• 0 psi runs Lo-speed (normal operation)
• 435 psi ( 600psi old) psi from priority activates hi-speed
440G/5xx Series Injector Head Motor

• REXROTH
• Bent axis piston motor
• One only
• Integral brake
• Brake Isolation valve
• Case drain pop off 40psi
• Selector in Cab for Variable / 2 speed

* Main advantage – Speed and Torque can be adjusted smoothly on

the run
440G/500 Series Injector Head Motor

• REXROTH Variable Displacement Motor

• 435 psi – Piston’s Minimum Stroke/Displacement – Motor’s
Minimum Torque and Highest Speed
• 0 psi – Piston’s Maximum Stroke/Displacement – Motor’s Maximum
Torque (Maximum Pulling Force) and Lowest Speed
• Case Drain hose must be connected and unrestricted for
all types of motors
• Protected by pop-off

If pop off continual leak, check all connections and

unrestricted flow, after - get help
Bent Axis Piston Motor
Injector Head Pull/Drive Pressure Ratio

• HR440G:
• - Hi-speed on injector: 6.8lb pull per psi
• - Lo-speed on injector: 13.2lbs pull per psi
• Use as a guide ONLY
• Other Injector heads may have different ratios

Mode 240 IH 260 IH 440 IH 480 IH

(lbs/ psi) (lbs/ psi) (lbs/ psi) (lbs/ psi)

Lo-Gear 12.6 13.8 13.6 21.7

Hi-Gear 6.3 6.9 6.8 10.8

HR580 Injector Performance
Private & Confidential 59
 Injector Head Brakes
Automatic Brake:
• 175 psi Full Release from the IH circuit (refer to Manual of
specific IH)
• Max 300 psi compatible( via pressure reducing valve)
Emergency Brake:
• 300psi from Priority Circuit to “unlock” Auto-brake system
• Emergency Brake Off – Normal operations
• Emergency Brake On - Maintenance and Hydraulic Runaway
Brake isolates valve:
• Testing the Brake – SM and Troubleshooting
• Close lock out valve, RIH/POH 2000psi
• Apply emergency brake, RIH/POH 2000psi
• Check pressure gauge in brake line for trouble shooting

The valve will open when the Emergency Brake is in the Off position (by means of pressure
coming from the Priority circuit) in the control cab thus allowing 300psi from the IH circuit to
release the IH brake. The valve will close when the Emergency Brake is in the On position thus
preventing the 300psi to release the IH brake. The purpose of having a Emergency Injector Head
Brake is two-fold: to aid in the case of a Hydraulic Run Away and to server as a safety device while
doing maintenance on the IH
Hydraulic Motor Brakes

 “41” - Steel disks

 “42” - Bronze/Steel Disks
 “X” - Brake release inlet
Counterbalance Valves

Primary functions
– Hydraulic lock on return side of
motors
– Pilot 450psi from drive side to
open
– Pressure release above 4500 psi
Adjusted by Hydra Rig only
– Special testing procedures
required
Dampening Valves for CBV

Dampening Valves
– Function to smooth out opening and closing of counter balance
valves
– Needle flow control valve
– Field Adjusted if injector head shudders: 2.5-3.5 turns open
 IH Counterbalance Valve Function

Open Closed in this direction

The CBV is a normally closed valve
CBV 1

CBV 2

Open Closed in this direction

IH Counterbalance Valve Function - RIH Mode

Once the pilot signal to the CBV 2 is 450psi, it will open and the pressure will bleed allowing the
IH Motor to turn
Pressure fromInthe
theP16
mean time,
comes pressure
THROUGH thewill build
Check upon
Valve - CBV
CBV 1istowards
a normally closed
the IH Motorvalve
Inlet
This pressure also TEES TOWARDS THE CBV 2 – Delivering a PILOT SIGNAL

CBV 1

CBV 2
 IH Counterbalance Valve Function 66

The CBV will also open when 4,500psi build up on the back side of the CBV due to forces acting
on the IH Motor(s) – Protects lines and motor from over pressure

66 Injector
Head
440 G Hydraulics Schematic Tracing
 CBV1 w/CV 68
IH Motor

HP Filters w/CV PRV @ 300psi IH Brake

Piston

Shuttle Valve
CBV2 w/CV

Run in Hole Mode

—High Pressure Lines

—Return Lines
—Regulated Pressure Lines
 CBV1 w/CV 69
IH Motor

HP Filters w/CV PRV @ 300psi IH Brake

Piston

Shuttle Valve
CBV2 w/CV

Out of Hole Mode

—High Pressure Lines

—Return Lines
—Regulated Pressure Lines
HR580 Injector automatic brake
Private & Confidential 70

70