DESCRIPTION (SIMILAR TO 1904)
skid mounted ctu consisting of control cabin, power pack, tubing reel, hr 680 injector, power hose reel, tot bop and stripper, and injector/bop transport skid.
1.0 control cabin model 301 (zone ll certified) – skid dimensions; approximately 168” l x 94” w x 105” t - 13,000 lbs skid mounted with crash frame. adjustable two point lift, with sling. sling to have vendor product certificates.
1.1 telescoping control cabin to be 90" long by 80" wide constructed of composite materials. 1.2 two (2) side access doors (one each side), sliding type window, rain gutter and stainless steel hardware. tinted front window with removable, hinged, metal guard, rain gutter and windshield wiper. large sliding type windows on side walls. flooring to be anti-slip.
1.2.1 two (2) exterior floodlights to be installed on upper front of cabin and two (2) interior fluorescent lights installed on ceiling of cabin and two (2) exterior floor lights mounted above porch. all lighting and wiring to be explosion proof-wired to zone ll standards per nfpa 70 (nec) class 1 div 2. electrical to be 60 hz.
1.2.2 captain's chair with armrest provided for operator comfort, one two (2)padded jump seats 20" wide, against left side wall. 1.2.3 one (1) one pen chart recorder provided. 1.2.4 cabin inside height is 76". 1.2.5 explosion proof-zone ll; roof mounted, 220vac air conditioner. 1.2.6 150’ powercord with zone ll plug and mating receptacle.
1.3 integral hose storage area located in front of cabin includes a removable bulkhead panel for hose connection. all hoses equipped with aeroquip quick disconnects on one (1) end, tagged with stainless steel washers, and stored on wrapping posts. hose lengths are as follows: 1.3.1 bop hoses are 125'. last 50’ to be fireproof hose. 1.3.2 injector hoses are 125'. skid mounted offshore coiled tubing unit order no. bs 11131rev-b specification no.: 201 - 10321 rev. date: 3-2-15 page 2 of 11 bs 11131rev-b (shah petroleum)
1.3.3 tubing reel hoses are 50'. 1.3.4 power unit and phr hoses are 30'. 1.4 "l" shape design control console with shelf. control console contains the following: 1.4.1 6 bank bop control valve with individual spring loaded locking handles. one of the six banks will operate the shear seal bop. bop to have emergency backup circuit supplied from an auxilieary air-over-pump. 1.4.2 bop pressure gauge. 1.4.3 air regulator valve, snaptite valve, and gauges to operate two dual acting stripper circuits. hydraulic supply for stripper is air-over-pump with manual override.
1.4.4 hydraulic weight indicator for hr-680 injector, 0-80,000 lbs. pipe heavy and 0-40,000 lbs. (pipe light) with dual english / metric scales mounted center of panel. 1.4.5 pressure regulator valve with isolation and gauges for three (3) injection traction circuits. 1.4.6 control valve for injector speed and direction, with 0-1000 psi gauge. 1.4.7 valve for injector manual brake control. 1.4.8 valve for injector motor control. 1.4.9 valves for injector chain and reel tubing oiler. 1.4.10 hydraulic pressure gauge for injector pull and push. 1.4.11 hydraulic valve, 3-bank for reel control. i.e. reel pay-off or take-up, levelwind raise and lower and levelwind override.
1.4.12 relief valve for reel tension control. 1.4.13 pressure gauge for reel tension. 1.4.14 valve for reel brake with gauge. 1.4.15 two (2) 6", 4:1 15,000 psi pressure gauges for wellhead pressure and circulating pressure to be mounted to right of weight indicator.
1.4.16 electric control for engine speed, kill and emergency kill. skid mounted offshore coiled tubing unit order no. bs 11131rev-b specification no.: 201 - 10321 rev. date: 3-2-15 page 3 of 11 bs 11131rev-b (shah petroleum)
1.4.17 pressure control with gauge for injector chain tension control. 1.4.18 is tachometer. 1.4.19 orion lv data acquisition unit t-ex (zone ll certified) 1.4.19.1 orionnet software-new license used with ctes das 1.4.19.2 computer, class 1 dive 2, wolverine 1.4.19.3 analog transducers (pipe heavy / pipe light) 1.4.19.4 analog transducers (circulating pressure / wellhead pressure) 1.4.19.5 proximety swithches (fluid rates/volumes, n2 rates/volumes) 1.4.19.6 encoder – h25 is 1.4.19.7 cerberus modeling and fatigue tracking software
1.4.19.8 cables, dust caps/plugs, bulkheads/connectors, cable reel necessary for installation and function.
2.0 power unit – high pressure open loop design (zone ll certified)
dims-102” wide x 112” long x 98” high 17,000 lbs. 2.1 skid mounted with crash frame, forklift tubes and 4-point lift with slings. slings to have vendor product certificates.
2.2 cat c-9 diesel engine, 340 hp @ 2200 rpm, with a pyroban, certified for atex, category 3g, lla, t3, iec60079 as applicable for zone ll service. engine to have spark arresting muffler. radiator sized for 120° f ambient. engine has system shutdowns for over temperature, overspeed, loss of oil pressure, loss of coolant, and high exhaust temperature as required for zone ll operation. engine will also have spark arrestor exhaust, sealed crankcase, crankcase breather flame traps, remote shutoff device, fuel shutdown valve, and anti-static fan drive belts and blades. engine is for export with no epa regulations 2.3 air starter system. 2.4 air compressor is 12 cfm. 2.5 controls for engine speed, kill and emergency kill (air to run). 2.6 piston type high pressure open loop pump for injector drive. skid mounted offshore coiled tubing unit order no. bs 11131rev-b specification no.: 201 - 10321 rev. date: 3-2-15 page 4 of 11 bs 11131rev-b (shah petroleum)
2.7 vane type double pump for reel, bop, and auxiliary functions. 2.8 pressure compensated 4-way vale for injector control. 2.9 selector vale for switching hydraulic power to auxiliary functions. 2.10 heat exchanger, sized for 120° f ambient. 2.11 four (4) 10 – gallon bladder type bop accumulators for bop. 2.12 fuel tank capacity 100 gallons, with diverter valve for external fuel supply. 2.13 hydraulic oil reservoir capacity 240 gallons. 2.14 air reservoir capacity 30 gallons.2.15 ladder integrated into protective frame.
3.0 model 3020 tubing reel: direct drive –177” l x 98” w x 151” h –capacity of 20,000’ of 1.50” tubing - gross lift capacity is 85,000 lbs.
3.1 skid: full-length drip pan; drain tubes in each corner; reel pivot provisions; 6” x 14” forklift pockets at 84” centers; “d-rings” on each corner for skid tie downs. 3.2 reel: double recessed drum design with continuous concave core to shaft structure; 84” diameter core x70” between flanges x 148” diameter outer flanges; two lift lugs at shaft; flanges have expanded metal panels; guide arch for tubing entering the core. tubing not included.
3.3 drive: planetary direct drive with integral brake capable of spooling 2” tubing in at 2,500 psi hydraulic pressure or less; crossover relief valve protection for motor.
3.4 levelwind: mechanicaly driven diamond leadscrew with adjustable clutch system; remotely operated hydraulic motor to override in either direction; dual-bar crosstrack design; hydraulicly raised to working position; couterbalance valve to maintain elevation.
3.5 relief valves: motor case drain and brake protected by pop-off relief valves. 3.6 chain guards: all chains have removable protection guards; levelwind chain guard has hinged cover for quick change out of sprockets and clutch adjustment. skid mounted offshore coiled tubing unit order no. bs 11131rev-b specification no.: 201 - 10321 rev. date: 3-2-15 page 5 of 11 bs 11131rev-b (shah petroleum)
3.7 pipe plugs: expandable neoprene plugs fully recessed in skid secured with 1/8” plastic coated lanyards. 3.8 name plate: stainless steel identification plate attached. 3.9 non-lift frame: removable protection frame; two ladders at opposite sides provide access to top of frame; pins attach frame to skid.
3.10 counter kit: hydra rig model rc-203 tubing, variable size, counter with vertical slide mount to compensate for tubing pay-off angle; dressed for 1.50" tubing, measuring in feet.
3.11 internal plumbing fmc 2x2 valves standard: non-h2s fmc integral 1502 type fittings rated at 10,000 psi; tee for ball launching or wireline adaptation; 2x2 shutoff valve between swivel and drum core. plumbing to have vendor product certificates.
3.12 external plumbing fmc 2x2 valves standard: non-h2s fmc integral 1502 fittings rated at 10,000 psi; dual inlet connections and 2x2 shutoff valves between swivel and inlets; integral mounted 4:1 debooster to monitor circulating pressure. plumbing to have vendor product certificates. 3.13 bulkhead connections: male aeroquip quick disconnect fittings; plastic caps.
3.14 lubrication system: tubing oiler mounted from counter; 30-gallon lubrication reservior; fill cap; level gauge; 140 psi relief valve; air actuated amot valve; air regulator; air pressure drain valve; lube drain valve. 3.15 hoses: hydraulic and grease lines are standard climate rated.
3.16 two point lift system: spreader bar arrangement for lifting entire loaded reel assembly or loaded drum only; solid link design; spreader bar stores against rear frame members when not in use. sling for reel assembly with vendor product certificates.3.17 data acquisition: mount for encoder installed.
3.18 tie-downs: reel drum locked into transport position by a chain and binder system on one reel flange.3.19 circulating swivel: hydra rig 10,000 psi 1-1/2” bore swivel; proof- tested to 15,000 psi; suitable for non-h2s service; flange mounted with compression face seal; protected by removable steel plate; components exposed to circulating fluids are replaceable. swivel to have hydra rig data package. skid mounted offshore coiled tubing unit order no. bs 11131rev-b specification no.: 201 - 10321 rev. date: 3-2-15 page 6 of 11 bs 11131rev-b (shah petroleum)
4.0 injector head hydra rig model hr-680
the hydra rig model hr-680 is designed for handling coiled tubing sizes from 1-1/4" od through 3-1/2" od. it is designed for operation with both open loop and closed loop hydraulic systems. pull capacities are as follows: 80,000 lbs. continuous pull capacity @ 4600 psi maximum speed 200 feet per minute snubbing capacity is 40,000 lbs. all structures and ancillary systems are designed to the 80,000 lb. tubing load limit, plus gross weight of injector (12,500 lbs.)4.1 the injector drive consists of dual planetary gear transmissions with deep reduction ratios. both drive assemblies have a single input, brake, and ouput sprocket.
4.2 the drive sprockets are one piece for precise alignment and strength.4.3 the injector is powered by dual high speed / high-pressure swash plate variable displacement piston motors.
4.4 modular brakes are mounted between the motors and gearboxes and are spring applied / pressure released. the brake control system is automatic / manual set.
4.5 the hydraulic drive motors are directly attached to counterbalance safety valves to prevent loss of control if power failure occurs.
4.6 both hydraulic lines supplying flow to the drive motors are protected with high pressure in-line filters mounted between the 1-1/2 inch quick-disconnect and counterbalance valves. the filters incorporate a visual condition indicator.
4.7 injector supplied with the patented “quick connect” chain assembly capable of running grippers for 1-1/4", 1-1/2", 1-3/4", 2", 2-3/8", 2-5/8”, 2-7/8” and 3-1/2” tubing sizes (to be specified at time of order). grippers are interchangeable with the hr-580. skid mounted offshore coiled tubing unit order no. bs 11131rev-b specification no.: 201 - 10321 rev. date: 3-2-15 page 7 of 11bs 11131rev-b (shah petroleum)
4.8 injector incorporates 200 pitch heavy duty roller chain links with precision cast “quick connect” carriers. the tubing grippers are a grooved and hardened, single piece, half round configuration, elastomerically balanced for optimum tubing grip. each of the carriers is supported by dual, sealed for life, heavy duty bearings. chains are interchangeable with the hr-580.
4.9 tubing traction system incorporates three (3) independent sets of two (2) rod type hydraulic cylinders. tubing traction is applied to the chain system through a pair of single piece reversible, thru hardened and ground steel skates. the skate system is designed for self-centering for uniform gripper and tubing loading. the traction system is remote controlled from the operator's console.
4.10 chain loop tension is provided by down tensioning with hydraulic cylinders. the system is remote controlled from operator's cabin.
4.11 injector chain lube system is a pressure spray system with the tank and pump mounted on the injector. 4.12 adjustable position tubing guide arch, with flared fold under tail and contoured steel rollers. see options 4.13 load cell to provide direct pipe heavy / pipe light weight indication. see options
4.14 a pin on mount for stripper is provided on the injector base. the customer specifies the stripper mounting configuration. stripper mount is interchangeable with the hr-560 and the hr-580.
4.15 complete injector assembly mounted on steel base. coupling panel installed at bottom front of injector. 4.16 outer lifting/crash frame has 4-point sling attachment points and is rated for 95,000 lbs operational lifting capacity. the standard 29,000 lb. shipping 4-leg sling assembly is provided. this sling assembly is for lifting the injector during shipment and wellsite installation only and is not capable of full injector load capacity.
4.17 one (1) set of steel short fixed legs for supporting the injector with stripper mounted is provided. 4.18 a stainless steel injector load chart for cabin included. skid mounted offshore coiled tubing unit order no. bs 11131rev-b specification no.: 201 - 10321 rev. date: 3-2-15 page 8 of 11 bs 11131rev-b (shah petroleum)
4.19 a selection from each of the following standard options is required to complete this specification: 4.19.1 tubing size: 1-1/4"1-1/2" 1-3/4" 2"2-3/8" 2-5/8”2-7/8”3-1/2”
4.19.2 stripper adapter type: 2.50 ds34 10k 2.50 sd 10k 3.06 sd 10k -or- 15k 3.06 over/under 10k -or- 15k 4.06 sd 10k -or- 15k 4.06 over/under 10k -or- 15k swiveling 15k mount (additional cost)
other
4.19.3 quick disconnect: aeroquip snaptite other 4.19.4 motor flow setting: 90 gpm 120 gpm 4.19.5 cabin label: imperial (us)metric 4.20 the following options are available at an additional charge, if not standard. 4.20.1 injector brakes: automatic / manual set automatic 4.20.2 injector long legs: not applicable aluminum telescoping steel telescoping 4.20.3 tubing guide arch: 60” radius w/flare 72” radius w/flare (standard) 100” radius w/flare 100” radius hydraulic folding (see 1.23.4 for options) 120” radius w/flare skid mounted offshore coiled tubing unit order no. bs 11131rev-b specification no.: 201 - 10321 rev. date: 3-2-15 page 9 of 11 bs 11131rev-b (shah petroleum)
4.20.4 hydraulic tubing hyd hold down boxes (0-4)
guide options
(if required) std manual fold tubing guide
hyd folding mast style design
hyd folding a-frame design
(recommended)
trailer mounted controls
injector mounted controls
(recommended)
control of each hold down box
one control for all hold down boxes
4.20.5 fall protection device: not applicable
yes, complete
yes, without fall arrestor
4.20.6 ic-200 counter: not applicable
yes
feet -or- metric
electronic encoder mount
4.20.7 shaft mounted chain not applicable
encoder mount: yes
4.20.8 load cells: dual hydraulic (pipe heavy / light std)
single hydraulic (pipe heavy)
electronic (pancake type)
electronic (load pin type)
dual electronic (load pin type)
remove snubbing loadcell hoop
4.20.9 wellhead pressure: not applicable
debooster on injector yes
4.20.10 walkways: (fold-down) not applicable
yes
4.20.11 certifications: not applicable
atex
zone i
ce
north sea
dnv skid mounted offshore coiled tubing unit order no. bs 11131rev-b specification no.: 201 - 10321 rev. date: 3-2-15 page 10 of 11
bs 11131rev-b (shah petroleum)
4.20.12 slings: not applicable
29,000# handling (3/4”)
50,900# (1”)
62,300# (1 1/8”)
77,900# (1 1/4”)
93,500# full rating (1-3/8”)
4.20.13 lift / pull test: not applicable
yes
4.20.14 other items:
5.0 texas oil tools pressure control equipment
5.1 m60tot-eh44l513x; texas oil tools solid block blowout preventer: 4.06” quad, 10m with 4:1 hydraulic debooster. pressure test sub for bop stand and test/lift bail to test bop’s on stand.
5.2 dsa4-0445x texas oil tools, 4.06” 10m side door stripper.
6.0 injector power hose reel/hoses
6.1 skid mounted, hydraulically powered hose reel to accommodate two (2) 1-1/2" x 125' long injector power hoses with hydraulic inc. connections.
6.2 one (1) 25’ jumper hose bundle for connection of power hose reel to power unit. hose bundle to store in transport skid.
7.0 injector head and bop transport skid
7.1 the injector transport skid has drip pans incorporated into the skid base with drain plugs.
7.2 the skid has a crash-frame with a 4-point lift with slings. slings to have vendor product certificates.
7.3 the transport skid is for transporting the injector, gooseneck, short and long legs, bop and stripper. the gooseneck pivots vertically for placing in skid. skid mounted offshore coiled tubing unit order no. bs 11131rev-b specification no.: 201 - 10321 rev. date: 3-2-15 page 11 of 11
bs 11131rev-b (shah petroleum)
7.4 a stand is provided for a 4.06” 10m quad that is capable of being used to pressure test the bop's to 10,000 psi wp. that has a
3/8" npt port near the base plate and has a needle valve. the stand will be of adequate size for the bop's to be stable on it when set down on uneven ground.
7.5 skid designed to transport injector, bop, gooseneck, legs, and stripper.
8.0 general specifications
8.1 complete unit sandblasted, primed and painted to hydra rig specification to customer specified color. the entire unit will be painted gray ral7040 (jones blair ahw 6010 / hr #rx00548).
8.2 complete unit assembled and tested, with the customer's witnessing acceptance, at hydra rig's fort worth, texas, usa facility.
8.3 three (3) owner's manuals and cd's will be supplied with each unit. coo and coc to be issued for unit.