,DanaInfo Spwest+95k Operating and Maintenance PDF

V95HP Quick Rig-Up Unit
Operating and Maintenance

Quick Reference Manual
Part No. 101392331

All information contained in this publication is confidential and proprietary property of
Halliburton Energy Services, Inc. Any reproduction or use of these instructions, drawings,
or photographs without the express written permission of an officer of Halliburton is for-
bidden.
2007 Halliburton
All Rights Reserved. Printed in the United States of America.
Part No. 101392331
Printing History:
First Printing (January, 2006)
Second Printing (April, 2007)
Section 1Description and Introduction
General Description ................................................................................. 1-1
Major Components .................................................................................. 1-1
Features ................................................................................................... 1-2
Safety Features ................................................................................. 1-2
General Features .............................................................................. 1-2
Specifications/Ratings ............................................................................. 1-3
Safety Guidelines ..................................................................................... 1-4
General .............................................................................................. 1-4
Personal Protective Equipment (PPE) .............................................. 1-4
Manuals and Other Resources ................................................................ 1-5
V95HP QRU Component Manuals .................................................... 1-5
Additional Resources Available on HalWorld .................................... 1-6
Section 2Operating Procedures

Transporting the Unit to the Jobsite ......................................................... 2-1
Job Setup ................................................................................................. 2-1
Pressure-Testing the BOP and Stripper .................................................. 2-6
Pressure-Testing Guidelines ............................................................. 2-6
Pressure-Testing Procedure ............................................................. 2-6
Pre-Treatment Inspection .................................................................. 2-7
Startup ............................................................................................... 2-7
Normal Operation for Tripping In ....................................................... 2-7
Normal Operation for Tripping Out .................................................... 2-8
Normal Shutdown .............................................................................. 2-8
Emergency Shutdown ....................................................................... 2-8
Daily Report ............................................................................................. 2-9
Post-Job Reports ..................................................................................... 2-9
Pre-Transport/Post-Transport CT Equipment Checklist .......................... 2-11
Power Pack Check ............................................................................ 2-11
House Check ..................................................................................... 2-11
Reel Check ........................................................................................ 2-12
Injector Check ................................................................................... 2-12
Pre-Job Inspection ................................................................................... 2-13
Pre-Job Inspection Checklist ............................................................. 2-13
i
Section 3Maintenance and Spare Parts
Introduction .............................................................................................. 3-1
V95HP QRU Pump and Motor Minimums/Maximums ............................. 3-1
Pump Flows ....................................................................................... 3-1
Pump and Motor Case Drains ........................................................... 3-1
Injector Spare Parts (Standard Service) .................................................. 3-2
Hydraulic Parts .................................................................................. 3-2
Valves and Bodies ............................................................................. 3-2
Valve Cartridges ................................................................................ 3-2
Inner Frame Parts and Assemblies ................................................... 3-3
Linear Bearing Chain Parts and Assemblies ..................................... 3-3
Gripper Chain Parts ........................................................................... 3-3
Chain Lube Parts ............................................................................... 3-4
Injector Spare Parts (Severe/Remote Service) ........................................ 3-5
Hydraulic Parts .................................................................................. 3-5
Valves and Bodies Parts ................................................................... 3-5
Hydraulic Valve Cartridges ................................................................ 3-6
Inner Frame Parts and Assemblies ................................................... 3-6
Linear Beams .................................................................................... 3-7
Lantec Gearboxes ............................................................................. 3-7
Outer Frame and Assemblies ............................................................ 3-8
Bearing Chain and Assemblies ......................................................... 3-8
Gripper Chain Assemblies ................................................................. 3-9
Gripper Chain Parts ........................................................................... 3-9
Power Pack/Tractor Spare Cartridges ..................................................... 3-10
Control House Spare Parts ...................................................................... 3-10
Section 4Troubleshooting
No. 1 Rule of Troubleshooting ................................................................. 4-1
Equipment Needed .................................................................................. 4-1
Troubleshooting the Control House ......................................................... 4-2
Control House Console Troubleshooting .......................................... 4-3
Injector Troubleshooting .......................................................................... 4-3
Power Pack Troubleshooting ................................................................... 4-6
Reel Troubleshooting ............................................................................... 4-7
ii
SECTION
Section
Preface
1
Description and Introduction
General Description
The Halliburton V95HP quick rig-up unit (QRU) provides faster, safer rig up with improved
reliability. The unit is a major improvement in coiled tubing (CT) operating efficiency, and its
designed-in reliability helps achieve maximum up-time on location.
The V95HP QRU is ideal for applications where deeper work, larger OD pipe, and higher
push/pull ratings are required. Precision control and reliability are achieved through a proven
V-Block gripper chain and split-beam injector technology with 95,000-lb pulling capacity.
The V95HP QRU tractors are available in two options.
Kenworth T800W chassis, C13 ACERT engine, 430 HP for standard service applications
Kenworth T800W chassis, C15 engine, 500 HP for severe service applications.
Both tractors are fitted with identical wet kit power packs.
Major Components
The V95HP QRU is made up of the following major components:
Tractor Operator house

Tractor wet kit Segmented tubing guide
Reel trailer Injector
Reel DAS (data acquisition system)
Figure 1.1, Page 1-2 shows the location of the main components on the unit.
January 2006 Description and Introduction 1-1

V95HP Quick Rig-Up Unit Operating and Maintenance Quick Reference Manual
Operator house Segmented tubing guide

(DAS)
Injector
Wet kit Reel
Tractor
Reel trailer
Figure 1.1Main components of the V95HP quick rig-up unit.
Features
Safety Features
A primary design parameter for the V95HP QRU is safety. The well-control stack consists of
heavy-duty primary pressure-control equipment rated for 15,000-psi working pressure and H2S
exposure. All connections are flanged with metal-to-metal seals. A remotely controlled isolation
valve contains pressure inside the reel for added safety if the reel swivel becomes damaged and
requires redressing. The injector is mounted on a tilt mechanism that enables tubing to remain
stabbed in the injector at all times, which is a significant safety benefit.
General Features
The V95HP QRU offers the following list of features. Table 1.1 (Page 1-3) lists the units ratings
and general specifications.
Micro-fine hydraulic controls
Increased size of power pack (300+ BHP)
Imbedded/shaftless reel allows larger hub diameter/width
Allows maximum tubing length to meet local weight limits
Triple-rear-axle truck (lift axle on forward rear set)
Quad-axle trailer (lift axle on forward set)
Injector mounted on the reel trailer:
is also mounted on a tilt mechanism that enables the tubing to remain stabbed in the
injector at all times
is equipped with a segmented tubing guide that has an effective base radius of
curvature of over 120, which minimizes bending strain in the critical section. The
segmented guide reduces tubing fatigue and rig-up issues.
1-2 Description and Introduction January 2006

Shaftless reel design with direct-drive motors

Halliburtons rugged reel swivel
Larger OD string capability
Improved tubing management capability
Increased tubing life
Precision injector control and superior reliability
Adapts easily to larger rental BOPs
Dual stripper allows redundant pressure control
Electronic data acquisition system (DAS) monitors all critical surface parameters and displays the
measured values in front of the operator and customer. Certain real-time calculations are also
performed and displayed.
Specifications/Ratings
Table 1.1V95HP QRU Specifications
General Specifications
Overall length (bumper to bumper) 76.5 ft
Width 96 in.
Height (148-in. OD reel) 13 ft, 6 in.
Weight (less tubing) 87,000 lb
Reel core diameter 84-in.
Trailer capacity Up to 60,000-lb payload of tubing
BOP 4 1/16-in., 15,000-psi, H2S-rated
Dual stripper 4 1/16-in., 15,000-psi, H2S-rated (over/under)
V-Block gripper chains (standard) 1 1/2-in. to 2 3/8-in.
Minimum handling temperature -4F (-20C)
Maximum operating temperature 122F (50C)
Various Ratings
Continuous-pull 85,000 lb
Intermittent-pull 95,000 lb
Snub 40,000 lb
Pump-through reel swivel 15,000 psi
Flow cross (standard) 15,000 psi
(four Lo Torc valves)
Working-pressure manifolds 15,000 psi

Safety Guidelines
General
The safety information in this manual should be used in conjunction with the standards and procedures
in the following:
Health and Safety Standards Manual (HSS, Part No. 770.00356) on the Health and Safety
Documentation website:
http://halworld.corp.halliburton.com/wrk/wrkhms/wrkhms_meap/hes_ap/SSDS_HMS/Misc/HSE
%20listing.doc
Coiled Tubing Operations Manual (CTOM, Part No. 997.09635)

http://halworld.corp.halliburton.com/hes/Hesps/hespspe/hespspe_CT/hespspe_CTMAp/hespspe
_CTMAp_manuals/hespspe_CTMAp_manuals_CTOps.asp
If the two safety documents contradict one another, consult your site supervisor for clarification.
Personal Protective Equipment (PPE)

Site supervisors are responsible for determining the correct personal protective equipment (PPE)
necessary for a particular well treatment.
Refer to the Category 7 standards in the HSS and procedures in Subsections 1.19, 1.20, and 1.21 of
the CTOM.
The minimum required PPE is a hard hat, steel-toed work boots, and coveralls. Most jobs require
safety glasses, ear plugs or muffs, and work gloves. Hazardous jobs or conditions may require a
chemical slicker suit, goggles or face shield, special gloves, and a self-contained breathing apparatus
(SCBA) or escape-pack breathing protection. When working at dangerous heights, personnel should
take other precautions, such as wearing a safety harness.

Manuals and Other Resources
V95HP QRU Component Manuals

For more specific information regarding a V95HP QRU component, refer to one of the following
companion manuals:
V95HP Quick Rig-Up Tractor Manual (SAP No. 101467495)

http://halworld.corp.halliburton.com/HES/Hesps/hespspe/hespspe_CT/hespspe_CTSE/hespspe_C
TSE_manuals/hespspe_CTSE_manuals_content/101467495.pdf
V95HP Quick Rig-Up Trailer Manual (SAP No. 101467450)

V95HP Injector Operation and Maintenance Manual (SAP No. 101332153)

http://halworld.corp.halliburton.com/hes/hesps/hespspe/hespspe_ct/hespspe_ctse/hespspe_ctse_
manuals/hespspe_ctse_manuals_content/101332153/101332153.pdf
V95HP Quick Rig-Up Segmented Tubing Guide Manual (SAP No. 101467451)
QMC Crane Operation, Maintenance, and Parts Manual

http://halworld.corp.halliburton.com/hes/Hesps/hespspe/hespspe_CT/hespspe_CTSE/hespspe_CT
SE_manuals/hespspe_CTSE_manuals_content/hespspe_CT_man_QMC6070/QMC6070.asp
V95HP Quick Rig-Up Reel Manual (SAP No. 101467452)

V95HP Quick Rig-Up Operator House Manual (SAP No. 101467453)


Additional Resources Available on HalWorld

For additional information regarding a V95HP QRU, refer to the following:
Halliburton CT Methods and Applications Website

_CTMAp.asp
CT Best Practices Website

_CTMAp_bestprac/hespspe_CTMAp_bestprac.asp
Halliburton CT Recommended Spare Parts List

http://halworld.corp.halliburton.com/hes/Hesps/hespspe/hespspe_CT/hespspe_CTSE/hespspe_
CTSE_manuals/hespspe_CTSE_manuals_parts.asp
Coiled Tubing Handbook (Part No. 04-086)

_CTMAp_manuals/hespspe_CTMAp_manuals_ct_handbook.asp
Coiled Tubing Operations Manual (CTOM, Part No. 997.09635)

_CTMAp_manuals/hespspe_CTMAp_manuals_CTOps.asp

SECTION
Section
12
Preface
Operating Procedures
Transporting the Unit to the Jobsite
1. Complete the Pre-Transport/Post-Transport Checklist (Page 2-11) just before transport-
ing the unit to the jobsite.
2. Perform the Job Setup procedure (see the following section).
3. Perform the Pre-Job Inspection (Page 2-13).
Job Setup
1. Position the unit on the jobsite.
a. Locate the reel trailer as close to the wellhead as is practical and orient it so that the
levelwind on the reel points at the wellhead.
b. Place the crane trailer as close to the reel trailer as is practical and orient it so that the
crane can reach the wellhead with the BOP, stripper, injector, and tubing guide stack.
2. Set up all the walkways and ladders including all hand rails.
3. Connect all the hose packages and cables between the components. Some of the hose
packages are different for land and offshore service. All individual hoses have numbered
tags attached to them that match bulkhead connection numbers on the major compo-
nents.
4. Connect electrical power to the operator house. Power is available from the power pack
or the optional hydraulically driven generator.
a. Turn off all electrical components inside the operator house.
b. Connect the power cable to the operator house.
5. Start and warm up the hydraulic power package:
a. Turn off all hydraulic functions inside the operator house.
b. For land service, the air supply is the air compressor on the tractor. For offshore
April 2007 Operating Procedures 2-1

service, connect the air supply to the power pack. The air supply is the rig/platform
air supply.
c. Start the hydraulic power package engine.
d. Allow the engine to run at idle for at least 3 minutes.
e. Continue to warm up the engine at 1,000 rev/min until the water temperature reaches
130F (54C). In cold weather, see additional warmup instruction, Page 6-9.
f. Increase the speed of the engine to 1,500 rev/min until the water temperature reaches
a minimum of 160F (71C).
6. Land service onlyprepare the crane for use:
a. Fully extend all outriggers.
b. Lower all outrigger feet to level the crane properly. Note soil conditions and use an
adequate size of pad under each foot.
Note Leave the tractor attached to the crane trailer. With the tractor attached, the
crane trailer is more stable in areas with poor soil conditions.
7. Raise the operator house to its working position and lock it into position by pinning the
four corner legs of the house at the correct height.
8. Inspect the BOP and stripper:
a. Ensure that the BOP and stripper are correct for the tubing size and well-treatment
fluids being used for this well treatment.
b. Visually check all sealing elements, including all union seals, ring-joint gaskets, the
stripper element, and O-rings.
c. Visually check all hoses and hose connections.
d. Pressure up each hose and visually check them for leaks.
e. Move all BOP rams to their open positions.
f. Check for any obstructions in the BOP and stripper.
g. For each BOP ram, perform this procedure:
i. Close the ram.
ii. Ensure that it closes completely and operates smoothly.
iii. Open the ram.
iv. Ensure that it opens completely and operates smoothly.
h. Ensure that the stripper seal expands and contracts as stripper pressure is increased
and decreased.
9. Function-test all the components from inside the operator house.
2-2 Operating Procedures April 2007

a. Operate all controls for the hydraulic power package.

b. Operate all controls for the BOP (if this step has not already been performed).
c. Operate all controls for the stripper (if this step has not already beenperformed).
Note After the functional test, leave the stripper control-valve in its RETRACT position to
help prevent the collapse of the stripper element.
d. Operate all controls for the reel assembly.

e. Operate all controls for the injector.
10. Release the shipping/handling restraints for the load pins.
a. Loosen the jack bolts that hold the injector inner frame in place.
b. The load pins now support the weight of the inner frame of the injector.
11. Connect the stripper to the bottom of the injector. In most cases, this connection will be made
with the hydraulic injector connector, where the top portion of the disconnect attaches to the
injector, and the bottom portion connects to the stripper. Make sure that both sections of the
hydraulic disconnect are clean and properly lubricated. If tubing is stabbed, go to Step 13.
12. Insert the coiled tubing through the tubing guide, if you have not already done so.
a. Spool about 6 ft (2 m) of tubing off the reel.
b. Install a clamp on the tubing at the outside of the levelwind trolley.
c. Insert (stab) the tubing through the tubing guide.
13. Insert the coiled tubing into the injector.
Caution Make sure that the balancing link is pinned securely when lifting the tubing
guide along with the lift bail. The mast will overturn if this pin is not secure.
Caution Never use only the sling to pick up the tubing guide because of the instability cre-
ated by the location of the tubing guide balance point.
a. Pull about 3 ft (1 m) of tubing out of the bottom of the tubing guide.

b. Install a clamp on the tubing at the bottom of the tubing guide.
c. Remove the tubing clamp previously installed at the levelwind.
d. Fully open the linear beams in the injector.
e. Install the tubing guide on top of the injector, while guiding the tubing into the gripper blocks
of the injector drive chains. The tubing guides mast (gooseneck) should be on the same side
of the injector as one set of gripper blocks.

f. Use the tubing guides four pins to secure it to the injector.

g. Center the tubing in the gripper blocks and close the linear beams in the injector.
Note An alternate procedure to the one outlined in Steps 11 and 12 is to install the tubing
guide on the injector first, and then to insert the tubing into the tubing guide and
injector at the same time.
14. Insert the coiled tubing through the stripper:

a. Apply sufficient linear-beam pressure to allow the injector to feed the tubing through the
stripper.
b. Remove the tubing clamp previously installed on the bottom of the tubing guide.
c. Operate the injector slowly and feed approximately 1 ft (0.3 m) of the tubing into the
stripper.
d. Lift the tubing guide/injector off the ground.
e. Operate the injector slowly and feed approximately 2 ft (0.6 m) of tubing through the
stripper.
f. Install a clamp on the tubing immediately below the stripper.
15. Align the tubing guide and injector to the reel:
a. Reduce the linear-beam pressure to 0 psi (0 kPa). This pressure reduction releases the
gripper blocks from the tubing.
b. Release the tubing guides rotating bearing lock. The tubing guides mast should be
pointed toward the reel.
c. Align the injector with the reel. One drive chain is oriented directly toward the reel and
one is oriented directly away from it.
16. Connect the stripper to the top of the BOP.
a. Apply sufficient linear-beam pressure to hold the tubing in place.
b. Remove the tubing clamp from the bottom of the stripper.
c. Set the stripper (with the tubing guide and injector attached) on top of the BOP.
d. Connect the stripper to the BOP. This connection is usually an API flange-type connection.
17. Install any downhole tools on the end of the coiled tubing.
a. Operate the injector slowly and feed about 2 ft (0.6m) of tubing through the BOP.
b. Install a clamp on the tubing immediately below the BOP.
c. Connect any tools to the end of the tubing.
18. If downhole tools are installed on the end of the tubing, pressure-test the blind rams of the
BOP using the procedure in Pressure-Testing the BOP and Stripper, Page 2-6. The pressure
test must be performed before downhole tools are installed on the tubing.
19. Connect the BOP (with stripper, injector, and tubing guide attached) to the top of the wellhead.
Caution Be sure the crane is rated for the load that is to be lifted at the maximum re-
quired radius.
a. Remove the tubing clamp from the bottom of the BOP.

b. Set the BOP (with tubing guide, injector, and stripper attached) on top of the wellhead. A
riser or a kill-line manifold may have been installed above the actual wellhead.
c. Connect the BOP to the wellhead (or riser or kill-line manifold).
d. This connection is usually an API flange-type connection.
20. Secure the injector in its position.
a. Level the injector as well as possible by adjusting its feet. Additional structures or stands may
be required.
b. Further restrain the injector by installing substantial guy wire cables (9/16-in. or 15-mm
diameter minimum) or chains to its four top corners. The opposite end of each cable/chain
must be connected to a secure object or a deadman.
c. While leveling and restraining the injector, do not apply any side force to the stripper, BOP,
or wellhead equipment.
21. Calibrate the DAS, including zeroing the weight indicator. You can find more information about
the operation of the data acquisition system (DAS) in Section 10 of this manual.
a. Turn on the DAS.
b. Zero the digital and analog weight indicators.
c. Ensure that the speed, depth, tubing pressure, wellhead pressure, rate, and total indicators all
read 0.
22. Pressure-test the BOP and stripper using the procedure in Pressure-Testing the BOP and Stripper.
If downhole tools have been installed, the blind rams of the BOP should already have been tested
(Step 16).
23. Zero the depth instruments. Reset the mechanical depth counter (depthometer) on the reel
assembly and the DAS to 0.

Pressure-Testing the BOP and Stripper
Pressure-Testing Guidelines
Follow the guidelines below to test the BOP and stripper:
Use clean water as the pressure-test fluid.

Apply all pressure from below the particular ram.
Ensure that the master valve at the wellhead is closed at all times during this procedure.
Test the blind rams with the tubing removed.
Note To determine the maximum pressure to apply, choose the lowest pressure of the
following:
maximum working pressure for the wellhead equipment
maximum working pressure for the surface equipment
1.5 times the maximum shut-in tubing pressure (SITP) for the upcoming
treatment
80% of the tubings rated burst pressure (for tubing rams)
Note Do not pressure test the slip and shear rams; they do not hold pressure.
Pressure-Testing Procedure
Perform the following procedure to test the BOP and stripper:
1. Remove the tubing from the BOP, if necessary.

2. Pressure-test the blind (top) rams of the BOP.
a. Close the blind rams.
b. Apply low pressure [200 and 300 psi (1380 to 2070 kPa)] to the bottom connection of the
stand and hold this pressure for at least 5 minutes.
c. To check the rams for leaks, monitor for any drop-off of pressure.
d. Increase to a high pressure as outlined in the Pressure-Testing Guidelines and hold this
pressure for at least 5 minutes.
e. To check the rams for leaks, monitor for any drop-off of pressure.
f. Relieve the pressure and fully open the blind rams.
3. Install the tubing through the BOP.

4. Pressure-test the tubing rams. Use the same procedure that was used to test the blind rams. The
high pressure should be applied through the tubing to prevent tubing collapse.
5. Pressure-test the stripper. Use the same procedure that was used for the tubing rams.
6. Ensure that all rams are now open.
Pre-Treatment Inspection
Follow the Pre-Treatment Checklist on Page 2-17 in the Operating Instructions Appendix before starting
the well treatment.
Startup
1. Increase the stripper pressure to at least 500 psi (3.4 MPa). More pressure may be needed to
contain the wellhead pressure after the master valve is opened.
2. To prevent tubing collapse, increase tubing pressure to wellhead pressure. The stripper may need
to be adjusted to contain well fluids.
3. Slowly open the master valve on the wellhead. Well fluids and their pressure can now flow
around the coiled tubing.
Normal Operation for Tripping In

1. Start injecting the coiled tubing into the well. Proceed slowly [less than 40 ft/min (12 m/min)]
until the end of the tubing/tool is clear of any surface equipment.
Important Do not exceed the recommended injection rate.
2. Check the coiled tubing weight at about 1,000-ft (320-m) intervals:

a. Pick up the tubing and slack off about every 1,000 ft (320 m), especially on the first trip into
the well. Pick up between 25 and 50 ft (8 and 15 m) of tubing.
b. Record both the pick-up and slack-off weights at each depth.
c. Near the end of production tubing, check for drag caused by buckled or corkscrewed
production tubing by picking up and slacking off about every 50 to 100 ft (15 to 30 m).
3. Check the coiled tubing weight just before approaching any known obstacles, and slow the injec-
tor speed to less than 40 ft/min (12 m/min) until the obstacle has been passed.
4. Maintain the hydraulic pressure in the injector drive circuit so that the injector will stall when
less than 10% of the total weight is set down on any obstruction. This action allows the tubing
and/or tools to land softly, which helps prevent buckling in the tubing.

5. Monitor the control console. See the specific operating instructions for the control console
found in Section 5.
Normal Operation for Tripping Out

1. When removing the coiled tubing, reduce the injector speed to less than 40 ft/min (12 m/min)
when approaching any known obstacles. Be particularly careful when entering production
tubing with any kind of tools attached to the end of the coiled tubing. Otherwise, proceed at
the job design speed.
2. At about 500 ft (150 m) below the surface, reduce the injector speed down and adjust the injec-
tor drive circuit pressure so that the injector will stall when any attached tools bump against
the stripper. This action allows the tubing and/or tools to land softly, which helps prevent
damage to the stripper and helps prevent tools from being dropped.
Normal Shutdown
1. After all tubing and tools have cleared the master valve, slowly close the master valve on the
wellhead to prevent additional well fluids and pressure from entering the BOP and stripper
area.
2. Bleed off any pressure from inside the coiled tubing. This step is normally performed by
venting the discharge manifold equipment upstream of the reel assembly.
3. Reduce the stripper pressure to 0 psi (0 kPa).
4. Bleed off any pressure from the wellhead above the master valve. If the tubing was
open-ended, then this pressure will have bled off when the tubing was bled. If it has not, then
perform the following steps:
a. Clear the area near the BOP bleed valve of any unnecessary personnel or equipment.
b. Open all rams on the BOP.
c. Open the BOP bleed valve installed in the bleed port on the BOP. Leave this valve open
until all pressure has bled off.
5. Purge all fluids from inside the coiled tubing. A nitrogen unit is usually used to flush all fluids
out of the tubing.
6. Remove the coiled tubing from the wellhead.
Emergency Shutdown
1. If you are tripping in or out, stop the injector.
2. Close the BOP slip rams. When these rams are closed, they act as slips to prevent the tubing
from slipping into the well.

3. Close the BOP tubing rams and lock them in place. When these rams are closed, they seal against
the outside of the tubing and prevent well fluids from entering the remainder of the BOP and
stripper area.
4. Lock these rams in place.
5. Stop pumping if any fluid is being pumped downhole.
Note If a backpressure valve is used on the tubing, maintain sufficient pressure in the
tubing to prevent collapse.
6. Close the fluid-inlet valve in the discharge-manifold equipment going to the reel.
7. Close all chokes and/or flowline valves.
8. Close the BOP shear rams only if the tubing rams did not close or did not seal properly against
the tubing. When closed, these rams will cut the tubing in two.
9. If the shear rams had to be closed, close the BOP blind rams. Closing the blind rams is necessary
when the treatment operator determines that the tubing rams did not close or did not seal properly
against the tubing.
Important The free end of the tubing must be pulled above the BLIND rams after the shear
rams have cut the tubing.
10. Stop the hydraulic power package and, if in land service, stop the generator set.
11. Leave the unit and report to the predetermined emergency meeting area.
Daily Report
Fill out the DOT Operator and Vehicle Daily Inspection Report (Halliburton form 2234-R3). Your
maintenance supervisor will provide you with the booklet that contains copies of this form and
instructions for using them.
Always complete this report when you finish operating this unit for the day and give it to the local shop
foreman. Completion of this report may be a government requirement of the country in which you are
operating this unit.
Post-Job Reports
A mandatory post-job report is the Coiled Tubing Tour Report. A sample of this report form can be found
in Section 1 of the CTOM. Give the completed report to your supervisor and the local shop foreman.

Another mandatory post-job report is the Coiled Tubing Job Log. A sample of this report form can be
found in Section 1 of the CTOM. Give the completed report to your supervisor and the local shop
foreman.

Pre-Transport/Post-Transport CT Equipment Checklist
Power Pack Check

Visually inspect the following items and take action to correct any problems or replace parts as needed.
Place a checkmark (9) beside the item when you have verified that it meets the required standards.
Pre Post
1. Hydraulic tank oil level. ( ) ( )

2. Oil leaks. ( ) ( )
3. Hanging or frayed hydraulic hoses. ( ) ( )
4. Bad pressure gauges. ( ) ( )
5. Leaking quick-disconnects. ( ) ( )
6. Cracks in metal support members. ( ) ( )
7. Loose nuts or bolts. ( ) ( )
8. Appearance/cleanliness. ( ) ( )
House Check
Pre Post
1. Oil leaks. ( ) ( )
4. Cracks in house frame or metal support members. ( ) ( )
6. Cracks in rear, side, and front window glass. ( ) ( )

Reel Check
Pre Post
1. Evidence of leaks in high pressure manifolding. ( ) ( )

2. Oil leaks. ( ) ( )
3. Gearbox and motor mounting. ( ) ( )
4. Levelwind not bent or missing parts. ( ) ( )
5. Reel flanges not bent or rubbing. () ( )
Injector Check
Pre Post
1. Oil leaks. ( ) ( )
2. Cracks in outer and inner frame. ( ) ( )
3. No spun pins in gripper or linear chains. ( ) ( )
4. Fresh oil on gripper and linear chains. ( ) ( )
5. Oil leaks. ( ) ( )

Pre-Job Inspection
Before operating the tractor and power package, perform a complete pre-job check (checklist follows).
All equipment must be in good operating condition before the engine is started. Inspections will help
prevent a failure later. If you cannot correct a problem, call the appropriate maintenance personnel.
A pre-job inspection should be performed before leaving the service center. If the unit is used offshore,
perform the inspection before each job. Use the Pre-Job Inspection Checklist that follows.
Pre-Job Inspection Checklist

Perform pre-job inspection as follows.
_____ 1. Check the tractor coolant level in the radiator. The level should be 1 in. (25 mm) below
the filler neck.
Warning Do not remove the cap from a hot radiator. Burns could result.
_____ 2. Inspect the engine coolant hoses and connections for leaks. Replace leaking or cracked
hoses and connections.
_____ 3. Check the engine belts for alignment, wear, and general condition. If one belt is defective,
replace all belts in the set.
_____ 4. Check the hydraulic heat exchanger. Remove any debris in the core; the core must be kept
clean for proper cooling of the hydraulic system.
_____ 5. Check the engine system gauges and controls. Ensure that the gauges are not broken and
that they show a reading. Ensure that the control valves operate. Check for any leaks
around the gauges, controls, or connections.
_____ 6. Remove the tractor air filter cover and check the element. Replace the filter if it appears
dirty. Ensure that the air filter restriction gauge is operational.
_____ 7. Check the tractor fuel tank. Ensure that the fuel tank is full and that the hoses and fittings
do not leak.
_____ 8. Check the hydraulic reservoir oil level with the sight glass. When the hydraulic system is
cold, the level should be 1 to 2 in. (25 to 51 mm) below the high-level mark. When the
hydraulic system is warm, the fluid should be at or above the high-level mark.
Caution Do not run the hydraulic system with a low oil level. Replenish the reservoir with
the recommended lubricant.
_____ 9. Check the hydraulic oil filter indicators. If the indicators show the filter in bypass mode,
change the filter elements.

_____ 10. Check the hydraulic directional valve for leaks. Tighten any loose connections. If
leakage is found around the valve, repair the leak before operating the unit.
_____ 11. Check the hydraulic pumps, hoses, and fittings for leaks. Repair any leaks.
_____ 12. Check the oil level of the engine. The engine should be level but not running while the
oil is being checked.
_____ 13. Check the hydraulic system pressure gauge. Ensure that the gauges are not broken and
that they show a reading. Check for any leaks around the gauges or gauge connections.
_____ 14. Check both the hydraulic bulkhead and the quick-disconnect fittings for leaks. Repair
any leaks and replace or repair any disconnects.
_____ 15. Check the hydraulic system hoses, adapters, and fittings for leaks. Tighten any loose
connections and replace any items that are defective.
For information about starting the V95HP QRU tractor, see the V95HP Quick Rig-Up Tractor Manual,
Section 6, Tractor Operation.

SECTION
Section
13
Preface
Maintenance and Spare Parts

Introduction
Section 3 includes general maintenance procedures and spare parts lists for the V95HP quick
rig-up unit. For additional information, see Manuals and Other Resources in Section 1 of this
manual.
V95HP QRU Pump and Motor Minimums/Maximums
Pump Flows
Injector pumps minimum 104 gal/min (combined)
Reel pump minimum 31 gal/min
House pump minimum 25 gal/min
BOP pump minimum 25 gal/min
Oil cooling pump minimum 55 gal/min
Fan drive pump minimum 24 gal/min (per discharge)
Pump and Motor Case Drains

Injector pumps maximum 7 gal/min (per pump)
Injector motor maximum 1.25 gal/min (per motor)
House pump maximum 2 gal/min
BOP pump maximum 2 gal/min
Reel motors maximum 1.5 gal/min (per motor)
January 2006 Maintenance and Spare Parts 3-1

Injector Spare Parts (Standard Service)
Hydraulic Parts
Table 3.1 lists the hydraulic part numbers for the 95K injector.
Table 3.195K Injector, Hydraulic Parts
SAP No. Vendor, Part No. Qty Description

101277152 Rexroth, 2 Hydraulic Motor, 6.52ci/107cc,
A6VE107HD1/63W-VZL020B 6,000 psi
101268652 Parker, 932670Q 2 10Q-10 Mircon high press filter
100035549 Acra, 213-2-3M-50 1 50-psi Pop-off valve, w/ 3/8 mpt
Valves and Bodies

Table 3.2 lists the valves/bodies part numbers for the 95K injector.
Table 3.295K Injector, Valves and Bodies

101326805 Sun, CKCB-XEN-ECI 1 PO check, 3,000-psi, 15-gal
Valve Cartridges
Table 3.3 lists the valve cartridge part numbers for the 95K injector.
Table 3.395K Injector, Valve Cartridges

101333569 Sun, CBGH-CCN-5000 psi 4 10:1 Counterbalance valve, 60 gal/min
101333574 Sun, XJOC-GXN 4 CB valve cavity adapt, 120/60 gal/min
101215649 Sun, PBFB-LNN 1 Valve cartridge, pressure reducing,
60800 psi
101215658 Hydra Force, PD10-40-0-N-60 1 Valve cartridge, directional
101215659 Sun, FXCA-XAN 1 Valve cartridge, .25 gal/min, flow control
101319738 Sun, CXDA-XAN 1 Valve check, 20 gal/min
3-2 Maintenance and Spare Parts January 2006

Inner Frame Parts and Assemblies

Table 3.4 lists the inner frame part/assembly numbers for the 95K injector.
Table 3.495K Injector, Inner Frame Parts and Assemblies

101277253 Rexnord, ZT8-2206 2 Bearing, bottom chain tension
Linear Bearing Chain Parts and Assemblies

Table 3.5 lists the bearing chain part/assembly numbers for the 95K injector.
Table 3.595K Injector, Bearing Chain Parts and Assemblies

101283560 Halliburton, 101283560 2 Chain assembly, linear, 95K injector
100027190 Tsubaki, #80, cotter pin 100 Cotter pin, f/#80 chain
101270218 Halliburton, 101270218 10 Roller assembly w/Iglide, f/#80 linear chain
100005567 Tsubaki, #80, link connector 10 Link, connector, 1-in. pitch, #80 chain
100005568 Tsubaki, #80, plate side 10 Plate, side, 1-in. pitch, #80 chain
100007475 Tsubaki, #80, link 10 Link, 1-in. pitch, #80 chain
100007471 Halliburton, 10007471 10 Spacer, roller chain, brass
Gripper Chain Parts

Table 3.6 lists the gripper chain part numbers for the 95K injector.
Table 3.695K Injector, Gripper Chain Parts

101287620 Gripper chain assembly, 1.502.50
100026158 Tsubaki, #200 roller link 10 Link, roller, #200 chain
100026159 Tsubaki, #200 link plate 10 Link, side plate, #200 chain
100026161 Tsubaki, #200 link connector 10 Link, connector, #200 chain
100035460 Tsubaki, #200 cotter pin 10 Pin, cotter, nickle plated, #200 chain

Chain Lube Parts

Table 3.7 lists the chain lube part numbers for the 95K injector.
Table 3.795K Injector, Chain Lube Parts

101280610 Hydra Force, HP-10-20T-6T-N 2 Pump, chain lube
101282096 Reid Tool, SB-3 2 Chain oiler pump, round ball
101283368 Perma USA, A-400 14 Chain oiler, applicator brushes
100026248 Gear lube heavy-duty oil, 90-wt, GL5 Chain lube oil

Injector Spare Parts (Severe/Remote Service)
Hydraulic Parts
Table 3.8 lists the hydraulic part numbers for the 95K injector severe/remote service.
Table 3.895K Injector, Hydraulic Parts for Severe/Remote Service

101277152 Rexroth, A6VE107HD1/63W-VZL020B 2 Hydraulic Motor, 6.52 ci/107 cc, 6,000 psi
100005571 Span, LFP212-3000-PSI-S 2 Pressure gauge, 03,000 psi
100008298 Whitey, B-43F4-A-PT 1 Valve, 90, 1/4-in. FMPT
101268652 Parker, 932670Q 2 10Q, 10 mircon high press filter
100035549 Acra, 213-2-3M-50 1 50-psi pop off valve, w/ 3/8 mpt
100027975 Oil Air, R-1-101 1 1 gal, 3,000-psi bladder
100031179 Texas Hyd,H54007432SS-0010 2 Cylinder, hydraulic f/gripper circuit
Valves and Bodies Parts

Table 3.9 lists the valves/bodies part numbers for the 95K injector severe/remote service.
Table 3.995K Injector, Valves and Bodies for Severe/Remote Service

101326805 Sun, CKCB-XEN-ECI 1 PO check, 3,000-psi, 15-gal

Hydraulic Valve Cartridges

Table 3.10 lists the valve cartridge part numbers for the 95K injector severe/remote service.
Table 3.10V95HP Injector, Valve Cartridges for Severe/Remote Service

100035535 CBIH-CCN 10:1 Counterbalance, 120 gal/min
100035536 CWIG-CGN 5:1 Counterbalance
101333569 CBGH-CCN, 5,000-psi 4 10:1 Counterbalance valve, 60 gal/min
101215649 PBFB-LNN 1 Pressure-reducing, 60800 psi
101215658 PD10-40-N-60 1 Pilot-directional, auto brake
101215659 FXCA-XAN 1 .25-gal/min Flow control
101319738 CXDA-XAN 1 Check valve, 20 gal/min
Inner Frame Parts and Assemblies

Table 3.11 lists the inner frame part/assembly numbers for the 95K injector severe/remote service.
Table 3.1195K Injector, Inner Frame Parts and Assemblies for Severe/Remote Service

100031177 Rexnord, ZBR-5400 2 Bearing, top drive sprocket
101277253 Rexnord ZT8-2206 4 Bearing, bottom chain tension
101283381 MCGill Mfg 10AL2426 32 Bearing, stiff bar
101237247 Torrington, 12SF20 8 Bearing, f/gripper cylinder clevis
101283906 Torrington, 10SF16 6 Bearing, f/bell crank bars
101276903 Halliburton, 101276903 2 Sprocket, gripper, upper drive
100002014 Halliburton,100002014 2 O-Ring, f/sprocket, gripper, upper drive
101276809 Halliburton, 101276809 2 Sprocket, gripper, lower driven
101288801 Halliburton, 101288801 4 Bolt, gripper chain tension adj
100027281 Halliburton, 100027281 4 Pin, roll, f/gripper tension bearing
100031176 Danly Die Springs, 9-3212-36 4 Spring, adj, gripper chain

Linear Beams
Table 3.12 lists the linear beam part numbers for the 95K injector severe/remote service.
Table 3.1295K Injector, Linear Beams for Severe/Remote Service

101277450 Halliburton, 101277450 8 Sprocket, f/linear beams assy
101288166 Torrington, W204KLL 8 Bearing, linear beam sprocket
101282029 Motion Ind, HO 185 8 Ring, C, bearing retainer
100082317 Halliburton, 100082317 2 Bearing, plate f/linear chain
101277520 Halliburton, 101277520 8 Hub, sprocket
101277512 Halliburton, 101277512 4 Shaft, sprocket
101282779 Halliburton, 101282779 2 Plunger, tension
101280606 Halliburton, 101280606 2 Sleeve, tension telescope
101282503 Ingus Inc, TFI-1618-16 2 Sleeve, tension plunger
101282491 Danly Die Springs, 9-2418-11 2 Spring, adj, linear chain tension
101283072 Halliburton, 101283072 2 Screw, tension adjust
Lantec Gearboxes
Table 3.13 lists the Lantec gearbox part numbers for the 95K injector severe/remote service.
Table 3.1395K Injector, Lantec Gear Boxes for Severe/Remote Service

100024591 Lantec Ind, 102747 2 Seal kit
100024592 Lantec Ind, 603279 18 Disc, friction, brake
100024593 Lantec Ind, 202615 20 Disc, divider, brake
100024594 Lantec Ind, 603303 60 Spring, brake

Outer Frame and Assemblies

Table 3.14 lists the outer frame and assembly part numbers for the 95K injector severe/remote service.
Table 3.1495K Injector, Outer Frame and Assemblies for Severe/Remote Service

100026319 SKF, GEZ 200 TE-2RS 2 Bearing, spherical, f/load pins
100028030 Waldes Truarc, N5000-315 2 Ring, retaining, f/load pin bearings
100081378 Halliburton, 100081378 4 Pin, latch, f/injector legs
100010153 Medalist Rein Leitzke, 21-08 4 Hair pin, f/injector legs
100081538 Halliburton, 100081538 2 Keeper, f/load pins
Bearing Chain and Assemblies

Table 3.15 lists the bearing chain and assembly part numbers for 95K injector severe/remote service.
Table 3.1595K Injector, Bearing Chain and Assemblies for Severe/Remote Service

101283560 Halliburton, 101283560 2 Chain assembly, linear, 95K injector
100027190 Tsubaki, #80, cotter pin 100 Cotter pin f/#80 chain
101270218 Halliburton, 101270218 10 Roller assy. w/iglide, f/#80 linear chain
100005567 Tsubaki, #80, link, connector 10 Link, connector 1-in. pitch, #80 chain
100005568 Tsubaki, #80, plate, side 10 Plate, Side, 1-in. pitch, #80 chain
100007475 Tsubaki, #80 link 10 Link, 1-in. pitch, #80 chain
100007471 Halliburton, 10007471 10 Spacer, roller chain, brass

Gripper Chain Assemblies

Table 3.16 lists the gripper chain and assembly part numbers for the 95K injector severe/remote service.
Table 3.1695K Injector, Gripper Chain Assemblies for Severe/Remote Service

101287669 Halliburton, 101287669 2 1.25- to 2.25-in. Gripper chain assy
Gripper Chain Parts

Table 3.17 lists the gripper chain part numbers for the 95K injector severe/remote service.
Table 3.1795K Injector, Gripper Chain Parts for Severe/Remote Service

100026158 Tsubaki, #200 roller link 132 Link, roller, #200 chain
100026159 Tsubaki, #200 link plate 132 Link, side plate, #200 chain
100026161 Tsubaki, #200 link connector 66 Link, connector, #200 chain
100035460 Tsubaki, #200 cotter pin 132 Pin, cotter, nickle plated, #200 chain
101206298 Halliburton, 101206298 66 1.25- to 2.25-in. Gripper block
101280615 Halliburton, 101280615 2 Insert, tubing guide, 1.25- to 2.00-in.
101284551 Halliburton, 101284551 2 Insert, tubing guide,1.50- to 2.50-in.
101284523 Halliburton, 101284523 2 Insert, tubing guide, 2.00- to 3.50-in.

Power Pack/Tractor Spare Cartridges

Table 3.18 lists the power pack/tractor part numbers for spare cartridges.
Table 3.18Spare Cartridges
SAP No. Vendor, Part No. Description

101215654 DSCH-XHN Valve, hot oil shuttle
101215655 RPEC-LNN Relief valve, hot oil shuttle
101215656 RVCD-LWN Relief valve, reel circuit
101215786 RV10-20F-0-N-12/5 500-psi Relief, reel circuit
101215657 PBDB-LBN 10 gal/min (old), Relief inj. motor charge
101321269 PRFB-LEN 20 gal/min (new) Relief inj. motor charge
101319738 CXDA-XAN Check valve, inj. motor charge
101215464 RPGC-FAN Relief valve, fan drive
Control House Spare Parts

Table 3.18 lists the control house part numbers for the V95HP QRU.
Table 3.19V95HP QRU Control House Parts
SAP No. Vendor, Part No. Description

101215643 MR10-47D-0-N Injector gripper position
100036284 MR10-40-0-N BOP
101215645 MR10-31-0-N Inj., reel brake/high-low speed
101209124 MR10-47C Levelwind
101215646 PR10-36B-0-N-30 Injector gripper pressure
101215647 PR10-36B-0-N-15 Stripper pressure
101215869 PD10-4013-0-N-60 Auto brake pilot, check valve
101215648 RPEC-OCN Inj./-reel max pressure adjust
101215649 PBFB-LNN House pilot pressure
101215650 PPDB-ODN Injector speed control

SECTION
Section
14
Preface
Troubleshooting
Use the following procedures and guidelines for troubleshooting the V95HP quick rig-up unit.
No. 1 Rule of Troubleshooting

In troubleshooting a coiled tubing unit, always consider the simple solutions first, such as
checking the gauges, unloader valves, or unattached hoses, etc.
Equipment Needed
1,000-psi Pressure gauge
5,000-psi Pressure gauge
Assortment of quick-disconnects
Assortment of JIC caps and plugs
Assortment of short DWB hose with JIC swivels
Two 5-gal buckets
January 2006 Troubleshooting 4-1

V95HP Quick Rig-Up Unit Operating and Maintenance Manual
Troubleshooting the Control House

Table 4.1 is a list of potential problems that you may experience with the V95HP QRU control
house and some possible causes.
Table 4.1Control House Troubleshooting Suggestions
Problem Possible Cause
Cannot get injector pump The injector unload valve at the power pack is not in the
pressure with maximum closed position.
pressure-adjust valve. The injector direction is not selected.
Pressure on the speed-control valve is not at least 80
psi.
With the injector direction selected, check the pilot
pressure on Lines 123 and 127.
The maximum pressure adjust cartridge needs to be
replaced (SAP No. 101215648).
Cannot get reel pump pressure The reel unload valve at the power pack is not in the
with maximum pressure-adjust closed position.
valve. The Rexroth valve is not in the tension position.
With the Rexroth valve in the tension position, Line 119
should be at 500-psi pilot pressure.
The hot oil gauge at the power pack should be between
300350 psi pressure.
The maximum pressure adjust cartridge needs to be
Reel levelwind is creeping in The levelwind override Hydraforce valve needs to be
one direction. recentered. Remove the handle and align the valve to
the positioning mark on the shaft body.
Reel levelwind is moving too Trace the hose from Port 3 on the override valve to the
fast or too slow. flow-control valve.
CautionOpening this valve too much will result in

valve squealing and loss of console pressure at
lower engine rpm.
No console pressure. The main valve under the console is closed.
The hydraulic hoses are not connected properly.
The quick-disconnect at Hose 102 needs to be replaced.
Cannot build sufficient hydraulic The valve on the bottom of the hydraulic tank (under the
pressure to operate the console) is closed.
well-control equipment using a
hand pump.
4-2 Troubleshooting January 2006

Control House Console Troubleshooting

Table 4.2 is a list of potential problems that you may experience with the V95HP QRU control house
console and some possible causes.
Table 4.2Control House Console Troubleshooting Suggestions
The Rexroth valve for the reel 1. Pull back the rubber boot on the valve.
will not stay in the tension 2. Place the valve in Neutral.
position.
3. Using an Allen wrench, adjust the friction screw.
Injector Troubleshooting
Table 4.3 is a list of potential problems that you may experience with the V95HP QRU injector and some
possible causes. For additional information, refer to the V95HP Coiled-Tubing Injector Operating and
Maintenance Manual (Part No. 101332153).
Table 4.3V95HP QRU Injector Troubleshooting Suggestions
The 50-psi pop-off on the return Hose 343 is not connected at either the injector and/or
is relieving. the power pack.
The quick-disconnect at Hose 343 needs to be replaced.
Hose 343 is kinked.
An injector hydraulic motor needs to be replaced. Check
the case drains on the motors; the maximum is 1.5 gpm
per motor.
The 1/4-gpm flow control for flushing the motor cases
needs to be replaced.
More than 500 psi is being 1. Try adjusting the pressure-reducing valve.
supplied to the brake. 2. The pressure-reducing valve may need to be replaced.
Less than 500 psi is being Replace with cartridge SAP No. 101215649.
supplied to the brake.
More than 1/4 gpm is being The flow control may need to be replaced. Replace with
supplied to flush the flow cartridge SAP No. 101215659.
control.
Less than 1/4 gpm is being
supplied to flush the flow
control.

Table 4.3V95HP QRU Injector Troubleshooting Suggestions (Continued)

Injector brakes will not release. Hose 332 is not connected at either the power pack
and/or the injector.
The quick-disconnect at Hose 332 may need to be
replaced.
The injector direction in the control house is not
selected.
The manual brake in the control house is not in the
release position.
The speed-control gauge in the control house is not
reading 80 psi minimum.
The speed-control gauge in the control house is reading
more than 200 psi.
The injector is not receiving 2,000-psi pressure through
Hose 332.
At the power pack, the injector motor precharge is not
150 psi.
If you have 2,000-psi pressure on Hose 332, but do not

have 500-psi pressure at the brakes:
The PD 10 cartridge may need to be replaced (SAP No.
101215658).
The pressure-reducing cartridge may need to be
Injector will go in-hole, but will At the power pack, the injector motor precharge is not
not come out-hole. 150 psi.
The speed-control gauge is not reading 125-psi (20)
pressure.
Injector will not go in-hole or Every quick-disconnect on the drive hoses may not be
out-hole. made up.
The pins on the gripper or linear 1. Check the oiler system for sufficient lubrication. Add oil if
chains have spun. needed.
2. Steam-clean the chains.
Gripper or linear chains are 1. Check the chain elongation.
loose.

Table 4.3V95HP QRU Injector Troubleshooting Suggestions (Continued)

The chain slips. The beam pressure is low. Increase the beam pressure
to the recommended value.
The relief grooves in the gripper blocks are filled with
debris. Remove debris from the gripper-block grooves.
The flow on the return side of the cylinder is restricted.
(a) Ensure that hoses are connected properly. (b)
Check for any damaged quick-disconnects or hoses and
replace them, if necessary.
Mechanical interference is preventing proper movement
of the chain. Visually check all contact points and check
for metal particles.
The gauge is faulty. Check the gauge and replace it, if
necessary.
The accumulator is not charged. Charge the
accumulator with nitrogen to 50% of the normal beam
pressure.
The injector does not turn in Pressure is not available. Check the pump output.
either direction. The quick-disconnects are not properly connected.
Check and tighten the quick-disconnects.
The brakes are set or are in poor condition. Check the
brakes.
The injector turns in only one The counterbalance valve is dirty or plugged. (a) Set the
direction. brake. (b) Remove and clean the counterbalance valve.
The hoses are not connected properly, keeping the
quick-disconnect from opening fully. Check the hose
connections.
The injector precharge valve has malfunctioned. Adjust
or replace the valve.
The tubing slips out of the grip- The gripper blocks are not the proper size. Install the
per chain. proper size gripper block for the tubing being run.
The injector is not properly aligned with the reel. Ensure
that the gripper chains are in alignment with the reel.
Injector 2-speed not working. Hose 331 is not connected at the injector or house.
Hose 331 may be kinked or pinched.
When in High, 500-psi pressure must be at Hose 331.
When in Low, 0-psi pressure must be at Hose 331.

Power Pack Troubleshooting

Table 4.4 is a list of potential problems that you may experience with the V95HP QRU power pack
and some possible causes. For additional information, refer to the V95HP Quick Rig-Up Tractor
Manual, Tractor Operation, Troubleshooting.
Table 4.4V95HP QRU Power Pack Troubleshooting Suggestions
No hydraulic charge pressure. The power pack engine is not started.
The PTO is not engaged.
The 20-psi cracking check at the hydraulic tank needs to
be replaced (SAP No. 100022621).
The charge pump needs to be replaced.
The wrong filter cannister may be installed.
Hydraulic filter indicators Replace the hydraulic filters immediately.
showing bypass.
No 150-psi injector motor The injector motor precharge valve cartridge may need to
precharge. be replaced (SAP No. 101215657).
Hot oil shuttle gauge is not The relief cartridge may need to be replaced (SAP No.
showing 300350 psi pressure. 101215655).

Reel Troubleshooting
Table 4.5 is a list of potential problems that you may experience with the V95HP QRU reel and some
possible causes.
Table 4.5V95HP QRU Reel Troubleshooting Suggestions
The reel is not keeping pace Check the hot oil shuttle gauge at the power pack for
with the injector. 300350 psi pressure.
The bearings may be dragging. Grease bearings if
needed.
The reel motors may need to be replaced. Check that
case drainage is no more than 1.5 gal/min per motor.
The 100-psi relief on the case Hose 403 may not be connected at either the power
drain is popping off. pack or the reel.
Hose 403 is kinked.
The reel motors may need to be replaced. Check that
case drainage is no more than 1.5 gal/min per motor.
Check the quick-disconnects.
The reel brake will not release. In the control house, the brake valve is not in the release
position.
Hose 420 is not connected.
Hose 420 should have 500-psi pressure with the brake
released.


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V95HP Quick Rig-Up Unit

Operating and Maintenance

Part No. 101392331

Part No. 101392331

Section 2Operating Procedures

The V95HP QRU tractors are available in two options.

Tractor Operator house

January 2006 Description and Introduction 1-1

Operator house Segmented tubing guide

Figure 1.1Main components of the V95HP quick rig-up unit.

1-2 Description and Introduction January 2006

Shaftless reel design with direct-drive motors

January 2006 Description and Introduction 1-3

Coiled Tubing Operations Manual (CTOM, Part No. 997.09635)

Personal Protective Equipment (PPE)

1-4 Description and Introduction January 2006

Manuals and Other Resources

V95HP QRU Component Manuals

V95HP Quick Rig-Up Tractor Manual (SAP No. 101467495)

V95HP Quick Rig-Up Trailer Manual (SAP No. 101467450)

V95HP Injector Operation and Maintenance Manual (SAP No. 101332153)

QMC Crane Operation, Maintenance, and Parts Manual

V95HP Quick Rig-Up Reel Manual (SAP No. 101467452)

V95HP Quick Rig-Up Operator House Manual (SAP No. 101467453)

January 2006 Description and Introduction 1-5

Additional Resources Available on HalWorld

Halliburton CT Methods and Applications Website

CT Best Practices Website

Halliburton CT Recommended Spare Parts List

Coiled Tubing Handbook (Part No. 04-086)

Coiled Tubing Operations Manual (CTOM, Part No. 997.09635)

1-6 Description and Introduction January 2006

April 2007 Operating Procedures 2-1

2-2 Operating Procedures April 2007

a. Operate all controls for the hydraulic power package.

d. Operate all controls for the reel assembly.

a. Pull about 3 ft (1 m) of tubing out of the bottom of the tubing guide.

April 2007 Operating Procedures 2-3

f. Use the tubing guides four pins to secure it to the injector.

14. Insert the coiled tubing through the stripper:

a. Remove the tubing clamp from the bottom of the BOP.

April 2007 Operating Procedures 2-5

Pressure-Testing the BOP and Stripper

Use clean water as the pressure-test fluid.

1. Remove the tubing from the BOP, if necessary.

2-6 Operating Procedures April 2007

Normal Operation for Tripping In

Important Do not exceed the recommended injection rate.

2. Check the coiled tubing weight at about 1,000-ft (320-m) intervals:

April 2007 Operating Procedures 2-7

Normal Operation for Tripping Out

2-8 Operating Procedures April 2007

April 2007 Operating Procedures 2-9

2-10 Operating Procedures April 2007

Pre-Transport/Post-Transport CT Equipment Checklist

Power Pack Check

1. Hydraulic tank oil level. ( ) ( )

April 2007 Operating Procedures 2-11

1. Evidence of leaks in high pressure manifolding. ( ) ( )

2-12 Operating Procedures April 2007

Pre-Job Inspection Checklist

April 2007 Operating Procedures 2-13

2-14 Operating Procedures April 2007