CONTROL CONSOLES

Coiled tubing control consoles may vary in appearance from one unit to another because of the age and type of the unit. Check that the console control functions are standardized and meet the requirements outlined in the design specifications for coiled tubing unit control consoles.

60K Control ConsoleThe operator can control and monitor all of the CTU’s functions (including thestripper and the BOP) from the control console. Figure 1 shows the sevenmajor areas of the control console panel.Figure 1—Control console panel

The console operator can control the following functions:• engine start• engine stop• engine speed• engine emergency kill• injector-gripper pressure• injector-gripper direction(grip or retract)• reel direction• reel holding brake• reel tension (pressure)• levelwind override direction• levelwind boom direction

• injector holding brake• injector direction (in or out)• injector pressure• injector-motor displacement• stripper position (strip or retract)• stripper pressure• stripper hand-pump pressure• auxiliary BOP rams (three)• BOP blind ram• BOP cutter ram• BOP tubing ram• BOP slips ram• accumulator pressureThe console operator can monitor the following parameters:• wellhead pressure• tubing pressure• weight indicator• console operating pressure• console pilot control pressure• power-package engine tachometer• injector gripper pressure• reel pump pressure• injector pump pressure• injector pump torque/speed pressure• stripper hydraulic pressure• stripper hydraulic supply (operating) pressure• BOP hydraulic supply pressure• alternator charging for both the power packand the house

The console contains manual hydraulic pumps that can supply emergencypressure for the control of vital functions if the main pump fails. All directionalcontrol valves are closed when the knob or lever is centered.

Engine ControlThe engine controls are located in the upper left area of the control console panel(Figure 1) The engine control area of the control console panel isshown in Figure 2.Figure 2—Engine control area of the console

The START, sTOP, and EMERGENCY KILL push buttons start and stop the engine. Allengine controls are pneumatically operated. The AIR THROTTLE regulating valvecontrols the engine speed. Clockwise rotation of the valve increases enginespeed. The tachometer at the far left side of the control console panel shows theengine speed.Note If you use the EMERGENCY KILL, you must reset the kill cylinderbefore the engine will restart.The controls for the outside flood lights, the air conditioner, and the heater arealso in this area. Underneath the tachometer controls are the voltmeters desig-natedfor both the power pack and the house alternators.

Primary InjectorThe PRIMARY INJECTOR or “gripper” controls are located on the left side of theconsole (Figure 1). The gripper control area of the control-consolepanel is shown in Figure 3.

Figure 3 – Primary Injector or Gripper control area of the console

The GRIPPER POSITION lever controls the engagement of the grip cylinders and thegripper blocks. The lever has two positions: GRIP and RETRACT. Once it is placedin the required position, the lever locks in place. Positioning the gripper positionlever to the GRIP or RETRACT position directs hydraulic pressure to the linear-beamgrip cylinders. In the grip position, applied pressure to the grip cylinders causesthe linear beams to exert pressure on the tubing OD through the gripper blocks.Sufficient pressure prevents the tubing from sliding in the gripper blocks as thetubing is injected into or removed from the well.Turning the GRIPPER PRESSURE ADJUST knob clockwise increases the gripperpressure. The gripper pressure must be adjusted to a level high enough toprevent slippage of the tubing at operating loads.Although pressure can be increased from the console, the operator must firstadjust the pressure to the required value and then open the bleed valve at theinjector's accumulator until the pressure is stabilized at the required value. Thisprocess is necessary because of a safety pilot-operated check-valve that preventsthe loss of beam pressure when hydraulic pressure is lost.

The OPEN FOR GRIPPER HAND PUMP valve should be closed under normal operatingconditions. If, however, hydraulic pressure is lost, the accumulator on theinjector should hold gripper pressure. If this accumulator pressure starts drop-ping,open the OPEN FOR GRIPPER HAND PUMP valve by turning the valve counter-clockwise.Then use the manual hand pump located under the console to holdpressure on the gripper blocks until the BOP can be activated or until the tubingis stable.To maintain control of the coiled tubing workstring, you must apply sufficientlinear beam pressure to the tubing to prevent slippage between the tubing and thegripper blocks. The recommended linear beam pressure for a given hoisting loadfor the 60k injector is defined by the following equations:p = 200 psi (when Q < 10,000 lb)p = Q ÷ 50 psi (when Q > 10,000 lb)where p is the hydraulic pressure (psi) applied to the linear beam cylinders(indicated by the operator control console gauge labeled GRIPPER PRESSURE) and Qis the axial hoisting load (lb) on the tubing.

Note These recommended values are based on conservative assump-tions.Many factors affect the gripping efficiency of the gripperblocks. Therefore, different beam pressures may be used basedon the conditions present.Excessive gripper pressure places unnecessary stress on the tubing and can resultin decreased tubing life and damage to the tubing. See the Gripper Block forCoiled Tubing Injectors Manual (Part No. 70.51140) for recommended gripperpressures for various tubing sizes and wall thicknesses.The GRIPPER PRESSURE gauge indicates the pressure applied to the gripper.

Reel ControlsThe reel and levelwind controls are located in the REEL area at the bottom of thecontrol console (Figure 1). The reel control area of the control-consolepanel is shown in Figure 4Figure 4—Reel control area of the console

The REEL TORQUE LEVER controls the direction and winding force of the tubingreel. The lever operates the directional valve to the main reel motor. The SLACK

(spool-off) position causes the reel to rotate in a direction that unwinds thecoiled tubing.Caution Care should be taken to prevent the tubing from unwrap-pingand birdnesting when the reel is in the slack mode.Unwrapping could result in tubing damage.The TENSION (spool-on) position causes the reel to rotate in a direction thatrewinds the coiled tubing. During normal operations, the reel is kept in theTENSION position all the time to ensure that the coiled tubing remains tightlywound on the reel.The MAX PRESS ADJUST knob controls the hydraulic pressure to the reel drivemotor. This knob is connected to the high- and low-set pressure-relief valveslocated on the reel’s power pack manifold block. Turning the knob clockwiseincreases the torque of the reel drive motor. Monitor the reel pressure during thejob and adjust it as necessary to maintain a consistent coiled tubing wrap on thereel.The PUMP pressure gauge indicates the reel pump pressure when the REEL TORQUE

valve is in the TENSION position.The HOLDING BRAKE knob sets and releases the brake on the reel. The reel holdingbrake is located inside the reel planetary gear box. The brake is a fail-safe, disc-type,spring-set/pressure-release brake. In the SET position, the hydraulic pres-sureis dumped off the brake piston, and the springs set the brake. In the RELEASE

position, pressure is applied to the brake piston and the brake is released to allowreel rotation.Caution Do not set the reel holding brake while the reel is turning.The reel holding brake is a parking brake only.Occasional interruption of the auto-levelwind may be necessary to ensure thatthe tubing wraps are uniform. The LEVELWIND OVERRIDE knob allows the operatorto interrupt the automatic levelwind mechanism on the reel to adjust the wraps of

tubing. The knob is spring-biased to the center (neutral) position. When the knobis released, it stops the override function and re-engages the automaticlevelwind.The LEVELWIND BOOM knob allows the levelwind tubing guide to be raised (UP) orlowered (DOWN) so that the correct relationship between the reel and the injectortubing guide can be made for optimum operation. The valve is also spring-biasedto the center position.

Injector ControlsThe injector pump and motor controls are located at the bottom center of theconsole (Figure 1). The injector control area of the control consolepanel is shown in Figure 4.

Figure 4 –Injector control area of the console

The INJECTOR SPEED lever (Munson-Tyson valve) controls the speed and directionof the injector. Specifically, it directs pilot pressure to the injector directionalcontrol, which both establishes the direction of the injector and functions as aflow-control valve that controls the amount of fluid to the motors. The injectorspeed is controlled relative to how far from the center position the lever isplaced. The injector is stationary when the lever is centered, and the injector is atfull speed when the lever is positioned in either of the extreme positions.The MAX PRESS ADJUST knob controls the hydraulic pressure at the injector drivemotors. The knob operates by venting the main relief valve on the powerpackage’s injector manifold. Turning the MAX PRESS ADJUST knob clockwiseincreases the power of the injector motors. The MAX PRESS ADJUST knob should beadjusted to the minimum amount of pressure necessary to overcome the load-inducedresistance.

The PUMP pressure gauge indicates the injector motor pressure regardless of thedirection of rotation. The gauge also acts as a spare weight indicator by takingthe pressure shown and multiplying by a factor of 12.Note The weight indicator is a more accurate device for measuring theactual injector forces.The LOW SPEED/HI TORQUE/VAR knob allows the operator to select the injectormotor’s mode of operation. In the LOW SPEED/HI TORQUE mode, the motors operateat maximum displacement (low speed) for maximum torque. In the VAR (vari-able)mode, the operator can change the motor displacement, and therefore,affect the injector motor speed and torque in special applications.

Note When the injector is in variable mode, the backpressure on thesystem can cause the injector speed to change. For example,operating the levelwind override causes the return pressure toincrease; the increase in return pressure causes the injectorspeed control pressure to increase, which causes the injectorspeed to increase.The ADJUST knob to the right of the LOW SPEED/HI TORQUE/VAR knob controls thespeed and torque of the motors in the VAR mode. Clockwise rotation of the knobincreases motor speed and causes a corresponding decrease in available torque.The pressure gauge next to the ADJUST knob indicates the injector motor controlpressure.The HOLDING BRAKE knob controls the injector holding brakes inside the planetarygear boxes that drive the injector. The brakes are fail-safe, disc-type, spring-set/pressure-release brakes. In the SET position, the hydraulic pressure is removedfrom the brake piston, and the springs set the brake. In the RELEASE position,pressure is applied to the brake piston, and the brake is released to allow rotationof the motors.

BOP ControlsThe valves and gauges controlling and displaying the operating conditions of theBOPs are located on the right side of the console. (See Figure 1) TheBOP control area of the control console is shown in Figure 5.Figure 5—BOP control area of the console

The BLIND, CUTTER, SLIPS, and TUBING levers control the rams on the quad blowoutpreventer. The three spare levers allow the operator to control additional safetyBOPs. For all BOP rams, the control-valve levers are locked in both the open andclose position to prevent inadvertent selection of either mode. The BOPs arenormally engaged when the tubing is stationary. Closing the BOP rams whilerunning tubing can interfere with tubing operations and damage the tubing.Dynamic well-pressure control is maintained with the stripper. To activate the BOPrams, disengage the locks, place the valve in the CLOSE position, and engage thelocks. To retract the rams, place the valve in the OPEN position.

If a system hydraulic failure occurs, a check valve on the supply side of the BOPcontrol manifold isolates the BOP controls. The house’s accumulator package cansupply power to operate the BOPs if the main system pressure is lost. A handpump is also available as a final emergency supply.The SUPPLY pressure gauge indicates the hydraulic pressure available for operat-ingthe BOPs. The gauge does not indicate the pressure available from theaccumulators.In the event of power loss from the power package, the accumulators storeenergy in the form of fluid pressure. The accumulators store enough energy toclose all BOP rams 1.5 times or to close, open, and close all the rams under“worst case” conditions.The OPEN FOR BOP HAND PUMP valve should be closed under normal operatingconditions. If hydraulic power is lost, the accumulators should supply power toactivate the BOPs. If, however, accumulator pressure is lost, open the OPEN FOR

BOP HAND PUMP valve by turning the valve counterclockwise. To activate the BOP,engage the BOP ram knob and use the manual hand pump.The ACCUMULATOR lever control releases pressure stored in the accumulators aftera job. All pressure should be released before any hoses are disconnected.

Stripper ControlsThe valves and gauges controlling and displaying the operating conditions of thestripper are located at the lower right side of the console (Figure 1).The stripper controls area of the control console is shown in Figure 6.Figure 6—Stripper control area of the console

The STRIPPER POSITION lever directs hydraulic pressure to the stripper. Moving thelever to the STRIP position applies pressure to the port which squeezes the stripperaround the tubing. This action provides a seal around the tubing to controlwellhead pressure. The RETRACT position removes pressure from the stripper.The STRIPPER PRESSURE ADJUST knob controls the amount of pressure (squeeze)placed on the tubing. Turning the knob clockwise increases the pressure.The HYDRAULIC SUPPLY pressure gauge indicates the pressure available for operatingthe stripper.

The STRIPPER PRESSURE gauge indicates the pressure being applied to the stripper.The OPEN FOR STRIPPER HAND PUMP valve should be closed under normal operatingconditions. If, however, hydraulic pressure is lost, open the OPEN FOR STRIPPER

HAND PUMP valve by turning the knob counterclockwise. Make sure that theSTRIPPER POSITION valve is in the correct position and use the hand pump locatedunder the console.To release the hand pump pressure to the stripper, open the valve labeled STRIP-PER

DUMP. The STRIPPER DUMP valve can also be used to reduce the stripperpressure without moving the STRIPPER POSITION lever into its RETRACT position.

Miscellaneous InstrumentsMiscellaneous gauges and instruments are located in the upper center, upper left,and upper right of the control console panel (Figure 1). These areas of the control console panel are shown in figure 7.

Figure 7 – Miscellaneous instruments area of the control console.

.The CONSOLE PRESSURE gauge indicates the operating pressure of the main hydraulicsystem.The PILOT PRESSURE gauge indicates the console pressure provided (500 psi or3400 kPa) to operate other console valves.The WELLHEAD PRESSURE gauge indicates the wellhead pressure. The gauge isisolated from the well fluids by a pressure debooster.The TUBING PRESSURE gauge indicates the pressure on the tubing. The gauge isisolated from the well fluids by a pressure debooster.

Caution The WELLHEAD PRESSURE gauge and the TUBING PRESSURE gaugeare special gauges with a 1:4 sensing-to-indicating ratio. Ifreplaced, these gauges must be replaced with identicalgauges. Failure to do so will result in pressure readings thatare only 25% of the actual wellhead or tubing pressure.The digital and analog weight indicators indicate the weight being supported bythe load pins located at the bottom of the injector. If properly “zeroed,” theseweight indicators will indicate the tubing loads, such as tubing weight andsnubbing force.Both weight indicators are a part of the data acquisition system (DAS). SeeSection 10, 60k CTU Data-Acquisition System and the DAS manuals (Part No.516.99006 and Part No. 516.99007) for more information.

30K/38K Control Console

The operator can control and monitor all of the CTU’s functions from the control console. Figure 8 shows the controls for a standard 30/38K coil tubing unit.

Figure 8 -

The console operator can control the following functions:- engine start- engine stop- engine speed- engine emergency kill- injector gripper pressure- injector gripper direction- reel direction- reel tension- levelwind override direction- injector direction(in or out)- injector speed- injector speed selector (high and low)- stripper pressure- stripper position- BOP blind rams- BOP cutter rams- BOP tubing rams- BOP slip rams- auxiliary BOP rams (three)- accumulator pressure The console operator can monitor the following parameters:

- wellhead pressure- tubing pressure- weight indicator- console operating pressure- injector gripper pressure- reel tension pressure- stripper hydraulic pressure- BOP supply pressure

The console contains manual hydraulic pumps that can supply emergency pressure for the control of vital functions if the main pump fails. All directional control valves are closed when the knob or lever is centered.

Engine ControlThe START, STOP, and EMERGENCY KILL push buttons start and stop the engine. All engine controls are pneumatically operated. The AIR THROTTLE regulating valve controls the engine speed.NOTE: If you use the EMERGENCY KILL, you must reset the kill switch on the power pack before the engine will restart.

Injector ControlsInjector “In – Out” (Directional Control)

The injector direction is selected manually by positioning the lever to the “in” or “out” position. This valve directs pilot pressure to the main directional control valve located on the power pack and causes the valve to supply power to the injector drive motor ports.

Injector Adjust (Pressure Control)The hydraulic pressure at the injector drive motors can be limited by adjusting the “injector pressure control” valve. This valve is an adjustable relief valve that is connected by a hose to the vent port on the main relief valve on the injector manifold block of the power pack. Turning the injector adjustment valve knob counterclockwise causes the maximum pressure directed to the injector motors to decrease. The adjusted pressure is the maximum pressure that is available to do work. It is a good operating practice to adjust this control only high enough to overcome the load induced resistance.

Injector ‘In – Out” Pressure GaugesTwo pressure gauges are mounted to the panel. One indicates the actual injector motor pressure in the “in” direction and the other in the “out” direction. By monitoring the pressure on the gauge and using the pressure factor found in the Injector section of the manual for the injector in use the operator may calculate the approximate load.NOTE: The weight indicator is a more accurate device for measuring the actual injector forces.

Beam Pressure (Injector Gripper Control)Positioning the Beam Pressure control lever to the “on” or “off” position directs hydraulic pressure to the linear beam cylinders. Application of pressure to the “on” cylinder ports causes force to be exerted on the tubing OD by the linear beams. The force then generates the frictional reaction force necessary to grip the tubing without sliding the gripper blocks on the tubing.NOTE: This control should have a “Weevil lock” on it to keep it from being accidentally moved to the “off” position while pipe is in the hole.

Beam Pressure Adjust (Injector Gripper Pressure Control)

The magnitude of the tubing frictional force is proportional to the amount of lateral force generated by the gripper cylinders. The gripper pressure must be adjusted to a level high enough to prevent slippage of the tubing at the operating loads. Too high a setting, however, places unnecessary stresses on the tubing. Higher stresses cause the life of the tubing to decrease. High gripper pressures also accelerate the wear rate on the injector chain components. A nominal setting of 1000 psi is recommended. Turning the knob clockwise increases the gripper pressure.Gripper pressure is isolated at the injector by a pilot operated check valve. Reducing the pressure on the house gauge will not reduce the pressure on the gripper beams. If the pressure needs to be reduced there is a bleed off valve on the injector where this may be done. The operator must first adjust the pressure to the required setting and then open the bleed off valve until the pressure is stabilized. Extreme care should be taken when doing this. NOTE: Refer to the “Gripper Block for Coiled Tubing Injectors Manual” (Part # 70.51140) for recommended gripper pressures for various tubing sizes and wall thickness.

Aux. BeamIf hydraulic pressure is lost on the console, the beam pressure has a check valve, which isolates it and allows pressure to be maintained on the beams. If this pressure starts dropping or needs to be raised the Auxiliary Beam two-way valve should be switched from the “Off” position to the “On” position. There is an emergency hand pump, located below the console, that will allow the operator to supply pressure to the beams when this valve is in the “On” position

Beam Pressure gaugeThe gauge “Beam Pressure” indicates the amount of hydraulic pressure that is being applied to the gripper cylinders on the injector.

Speed Control “High – Low”The injector speed selector has a pre-set pressure on most units and only needs to be shifted to high or low to be activated. On some older units this control has a pressure control adjustment which needs manually set. This should be set at 1500 psi. When running in the hole the 30K injector should be shifted from high to low when the weight reaches approximately 10,000 lbs. When pulling out of the hole it may be shifted back into high when the weight reaches approximately 10,000 lbs. The injector should be stopped and put in neutral to carry out this operation.The 38K injector may be shifted at 12,000 lbs.

Chain OilerThe chain oiler air operated button provides the operator with a means of lubricating the chains while tripping in and out of the hole. The chains should be oiled approximately every 10,000 running feet. Refer to the Injector section of this manual for types of acceptable lubricating oil.

Pump “A”, “B”, “C”Three two-way ball valves mounted on the panel permit the operator to selectively engage the main injector drive pumps on the power pack. Setting the dump valve to the “vent” position causes the pump unloader to vent, thus diverting the entire pump flow to the tank. Venting all three valves will unload all three pumps. This is a convenient method of selecting injector speed by diverting some of the excess flow to the tank at a low pressure drop. The other method of controlling injector speed is to reduce the injector pressure until the relief valve bypasses some of the fluid flow. The excess pump flow will then be dumped across the main pressure relief valve, reducing the flow to the motors and causing the speed to decrease. A disadvantage of this speed control method is the wasted energy that is evident by the heat input into the hydraulic oil.

Reel Controls

Reel “In – Out” (Directional Control)The Reel directional control valve is used to select the direction that the reel turns. Positioning the lever to either the “In” or “Out” position causes a pilot signal to shift the main reel motor directional valve (on the power pack) in the direction to power the reel motor to the “in” or “out” direction. In most normal operations, the reel will always be in the “out” mode, whether going in or pulling out of the hole. It is necessary to maintain tension on the reel to prevent birdnesting.

Reel AdjustThe Reel Adjust valve allows the operator to adjust the pressure that is powering the reel drive motor. Turning the knob counterclockwise decreases the pressure at the motor port. This valve is connected to the high and low set pressure reducing relief valves located on the power pack reel manifold block. The reel pressure should be monitored during the job and adjusted as necessary to maintain a consistent wrap on the reel.

Reel Motor Pressure gaugeThe reel pressure gauge located on the panel permits the operator to monitor the hydraulic pressure to the reel drive motor that is producing the tension on the tubing.

LevelwindOccasional interruption of the auto-levelwind may be necessary to ensure that the tubing wraps are uniform. The “Levelwind” directional control knob allows the operator to override the auto-levelwind when necessary. The operator should observe the direction that the levelwind carriage moves when the valve is selected. BOP & Stripper Controls

BOP Control ValvesThe Blind, Cutter, Slips and Tubing levers control the rams on the quad blowout preventer. The three spare levers allow the operator to control additional safety BOP’s. For all BOP rams, the control valve levers are locked in the open position to prevent accidental closing. The BOP’s are normally engaged when the tubing is stationary. Closing the BOP rams while running tubing can interfere with tubing operations and damage the tubing. To activate the BOP rams, disengage the locks and place the valve in the CLOSE position. To retract the rams, place the valve in the OPEN position.

BOP Pressure gaugeThe BOP Pressure gauge allows the operator to see the hydraulic pressure available for the BOP functions.

Aux. BOPIf a system hydraulic failure occurs, a check valve on the supply side of the BOP control manifold isolates the BOP controls. The house’s accumulator package can supply power to operate the BOPs if the main system pressure is lost. The Auxiliary BOP two-way valve should be switched from the “Off” position to the “On” position and the desired BOP valve selected.A hand pump, located below the console, is also available as a final emergency supply.

StripperThe stripper valve is a two way valve that allows the operator to select the “Dump” position for decreasing or bleeding off the pressure on the stripper or select the “Off” position to maintain the required hydraulic pressure on the stripper.

Air RegulatorThe Air Regulator allows the operator to adjust the amount of air pressure needed to activate the pneumatically powered pump mounted underneath the console. This pump supplies the pressure to hydraulically energize the stripper packoff.

Air Pressure gaugeThe air pressure gauge located on the console lets the operator see how much air pressure is being applied to the pneumatic powered pump.

Stripper Pressure gaugeThe stripper pressure gauge allows the operator to see how much hydraulic pressure is being applied to the stripper packoff.

Aux. StripperIn the event of a system hydraulic failure or loss of air supply, a check valve on the supply side of the stripper isolates the stripper to prevent loss of pressure. The auxiliary stripper two-way valve may be switched from the “Off” position to the “On” position and pressure may be supplied with the emergency hand pump, located below the console.

Miscellaneous Instruments

The Console Pressure gauge indicates the console pressure available to operate the console valves. This pressure should normally be at 1500 psi.

The Wellhead and Tubing Pressure gauges read the pressures on the wellhead and tubing. These gauges are each isolated from well fluids by pressure deboosters.NOTE: On some units these gauges are special gauges with a 1:4 sensing to indicating ratio. If replaced, these gauges must be replaced with identical gauges. Failure to do so will result in pressure readings that are only 25% of the actual pressure.

Weight Indicators may be digital, analog or bladder type.The digital and analog weight indicators indicate the weight being supported by the load pins located at the bottom of the injector. If properly “zeroed,” these weight indicators will indicate the tubing loads, such as tubing weight and snubbing force. Both indicators are a part of the Data Acquisition System (DAS). See the DAS manual (part # 516.99007) for more information.The bladder type (Martin-Decker) weight indicator only indicates tubing weight and will not measure snubbing forces.

There are toggle switches located on the console for operation of lights, heater, air conditioner and crane on most units.