CPI-80 INJECTOR MANUAL

April, 2012

Model CPI-80 Injector Specifications:

 Pull Force - 80,000

 Snub Force - 40,000
 Motors - 4 x MSE-11-1 POCLAINS
 Brakes - Internal, hydraulic release
 Height - 64”
 Length - 40”
 Width - 36”
 Weight - 4800 lbs.(including gooseneck)
 Chain Type - 140-3
 Speed High - 40 meters/minute at 60 GPM hydraulics
 Speed Low - 20 meters/minute at 60 GPM hydraulics
 Tubing Sizes - ¾” through 2-3/8”

Drive & Braking System:

The injector is driven by four MSE 11-1 POCLAIN hydraulic cam lobe radial piston
motors. These have a splined shaft drive that slips in from both ends to our drive
sprockets. This positions our drive chain sprockets directly over the motor shafts, thus
transferring the torque from the motors directly to the driving sprockets. This injector
requires 60 gallons per minute with pressures up to 5800 psi.

Each motor has its own internal multi-disc brake which is hydraulically released (fail
safe). These brakes can hold 1½ times the torque of the motors. The motors also have a
two speed capacity which gives high speed low torque and low speed high torque.

Manual-CPI-80 Page 1 of 12 April, 2012

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Traction System:

Traction to the tubing is gained from a 36” long hardened skate bar, with skate roller
chains riding around the circumference of the skate bar. When the six skate cylinders are
closed, the skate rollers transfer the pressure from the skate on to the back of the injector
dies. At any time there is always a minimum of two rollers touching the injector die.

Skate Cylinders:

There are six 3.5” bore skate cylinders per Injector putting out a total retraction force at
3000 psi of 150,600 lbs. Most jobs require a maximum of 1000 psi skate pressure but this
can vary with the type of well, size of pipe and oily/waxy wells. Always use as low a
skate pressure as required; this will result in longer life of the skates, rollers and dies, as
well as better pipe life.

Skate Chains & Rollers:

The rollers are machined out of 4140 shaft and hardened to approximately 54 Rockwell.
Celtic performed a destructive test on these rollers and the average fail pressure was
136,000 lbs. force. At the full 3000 psi skate pressure, the most pressure these rollers
should ever see is 3140 lbs.

Celtic Pride uses only Diamond oilfield chain, for the skates we use 100-2 connectors.
There are 66 rollers and 33 connectors per chain per side.

Skate Wear Strip:

A tool steel wear strip is attached to the skate face. This part takes all of the pressure and
wear from the skate rollers. This tool steel strip is also hardened to approx. 56 Rockwell.
In the event of eventual wear on the skate, the tool steel strip should be the only part that
will need to be replaced, not the whole skate.

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Injector Dies & Chain:

The injector dies are either cast with a machined face, or a fully machined 4140 die with
seven horizontal ribs. Either way, the face is machined to get a perfectly even size on size
fit with the pipe. The dies are also hardened to approx. 56 Rockwell for longer life. These
dies come in sizes from ¾” through to 2-3/8”. The die/chain size is 140-3 with 70 dies
per chain per side. A destructive test was also performed with the fully machined dies.
220,000 lbs. force was applied via a size on size solid shaft with no damage to the die.
This test was also done with cast dies with a force of approx. 70,000 lbs. breaking the die.
At full 3000 psi skate pressure, the most force each die should see is 3960 lbs.

Accumulator Bottles:

A 1 quart accumulator bottle is tied into the skate system to help avoid breaking dies or
cylinders in the case of a larger object being pulled into the injector without skate
pressure being relieved. Most skate hydraulic circuits will have a pressure reducing relief
cartridge to maintain the set pressure at all times. But in the event of a large object going
through the injector at speed, this cartridge may lock up if the shock is too large.
Normally, the skate circuit and stripper circuit will be tied into a 5 gallon accumulator
bottle so in the event of hydraulic failure, both circuits will have a back-up supply.

Main Chain Tension:

Chain tension is applied through vertically moving the lower idler sprocket plate up or
down through the means of a turnbuckle. When the required tension is reached, 8 x ¾”
locking bolts are then tightened to help keep it in place. Hydraulic chain tension is also
an option but we have discovered in the past that with this system, it is too easy to over-
tension the chains.

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Skate Chain Tension:

The skate chain tension is applied by loosening off the four ½” holding bolts and turning
the 1” ratchet system. Approximately 200 foot lbs. should be applied to this tensioner to
help keep the skate rollers on the guide groove and to reduce injector noise.

Arch:

The arch has a 72” radius with 16 aluminum arch rollers. The arch is split in the middle
with a 3” bore hydraulic cylinder folding and opening the arch. The hydraulic cylinder
has a built in holding valve attached in the event of hose failure, etc. The end section of
the arch is flared to allow the tubing to move freely across the drum. Because of the
excessive length of the arch when fully opened, an aluminum safety channel is supplied
as a back-up to the holding valve on the cylinder. The arch is designed to accommodate a
Celtic spring mounted magnetic pickup counter wheel.

Injector Cage:

The injector is enclosed in a rectangle tubing cage designed with fifteen pickup points.
The purpose of the cage is to ensure the pull from the picker will not interfere with the
weight indicator. The cage is engineered for 12,000 lbs., with a safety factor of 5:1.
The injector is designed to be used with either an electronic or hydraulic load cell.

Side Door Stripper:

The base of the injector is designed to accommodate any side door stripper of the
customers choosing. Normally, a 5K Celtic side door stripper or a 10K Progressive side
door stripper is used. The Injector will be plumbed with two 3/8” lines for stripper
operation along with a ¼” line for stripper lube.

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PHONE 403-362-7044 FAX 403-362-7011 CELL 403-501-1180

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Injector Performance:

QTY of Meters 4 Torque Per Motor in lbs. Force Per Motor Rpm Per
in lbs. Motor
Displacement 76,751 22,741 33.185
cc/each 1536
Sprocket
Diameter " 6.75
Mechanical TOTAL INJ 90,965 STATIC 72,772
Efficiency 0.93 PULL PULL
Volume Meters Min- 17.865 Meters Min-High 35.731
Efficiency 0.95 Low
Pressure PSI 5800
Flow GPM 60 Models Displacement
Charge PSI 300 MS11-0 1048
MS11-1 1147
MSE11-0 1404
MSE11-1 1536 ( 95 K )

Injector Motors:

The Injector motors are a cam load radial piston type, the total Injector pull is achievable
if the cams are able to rotate. The brakes are a pressure release type for safety reasons, in
that if hydraulic pressure is lost, the brakes will automatically apply within approx. three
seconds. If the brake lines are removed for any reason, the Allan Head Bleed Screw
should be removed and brakes functioned to bleed any air out of the system. This bleed
screw is located on the back of the brake housing.

Always ensure the charge pressure stays at approx. 300 psi. At around 180 psi, the brakes
will start to apply, the maximum pressure before any seals start to blow is 425 psi.
The maximum working pressure for the MSE 11-1 motors is 5800 psi.

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PHONE 403-362-7044 FAX 403-362-7011 CELL 403-501-1180

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Counter:

The counter wheel is spring mounted at the base of the arch, it consists of a one meter
circumference flat wheel with 36 magnets pressed into an aluminum face. These magnets
are installed positive, then negative all the way around. The magnetic pickup is bolted to
the outside of the arch reading the pulses of the magnets. The pickup should be approx.
¼” away from the magnets.

Control Panel – Operating the Injector:

The HUSCO joystick is designed in such a way that the further forward or backward you
move the joystick, the faster the chains will turn. The joystick has a de-tent kit that will
hold it at whatever speed is selected. The joystick only controls the speed, not the force
pulling. The injector will stop once the joystick is returned to neutral.

When not in use, always engage the injector brakes and return joystick to neutral.

The Hydraulic conversion of….

The in-hole relief valve is set to a maximum of 4000 psi. Even this pressure is high for
normal operations as too much in-hole pressure can cause the pipe to be damaged or bent
if a collar or obstruction is hit going in-hole.

The out-hole relief is set to use the full capacity of the LINDE hydraulic pump. If
required, a full 6000 psi can be dialed in. As a quick guide, in low speed at 6000psi relief
pressure the Injector can pull 80,000lb. In high speed at 6000psi it can pull 40,000lb.

When running pipe in-hole the operator must ensure he has enough out-hole pressure on
the relief valve to hold the string weight from running away. For example, a rod string of
20,000lb would need at least 1500psi relief pressure in low speed and 3000psi in high
speed.

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When running in-hole, if desired, the operator can dial the out-hole relief in completely to
ensure he will always have enough back pressure holding the pipe.
The two speed can be changed on the fly, but it is advisable to slow down before
switching speeds from high to low or vice versa.

The skates and stripper are usually tied into a separate 5 gallon accumulator bottle, in the
case of losing hydraulic pressure you will still have these functions. If pressure on the
accumulator circuit is available, the skates can handle up to 3000 psi for short periods.
For most operating procedures, pressures of up to 1200 psi will be more than sufficient.
The rule of thumb is to use as little pressure as required to grip to the pipe without
slipping. This can vary depending on the depth of the well, obstructions in the well, the
condition of the co-rod and the condition of the dies. The lower the skate pressure, the
better the wear life you will get out of the dies, skate pins, cylinders, etc.

The injector brakes work via a pressure release system. This safety feature means that if
you lose hydraulic pressure, the brakes will automatically activate. This can be manually
over-rode if required.

In the event of a run-away immediately activate the Injector brakes, these brakes can
handle 1 ½ times the force of the motors.
Always ensure sufficient out-hole pressure when running in hole to prevent the pipe
getting string heavy.

CAUTION: ENSURE all operators and/or personnel are trained and confident
with use of Injector operations and your company has established
safe work procedures
ENSURE all operators follow all OHS regulations
DO NOT use more skate pressure than required
DO NOT switch high/low speed without slowing down
ALWAYS ensure injector is in neutral and activate injector brakes
when not in use

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PHONE 403-362-7044 FAX 403-362-7011 CELL 403-501-1180

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www.celticpride.ca celticpride@eidnet.org
Maintenance:

BEARINGS
The only bearings on the Injector are the sealed idler bearings which have an average of
three years of life depending on the use.

GREASE NIPPLES:
12 skate cylinder bushings, grease once a month to prevent parts from seizing up.

INJECTOR CHAINS – LUBRICATION AND TENSIONING

Keep the injector chains well lubricated. We recommend white lithium spray grease at
least a full can once a week.
The main injector chain will need to be adjusted as required. When the chain tension is
correct, you should be able to pull out approximately 1” of deflection in the center of the
chain by hand.
CAUTION: NEVER TEST TENSION UNLESS BRAKES ARE ON AND JOYSTICK
IS IN NEUTRAL.

SKATE CHAINS
The 100-2 skate chain must be checked monthly for wear. The cotter pins should be
checked regularly to ensure all are in place and not damaged.

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Standard Injector Parts Breakdown:

 4 x MSE 11-1 POCLAIN motors

 2 x 140-3 drive sprockets
 2 x 140-3 idler sprockets
 4 x idler roller bearings
 2 x 7-3/8” idler pins
 2 x 6” x 5/8” idler plates
 2 x chain tension turn-buckles
 4 x 1¼” turn-buckle pins
 6 x 3 1/2” bore skate cylinders
 1 x 3” bore arch tilt cylinder
 6 x 2” skate pins
 2 x adjustable skates
 2 x 100-2 skate chains (64 rollers per side)
 2 x main injector chains (74 dies & saddles per side)
 2 x upper side safety guard plates
 2 x lower side safety guard plates
 1 x 1 meter counter wheel and bearings
 1 x magnetic pick-up
 13 x standard aluminum arch rollers
 4 x flared aluminum arch rollers
 2 x 12” x 2 3/8” side arch rollers
 Electronic or hydraulic load cell

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PHONE 403-362-7044 FAX 403-362-7011 CELL 403-501-1180

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 Motor Hoses

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Manual-CPI-80 Page 11 of 12 April, 2012

PHONE 403-362-7044 FAX 403-362-7011 CELL 403-501-1180

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Manual-CPI-80 Page 12 of 12 April, 2012

PHONE 403-362-7044 FAX 403-362-7011 CELL 403-501-1180

MAILING ADDRESS: BOX 89 RAINIER, AB T0J 2M0 SHOP: LOT 5, MARTIN INDUSTRIAL PARK, BROOKS, AB
www.celticpride.ca celticpride@eidnet.org