Description

Offshore Coil Tubing Skid Unit 80K

Overview

This complete offshore coil tubing unit (CTU) is a fully skid-mounted, rig-safe system engineered for demanding offshore well intervention operations. The package includes five major assemblies: a Control Cabin/Hose Reel Skid, Hose Reels & Hoses, a High-Pressure Open-Loop Power Pack, a Gear Drive Tubing Reel Assembly, and an Injector Head — all sandblasted, primed, painted, and factory acceptance-tested at a USA facility. The Unti comes with an additional 80K Injector HR680 fully refurbished.

Major Components

1. Control Cabin / Hose Reel Skid

• Aluminum cabin with 4-point lift and full surrounding crash frame (pin-connected for removal)
• Cabin elevates via four (4) hydraulic cylinders with mechanical lock; interior approx. 111″ (L) × 76″ (H)
• Explosion-proof exterior floodlights and interior lights wired to Zone II, UL Class I, Division II, Groups A, B, C & D (220V – 50Hz)
• Explosion-proof rooftop air conditioning unit
• Sliding access platforms with ladders, anti-slip grating, and handrails
• Full-width forward window (high-strength ¼” glass) with electric windshield wiper system
• “L”-shaped control console featuring:
  • 8-bank BOP control valve with flip-up lockout latch
  • Dual 6″, 15,000 PSI gauges (wellhead & circulating pressure, 4:1 de-boosted)
  • 80,000 lb. weight indicator (injector)
  • CTES monitoring system (Orion & Cerberus)
  • Electronic engine speed, kill, and emergency kill controls
  • Injector traction, brake, chain tension, and speed controls
  • 3-bank hydraulic valve for reel pay-off/take-up, levelwind raise/lower and override
• Air-driven emergency backup pump (5,000 PSI to stripper)
• Skid Dimensions: 14′ (L) × 8’6″ (W) × 8’2″ (H) | Weight: 12,000 lbs.

2. Hose Reels & Hoses

• (1) Hydraulically powered hose reel for injector control hoses (125 ft, size-optimized)
• (1) Hydraulically controlled BOP hose reel with 12 hoses × 125 ft (fire-resistant last 15 ft) + 4 extra BOP lines
• Skid-mounted hydraulic power hose reel for two (2) 1-½” × 125 ft injector power hoses
• Bulkhead panel for direct jumper-hose connection; reels are removable from cabin skid
• All hose bundles: quick disconnects with indexed connections, oil-resistant jacketing, chain support for weight during operation
• Cold-drawn steel drive sprockets (not cast)
• 30 ft jumper hose bundle included for power unit connection

3. High-Pressure Open-Loop Power Pack

• Engine: Caterpillar C-15 Diesel, rig safe, with triple pump drive on flywheel housing
• Full protective 4-point lift frame (welded, fully surrounding)
• Stainless steel / waterproof control panel with electric throttle, electronic fuel kill, emergency air shutoff, and engine gauges
• System shutdowns: over-temperature, overspeed, loss of oil pressure, loss of coolant, high exhaust temperature
• Spark arrestor exhaust, sealed crankcase, crankcase breather flame traps, anti-static fan drive belts
• Diesel-lubricated air starter with 30-gallon reservoir; Bendix AD-9 air dryer (rated to 100% humidity, -10°C to +45°C)
• 12 CFM engine-driven air compressor
• All hydraulic pumps: Denison brand
• Injector drive: 120 GPM Denison variable displacement open-loop load sense axial piston pump
• Stainless steel hydraulic oil reservoir (240-gallon capacity) and fuel tanks (100-gallon diesel, stainless steel)
• Air-to-oil heat exchanger sized for 140°F ambient; heavy-duty solder-dipped radiator
• Four (4) 3,000 PSI BOP accumulators (10 gallons each); nitrogen bottle for emergency engine start
• 30-gallon air reservoir with filter and regulator
• Skid Dimensions: 13′ (L) × 8’5″ (W) × 8′ (H) | Weight: 14,600 lbs. (full fluids)

4. Gear Drive Tubing Reel Assembly

• Capacity: Up to 18,000 ft of 1-½” coiled tubing
• Spool: 120″ OD rim, 72″ core diameter, 72″ inside width
• Gear drive with integral brake; spools 2″ tubing at ≤2,500 PSI hydraulic pressure
• Mechanical diamond leadscrew levelwind with adjustable clutch, hydraulic override, counterbalance valve
• Internal & external plumbing: SPM 2×2 valves, 10,000 PSI integral 1502-type fittings; flange-mounted 4:1 debooster
• 10,000 PSI circulating swivel (2″ bore, proof-tested to 15,000 PSI; H2S and non-H2S service)
• 30-gallon lubrication reservoir with spray wand system
• Spreader bar (stamped 100,000 lbs.) with two-leg sling, shackles, master link, and thimbles
• Tubing guide counter adjustable for 1″ through 2.88″ tubing; reads in feet or meters
• Non-lift removable protection frame with dual access ladders; encoder data acquisition mount
• Skid Dimensions: 148″ (L) × 102″ (W) × 122″ (H) | Full-length drip pan with corner drains

5. Injector Head

• Handles coiled tubing 1-½” OD through 3-½” OD; compatible with open-loop and closed-loop hydraulic systems
• Pull Capacity: 80,000 lbs. continuous @ 4,400 PSI | Max speed: 150 ft/min (60 GPM) | Snubbing: 40,000 lbs.
• 33:1 deep reduction gear drive transmission with dual output shafts and dual oil seals
• Dual high-speed/high-pressure bent-axis variable displacement piston motors with counterbalance safety valves
• Spring-applied/pressure-released modular brake between motor and gearbox
• 200-pitch heavy-duty roller chain with precision cast carriers; grooved and hardened half-round gripper blocks
• Gripper sizes available: 1-½”, 1-¾”, 2″, 2-⅜”, 2-⅞”, 3-½”
• Dual single-acting hydraulic load cells (pipe-heavy and pipe-light indication)
• 4-point outer lifting/crash frame rated for 90,000 lbs. operational lifting capacity
• 72″ radius tubing guide arch with contoured steel rollers (fold-down or removable)
• Telescoping and fixed support legs included; stripper flange mount (configuration per purchaser spec)
• Injector transport skid with crash frame accommodates injector, stripper, BOPs, and gooseneck

General Specifications

• Complete unit sandblasted, primed, and painted to purchaser-specified color
• Full factory assembly and acceptance testing performed at USA facility
• All lifting eyes load-tested to minimum 1.5× rated SWL with post-test NDE inspection; documentation provided
• All hoses supported with clamp systems and protected with rubber sleeves
• Self-locking nuts used throughout where required