Tubular Running Services

© 2020 | Al Masaood Oil & Gas

1
Power Unit Maintenance

2
 Table of Contents
1. Introduction 4
2. Deutz Engine 4
2.1.Models Used 4
2.2.Maintenance Schedule 5
2.3.Service and Maintenance 6
2.3.1. Checking Engine Oil Level 6
2.3.2. Engine Oil Change Intervals 6
2.3.3. Changing Engine oil 6
2.3.4. Changing Oil Filter 7
2.3.5. Changing Fuel Filter 7
2.3.6. Cleaning Air Filter 8
2.3.7. Cleaning Oil Bath Air Cleaner 8
2.3.8. Cleaning Dry Type Air Cleaner (Filter Cartridges) 8
2.3.9. Checking and Changing V-Belts 9
2.3.10. Cleaning the Engine 9
2.3.11. Checking Air Starter Assembly 9
2.3.12. Exhaust System 9
2.3.13. Hoses and Gauges 9
3. Hydraulic Pump 10
4. Skid 10
5. Sleave Cylinder 10
6. Maintenance Checklists 11
6.1.Routine Checklist for Diesel Hydraulic Power Unit 11
6.2.Preventive/Periodic Checklist for Hydraulic Power Unit 11

3
1. Introduction
Hydraulic Power Unit is designed to provide hydraulic power to tubular running and
tubular handling equipment. It can either be diesel powered or electric powered. Diesel
powered Hydraulic Power Unit is powered by an air cooled 3/4/6 Cylinder Deutz Engine
whilst Electric Power Unit is powered by an electric motor.
It is important to maintain the power unit in a condition that will provide continued safe
operation.
Maintenance of Diesel Hydraulic Power Unit involves the maintenance of the Engine,
Hydraulic Pump, Skid and their accessories.

2. Deutz Engine
2.1. Models used:
F6L 912 or F4L 912

Service Side of F4L 912

4
 Exhaust Side of F4L 912

2.2. Maintenance Schedule:

5
2.3. Service and Maintenance:
2.3.1. Checking Engine Oil Level
 Ensure that the engine or vehicle is in a horizontal position.
 Warm engine: Switch off engine, wait 5 minutes and check the oil level.
 Warm engine: Switch off engine, wait 5 minutes and check the oil level.
 Remove the oil dipstick.
 Wipe the dipstick with a non-fibrous, clean cloth
 Insert it to the stop and remove again
 Check the oil level, and if necessary, top up to the “MAX” mark.– If the oil level
is only just above the “MIN” mark, more oil must be added.

2.3.2. Engine Oil Change Intervals

The oil change intervals are dependent on the engine application and the quality of the
lube oil.
If the engine runs fewer hours during the year than stated in the table, the oil should be
changed at least once a year.

Engine Series Engine Version Lube Oil Change Intervals in Op. Hrs
Normal Use High Use
Naturally Aspirated 500 250
912/913
Turbocharged 500 250

2.3.3. Changing Engine Oil

 Ensure that the engine or vehicle is on a level surface.
 Allow the engine to warm up
 Switch off the engine.
 Place oil tray under the engine.
 Unscrew drain plug.
 Drain oil
 Fit oil drain plug, with the new gasket and tighten firmly
 Fill with lube oil
 Check oil level

6
2.3.4. Changing Oil Filter

 Undo the filter cartridge using a commercial tool and spin off.
 Catch any dripping oil.
 Clean any dirt from the filter carrier rim.
 Lightly oil the rubber gasket of the new oil filter Cartridge
 Screw in the new cartridge finger tight against the gasket
 Tighten the oil filter cartridge with another half turn.
 Check oil level,
 Check oil pressure
 Check cartridge seal for leaks

2.3.5. Changing of Fuel Filter

 Close fuel stopcock

 Undo fuel filter cartridge with commercial tool and spin off
 Catch any fuel
 Clean any dirt from the filter cartridge with a final half-turn.
 Apply light film of oil or diesel fuel to the rubber gasket of the new fuel filter
cartridge
 Screw in the new cartridge finger tight against the gasket.
 Tighten the fuel filter cartridge with a final half turn.
 Open fuel stopcock
 Check for leaks.

7
2.3.6. Cleaning Air Filter
 The amount of dirt in the air cleaner depends on the amount of dust in the air and
the size of the air cleaner used. If a high level of dust is anticipated, a cyclone-type
precleaner can be fitted to the air cleaner.
 Cleaning intervals will have to be determined from case to case.
 If dry-type air cleaners are used, they should be cleaned only in accordance with
the service indicator or the service switch.

2.3.7. Cleaning Oil Bath Air Cleaner

 Turn engine off and wait about 10 minutes for the oil to drain from filter housing
1.
 Release snap clips 2 and remove oil cup 3 together with filter element 4. Take care
not to damage the rubber gasket 5.
 Remove dirty oil and sludge. Clean oil cup.
 Clean filter element 4 in diesel fuel and allow to drip-dry.
 Clean filter housing 1 if very dirty.
 Inspect and replace rubber gasket 5 and 6 if necessary.
 Fill oil cup with engine oil up to the mark (arrow)
 Refit oil cup and element to filter housing and secure with snap clips.

2.3.8. Cleaning Dry Type Air Cleaner (Filter Cartridges)

 Undo clip fasteners 1.

 Take off hood 2 and remove cartridge 3.
 Clean cartridge (replace at least once a year).

8
  Clean cartridge 3. Blow out from inside out with dry compressed air (max. 5 bar),
(or in difficult cases, tap out, taking care not to damage the cartridge, or wash
according to manufacturer’s instructions). Through regular removal and
replacement, the gaskets on the filter cartridge can become damaged. Check paper
filter (light showing through) and gaskets for damage. Replace if necessary.
 Install cartridge 3, replace hood 2 and do up clip fasteners 1.

2.3.9. Checking and Changing V-Belts

 Inspect entire V-belt for damage.
 Replace damaged V-belts
 After installing new belts, run engine for 15 minutes, then check belt tension

2.3.10. Cleaning the Engine

 Switch off the engine during cleaning.
 Cover electrical/electronic parts
 Pass compressed air or steam jet to clean the engine

2.3.11. Checking Air Starter Assembly

 Check Air inlet filter and lubricator
 Replace if required

2.3.12. Exhaust System

 Make sure that the exhaust pipe is free of rust
 Exhaust pipe should be covered with heat absorbing substance.

2.3.13. Hoses and Gauges

 Check all hydraulic hoses inside and outside of the hydraulic oil tank for damages.
Replace if needed.
 Check all diesel hoses and pipes in the fuel circuit for damages. Replace if needed.
 Pressure and return hose fittings should be routinely cleaned and made free from
any kind of dirt.
 Check for proper functioning of hydraulic pressure gauges, temperature gauge and
engine meterage gauge.

9
3. Hydraulic Pump

 Check for leaks from hydraulic pump

 Leak normally occurs from the wear and tear of pump shaft or bearing
 Replace shaft, bearing and seals as required when there is leak
 Check HRC coupling and jaw coupling
 All parts of hydraulic pump except outboard bearing are lubricated by the
hydraulic oil in the circuit.
 Oil should be changed in regular schedule

4. Skid
 Check the Power Unit skid for any physical damages.
 Make sure the engine is mounted properly on the skid.
 Make sure hydraulic tank and diesel tank are labeled with red and yellow colours
respectively
 Diesel tank should be filled more than 1/2 and Hydraulic tank should be filled
more than 2/3rd of their capacities before sending for jobs.
 Check the validity of fire extinguisher and make sure it is kept properly in its case.

5. Sleave Cylinder
 Check sleave cylinder is working properly.
 Replace Orings on regular intervals and whenever needed

10
6. Maintenance Checklists

6.1. Routine Maintenance for Diesel Hydraulic Power Unit

 Wash and clean properly
 Check level of Hydraulic Oil
 Check level of Engine Oil
 Check level of Diesel Oil
 Check dates of replacement of filters-Engine Oil, Diesel Oil
 Check Air Filter and Air starter assembly
 Check hydraulic pump and make sure there is no leakage
 Check hydraulic hoses and fittings
 Check hose fittings on hydraulic tank
 Check hydraulic pressure gauges
 Check sleave cylinder functionality
 Check diesel hoses and fittings
 Check chalwyn valve
 Check all gauges
 Check emergency shut off system
 Colour code

6.2. Preventive/Periodic Maintenance Checklist for Diesel Hydraulic Power Unit

 Check the state of hydraulic hoses and gauge inside the tank. Replace if needed
 Wash and clean properly
 Check level of Engine Oil
 Check level of Diesel Oil
 Check dates of replacement of filters-Engine Oil, Diesel Oil
 Check Air Filter and Air starter assembly
 Check hydraulic pump and make sure there is no leakage
 Check hydraulic hoses and fittings
 Check hose fittings on hydraulic tank
 Check hydraulic pressure gauges
 Check sleave cylinder functionality
 Check diesel hoses and fittings
 Check chalwyn valve
 Check all gauges
 Check emergency shut off system
 Check fuel pump
 Check fuel injection system
 Refill hydraulic oil inside hydraulic tank
 Perform NDT on lifting eye pads of the skid

11