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HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Maintenance
Inspection
Perform periodic inspections as presented in Maintenance instructions. Operator and
maintenance personnel must be aware of any discrepancies and the discrepancies shall be
corrected before the system is put into operation. During these inspections, check the
following:

• Cleanliness: Inspect all nitrogen components for cleanliness. Remove all forms of
foreign material and contaminants from equipment. Give special attention to couplings
to ensure that no contamination or foreign materials can enter the nitrogen system.

• Corrosion: Inspect entire nitrogen system for any forms of corrosion. Clean and
inspect corrosion area. Repair as needed. Take preventive measures to inhibit future
corrosion.

• Weldments: Inspect all welded parts for evidence of cracked or broken welds.
Determine cause and take measures to prevent future failures. Repair as needed

• Glass: Inspect all glass components for cracks or breaks. Repair or replace as
needed.

• Leakage: Inspect all fittings and tubing for looseness and signs of leakage. Repair as
needed.

• Valves: Check all valves for general condition, missing parts, and signs of leakage.
During operation of the system, inspect valves for ease of operation and positive
seating. Note problem areas and make repairs when conditions permit.

• Hoses: Inspect hoses for excessive wear. Inspect fittings for wear or physical
damage. Remove and Repair as needed.

• Attaching Hardware: Inspect entire system for loose or missing hardware (such as
nuts, bolts, etc.). Replace and re-torque as required.

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HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Daily Maintenance (Before Start-Up) (Ref.: Fluid Specifications)


1. Check the following fluid levels:

• Coolant tank

• Triplex Pump lube tank

• Engine oil

• Engine radiator coolant

• Hydraulic reservoir

• Triplex gear box sight glass

• Diesel fuel.

2. Drain any condensation from pneumatic (Air) and hydraulic reservoirs.

3. Check that all hydraulic suction valves on the hydraulic tank are open.

4. Grease bearings on water pump.

Daily (After Shutdown)


1. Fill diesel, hydraulic, and lubrication reservoirs. Maintaining full reservoirs prevents
condensation from forming inside the tank.

2. Check all high pressure plumbing attaching hardware (such as nuts) for tightness.

3. Check all hydraulic and lubrication lines for leaks.

4. Check coolant circuit for leaks.

5. Check engine belts.

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HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Weekly (Every 75 Hours of Operation)


1. Drain and clean all drip pans.

2. After the first 60 to 80 hours of operation of a new unit, change the hydraulic fluid
and clean or replace the following hydraulic filter elements.

• Both Suction Strainers (hydraulic and lube oil).

• Coolant Filter.

• Lube Oil Filter

• Return Filter(s).

3. Check all critical bolted connections for tightness, including but not limited to, the
following:

• High and low pressure plumbing supports.

• All major component mounting bolts.

• Guard bolts.

4. Refer to Engine Service Manual for scheduled maintenance and procedures for the
engine.

Bi-Weekly (Every 150 Hours of Operation)


1. Drain and replace engine oil and filters. (Refer to Engine Service Manual).

2. Check and replace, if necessary, engine fuel filters. (Refer to Engine Service
Manual).

3. Check engine air intake connections for tightness. Check rubber seals and ducts for
deterioration that could cause leaks.

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HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Monthly (Every 300 Hours of Operation)


1. Perform Bi-Weekly Maintenance.

2. Replace coolant return filter(s).

3. Replace engine air filter elements. (Refer to Engine Service Manual).

4. Check engine drive belts for tension and deterioration. (Refer to Engine Service
Manual).

5. Remove, clean or replace air compressor intake filter as required

Annually (Every 2000 Hours of Operation)


1. Perform Monthly Maintenance.

2. Drain hydraulic and lubrication tanks and clean thoroughly. (US POT Petroleum
Naphtha UN1255 or equivalent.)

• Replace the following filters:

a) Both Suction Strainers (hydraulic and lube oil).

b) Coolant Filter.

c) Return Filter(s)

d) Lube Oil Filter.

• Check suction hoses for deterioration and replace as necessary.

• Replace fluids with new clean fluid. (Refer to Fluids Specifications.)

3. Check all hoses and clamps on hydraulic, lubrication, and coolant circuits. Replace,
repair or tighten as required.

4. Drain coolant fluids in vaporizer coolant circuit and engine coolant circuit. Flush
system with clean water. Replace coolant fluids (ethylene glycol mixture and fresh
water. (Reference fluid specification.)

NOTE: Fill Coolant Tank Then Run Engine Until Tank Level Falls To About Ten Inches
(25.4cm) Deep. Refill And Repeat The Process Until Water Level Does Not Fall
After Starting Engine. It Will Be Necessary To Bleed The Air Out Of The Engine

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HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Block While The Unit Is Running Using The Air Bleed Valve Located In The
Coolant Header Over The Front Of The Engine. Failure To Do This Will Cause
Engine Overheating.

Cleaning
• Cleaning Precautions – Follow precautions related to cleaning the system and its
components. Follow specific precautions that accompany cleaning solutions or
solvents. The following precautions are standard to the system. Always observe them
when cleaning is required.

1. Wear appropriate safety equipment when using cleaning solutions, solvents and
compressed air.

2. Always follow specific warnings that apply to soaps and solvents.

3. Provide adequate ventilation when using solvents. Avoid prolonged breathing of


vapors and contact to the skin. Know what to do if any personnel become over
exposed to solvents.

4. When using solvents, always keep these items away from any source of flame,
sparks or heat. Do not leave any containers open. These substances can ignite or
form harmful gases when heated.

• Cleaning Procedures - Cleaning the system and its components may require different
methods depending on the part and the degree of contamination.

1. System: Use Hotsy Detergent Super XL or equivalent in general cleaning of the


system. Use standard cleaning methods. After washing, thoroughly rinse all
affected areas with water. Allow to air dry and wipe clean with a clean lint free
cloth.

2. Nitrogen Parts - Observe common solvent handling procedures while cleaning. Use
trichlorotrifluoroethane to clean nitrogen parts. The nitrogen parts must be cleaned
removing any forms of oil or grease. These substances will freeze on contact with
liquid nitrogen (LN2) and contaminate the system or interfere with its operation.
Remove all forms of moisture and debris on couplings before replacing protective
caps.

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HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

CAUTION

CGA CAPS DO NOT SEAL. USE A SEAL (SUCH AS A PLASTIC BAG)


BEFORE STEAM CLEANING OR PRESSURE WASHING.

Troubleshooting:
In many instances a component or system may develop a problem for which there is no
immediate clear cause. It is recommended, to avoid needless disassembly, the following
procedures be taken to isolate the portion of the circuit where the problem exists.
REVIEW SAFETY SUMMARY BEFORE TROUBLESHOOTING. The procedures
are as follows:

1. Operate the system or circuit to confirm the problem actually exists.

2. Check for obvious problem's first.

3. Check the oil level in the hydraulic reservoir to ensure that it is full.

4. Check to ensure hydraulic filters are clean

5. Check to ensure all system gauges, valves and other components are functioning
correctly.

6. Check to see what recent repair or maintenance has been performed. Inspect these
areas for possible cause of problems.

NOTE: It Should Be Emphasized That Cleaning The Equipment Prior To Inspection Will
Make The Job Easier, Take Less Time, And Will Reduce The Chances Of
Contamination.

Common equipment malfunctions are presented in the following sections:

• Engine Troubleshooting Guide

• Nitrogen Pumping System Troubleshooting Guide

• Tank Troubleshooting Guide.

NOTE: These Guides Are A Summarized Lists Of Troubles, Probable Causes And
Remedies. Should A Series Of Malfunctions Occur, Then Suspect A Lack Of Daily
Scheduled Inspections And Maintenance.

NOTE: The Following Troubleshooting Guides Are Simple Checks That Field
Maintenance Can Make. Any Detailed Engine Problems Should Be Performed By
An Authorized Engine Repair Facility.. Field Maintenance Personnel Should

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Possess A Good Understanding And Working Knowledge Of The Properties And


Dangers Of Nitrogen And High Pressure Pumping Equipment Before Attempting
To Troubleshoot This Unit.

Engine Troubleshooting Guide


Problem A: Engine Starter Not Turning Over (Ref. Air Schematic)

PROBABLE CAUSE REMEDY


1. No Air Pressure Check system air pressure
2. Faulty Start Button. Insure start valve is pressurizing diaphragm valve
3. Check Diaphragm Valve (Dump Valve to Remove air pilot line and push start button. If good
Starter) to be sure it is opening and delivering air pressure and volume comes through pilot line,
air supply to starter re-install pilot line. Remove supply hose to starter,
push start button. If diaphragm valve opens and
discharges large air volume, the valve is all right
4. Starter seized If you are sure starter is getting good air volume
and pressure, but starter will not turn, remove and
repair or replace as necessary.

Problem B: Engine Cranks But Will Not Start

PROBABLE CAUSE REMEDY


1. Slow cranking speed Refer to A
2. Low ambient temperature Using starting aid (ether) below 15°F. Check
engine manual to be certain ether starting is
approved
3. Engine not getting fuel Check fuel tank level, fuel filters, fuel lines, valves,
supply and return, and fuel pump
4. Check Normal Kill cylinder to see if it is stuck Repair or remove and replace normal kill cylinder
in Kill position
5. Throttle linkage binding Check linkage and make adjustments as necessary
6. Poor quality fuel, incorrect fuel or water in fuel Drain fuel, change filters, and replace fuel
7. Improper oil viscosity Drain oil, change filters, and replace oil
8. Check the Emergency Kill “Flapper” to see if Reset Emergency Kill “Flapper”.
it is in closed position.

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HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Problem C: Engine Misfiring


PROBABLE CAUSE REMEDY
1. Poor quality fuel Drain fuel, change filters, and replace fuel
2. Air in fuel system Check for air in fuel system mainly on suction side
of fuel pump.
3. Broken or leaking fuel lines Check for fuel leaks and replace defective parts
4. Restrictions in fuel lines Check fuel flow. Replace fuel lines as necessary
5. Low fuel pressure Check fuel level and kinks in fuel lines. Change
fuel filters
6. Defective fuel injectors or pump Contact authorized engine repair representative

Problem D: Engine Stalls

PROBABLE CAUSE REMEDY


1. Fuel tank vent plugged Check tank vent and repair as necessary
2. Low fuel supply Refer to C, Item 5
3. High parasitic loading (e.g., LN2 pump Check for engine loading during starting
hydraulic pump speed control.)

Problem E: Erratic Engine Speed

PROBABLE CAUSE REMEDY


1. Air leaks in fuel suction line Check for air leaks and repair as necessary
2. Throttle linkage loose Check throttle linkage
3. Engine governor problems Contact authorized repair representative

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HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Problem F: Low Power

PROBABLE CAUSE REMEDY


1. Restrictions in air intake system, clogged air Check air pressure in air inlet manifold. Replace
filter air filter and make necessary repairs to air system
2. Poor fuel quality Refer to B, Item 6
3. Damaged or restrictions in throttle linkage Check linkage, adjust or replace if necessary
4. Emergency Kill “Flapper” partially closed Check “Flapper”, reset or repair as necessary
5. Normal Kill cylinder partially extended Reset cylinder or Repair as needed

Problem G: Engine Over-Heating

PROBABLE CAUSE REMEDY


1. Coolant level low Determine cause, replace defective parts and
replace coolant
2. Expansion tank cap Replace expansion cap
3. Defective thermostat Replace thermostat
4. Defective coolant pump Replace coolant pump
5. Fan not engaging fully (full RPM) or turning Inspect fan speed. Repair as necessary

Problem H: Low Engine Oil Pressure

PROBABLE CAUSE REMEDY


1. Oil leakage, low level Check for leaks and repair as necessary
2. Incorrect oil viscosity Drain oil, change filters and replace oil
3. Defective oil gauge Replace oil gauge
4. Clogged oil filter Replace oil and filters
5. Defective oil pump Contact authorized repair representative
6. Excessive engine wear Contact authorized repair representative

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HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Problem I: Oil In Coolant

PROBABLE CAUSE REMEDY


1. Defective oil cooler core or seals Contact authorized repair representative
2. Blown head gasket Contact authorized repair representative

Problem J: Coolant In Oil

PROBABLE CAUSE REMEDY


1. Defective oil coolant core or seals Contact authorized repair representative
2. Blown head gasket Contact authorized repair representative
3. Defective coolant pump Contact authorized repair representative
4. Cylinder sleeve seals failure Contact authorized repair representative

Nitrogen Pumping System Troubleshooting Guide

Problem A: Low Flow Rate To Unit From LN2 Tank

PROBABLE CAUSE REMEDY


1. Low tank pressure Increase tank pressure
2. Supply valve not fully open Open valve fully on LN2 tank and skid
3. Return valve closed or partially closed Open valve fully on LN2 tank and skid
4. Suction strainer on LN2 tank clogged Clean or replace strainer
5. Y strainer on skid clogged Clean or replace strainer
6. Clogged piping or transfer hoses Inspect piping and hoses to insure free flow

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HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Problem B: Moisture In Stem Packing

PROBABLE CAUSE REMEDY


Moisture in stem packing Thaw valve and dry out packing

Problem C: Boost Pump Will Not Turn

PROBABLE CAUSE REMEDY


1. Hydraulic valve closed at boost pump Open valve
2. Locked up from ice formation Turn the shaft coupling with a pipe wrench. Do
not use excessive force. If pump will not turn,
thaw out and dry out pump
3. Suction valve to hydraulic pump closed Open valve
4. Defective hydraulic pump Disconnect motor supply hose. Plug hose and cap
motor. Test pump pressure if pump does not build
pressure. Check system relief valve. If relief valve
is all right, remove and replace pump
5. Defective motor. Replace motor
6. Defective sequence valve Replace sequence valve.

Problem D: Triplex Pump Will Not Rotate.

PROBABLE CAUSE REMEDY


1. Improperly adjusted cold end. Adjust cold end properly
2. Over pressure shutdown is active or tripped Reset to operating position
3. Check pump drive coupling to insure drive Replace damaged or broken drive coupling
components are not slipping off input shaft
4. Check main system pressure. If pressure rises Remove Triplex dump drive coupling. Attempt to
above required to drive Triplex, one of the rotate Triplex. If hydraulic motor and reduction
following is locked up: gear box rotate, the Triplex is locked up. If the
motor and reduction gear box do not turn, remove
• Hydraulic drive motor.
motor from the gear box and attempt to rotate
• Reduction gear box motor. If the hydraulic motor rotates, the gear box
should be repaired or replaced. If the hydraulic
• Triplex pump motor does not turn, repair or replace the hydraulic
motor

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HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Tank Troubleshooting Guide


Problem A: Low Flow Rate To Pumping Skid

PROBABLE CAUSE REMEDY


1. Low tank pressure Build pressure on LN2 tank
2. One or more valves required for liquid supply Check supply and return valves to make sure they
not fully open are fully open
3. Ice or contamination in supply line filters Check for ice or contamination in LN2 supply
filters/strainers

Problem B: Frozen Valve Stem

PROBABLE CAUSE REMEDY


Moisture in stem packing Thaw and dry valve packing and packing gland
with dry nitrogen gas

Problem C: Valve Leaking Vapor And Liquid

PROBABLE CAUSE REMEDY


Foreign material or ice on valve seat Disassemble valve and repair or replace as
required

Problem D: Tank Will Not Build Or Maintain Pressure

PROBABLE CAUSE REMEDY


1. Line to pressure building coil obstruction. Ice Clear obstruction and/or open valve
or valve closed
2. Low liquid level Fill tank
3. Leak to atmosphere Locate leak and repair

Problem E: Excessive Tank Pressure

PROBABLE CAUSE REMEDY


1. Defective pressure gauge Check indicator. Replace if necessary
2. Road relief not functioning Repair or replace road relief as required
3. Pressure building valve open Close valve

FOR FURTHER ASSISTANCE CALL HYDRA RIG SERVICE DEPARTMENT


(817) 457-1521.
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