Page 1 of 6

Power Unit Various Manufacturers Diesel Zone 2 - 4 Cyl - SOP (FULL SOP)
Document Document
Document Level Revision No. Revision Date Prepared By Approval
Number Classification

GL-TRS-OEPS-L4- L4 Technical Work TRS Technical TRS GBU

Controlled 12 July 24, 2019
564 Instruction Committee Approval Board

TABLE OF CONTENTS
Part Description
1 Purpose
2 Scope
3 Definitions
4 Procedure
5 Reference & Attachments
6 Document Change Record
1. Purpose
Weatherford work instructions are intended to clearly define the minimum requirements for the safe use of equipment and to protect
employees, materials, and the environment. This document also serves as a guide for complete conformity to Weatherford quality
policies. The operation and maintenance of relevant equipment covered by this Work Instruction is intended ONLY for qualified
Weatherford employees and contracted personnel working on behalf of Weatherford. Anyone else shall not operate and maintain the
equipment unless authorized to do so. Every effort has been made to ensure the accuracy of this work instruction; however, the
specifications and requirements of the original equipment manufacturer (OEM) always supersede this document and must be
followed. This work instruction shall remain in effect unless otherwise approved, in writing, by a member of Global Product Line
Management.

2. Scope
The scope of this document covers the following equipment:
Various Manufacturers Zone 2 -
4 Cyl
3. Definitions
in - Inches, length, USCU psi - Pound per square inch of Pressure, USCU
mm - Millimeter, length, Metric Systembar - Unit of Pressure, Metric System
gpm - Gallons per Minute, USCU ohms - Unit of Electrical Resistance
l/min - Liters per Minute, Metric SystemCS - Critical Step
RPM - Revolutions per Minute
Task Risk Assessment (TRA) Symbol Definition
The following symbols are used throughout this Work Instruction, under the Critical Steps (CS) column,
to indicate a related QHSE awareness or action item.

R Critical to Quality
, NOTE!

 Critical to Health & Safety

G CAUTION!!

L Visual Inspection
+ WARNING!!!

N Witness Point - Notify Supervisor to overlook the work while it is

performed. Activity may proceed. No Supervisor’s signature is required.

I Hold Point - Work stopped for direct Supervisor to verify the work and
sign-off on the step.

Check off each step that is completed.

Any step that is not applicable, for any reason, should be annotated with “N/A” on the work instruction and a comment

, included as to why it is not applicable.

Sign and date each section that is completed.
Portions of this work instruction may already be in progress. Verify all signatures and the prior work performed, and
continue as required.

© 2016 Weatherford All Rights Reserved Proprietary and Confidential – Trade Secret
 Page 2 of 6 1

Power Unit Various Manufacturers Diesel Zone 2 - 4 Cyl - SOP (FULL SOP)
Document Document
Document Level Revision No. Revision Date Prepared By Approval
Number Classification

GL-TRS-OEPS-L4- L4 Technical Work TRS Technical TRS GBU

Controlled 12 July 24, 2019
564 Instruction Committee Approval Board

Power Unit Various

Serial Number: 1 Description: Manufacturers Diesel Zone 2 -
4 Cyl

Job / Work Order Number: 1 Motor Hour Meter Reading: 1

12 Months / As per running

Today's Date: August-8-2019 9:22 NDT / Major Survey Schedule:
hours or 12 Months
Dropped Object Visual Inspection CS Initial Comments

1
Visually inspect all of the surfaces of the equipment to ensure that there are no
tools or loose items left on the internal and external surfaces of the equipment.
Check Shackle, Screw & Nut, Safety pin, Sling and lifting eyes
L
Potentially dropped tool,
improper Shackle /
improper screw&nut that
use for shackle/improper
2 sling/ do not put safety pin
in screw of shackle. Fatality
resulting from an injury or
trauma. Man under
elevated tool.

Check the connection / hinge points of the doors

Potentially dropped door,

improper Fatality resulting
3
from an injury or trauma.
Man under elevated tool.

Check Forklift Pockets inside.

Potentially dropped object,

inspection forklift pockets
prior to be lifted by
4 Forklift.Up to a fatality
resulting from an injury or
trauma. Man under
elevated tool.

© 2016 Weatherford All Rights Reserved Proprietary and Confidential – Trade Secret 1
 Page 3 of 6 1

Power Unit Various Manufacturers Diesel Zone 2 - 4 Cyl - SOP (FULL SOP)
Document Document
Document Level Revision No. Revision Date Prepared By Approval
Number Classification

GL-TRS-OEPS-L4- L4 Technical Work TRS Technical TRS GBU

Controlled 12 July 24, 2019
564 Instruction Committee Approval Board

Caps and secondary retention for connectors of 1" & 1 1/4" and Check adjustment
of Pneumatic connector.

Potentially dropped object,

check adjustment of Caps
for connectors of 3/4", 1", 1
5 1/4", and verify that each of
the cap had Sling. Check
adjustment of Pneumatic
Connector.

Visually inspect the smaller components of entire tool assembly for obvious dropped
object potential such as:
- Missing bolts, nuts, cotter pins, lynch pins, lock wire, washers. Install as
necessary. Refer to GL-TRS-OEPS-L4-08 Bolt Torque Requirements Technical
Reference sheet for specifics torque values. For Proper lock wire installation refer to
GL-TRS-OEPS-L4-644 PROPER SAFETY WIRE TECHNICAL REFERENCE
SHEET.
- Obviously disengaged nuts, bolts. Tighten as necessary. Refer to GL-TRS-OEPS- Various small components
L4-08 Bolt Torque Requirements Technical Reference sheet for specifics torque or bolting material dropped
values; during normal operation,
- Split pins must be bent sufficiently to prevent them from falling out. Where there is
transportation and lifting.
a danger that personnel will be exposed to the sharp ends, the pin must be bent as
6 shown in the image above. (Insert Image). Split pins should be made of a steel Up to major resulting in
suitable for the operational environment; injuries due to becoming
- Only 4-Part shackles (bow, pin, nut and split pin) are in use; loose during normal
- Ensure no hairpins, welding rods or home-made pins are used; operation, transportation or
- Ensure no double-nut arrangement (unless specified in the OEM manual) is used lifting.
on any part of the tool, if it subject to any load or rotational force;
- All eye bolts not used for primary lifting are removed from the tool assembly
(unless designed for use during tool's operation).
- Ensure the length of lanyards is sufficient to just provide engagement and
disengagement of the components they retain to avoid them being snagged.

Print Name: Signature:

Date: Comments:
Pre-Operational Procedures CS Initial Comments
Read and understand all OEM safety and handling instructions prior to performing any operation.

, If scope or work changes, it is important that all personnel involved in the operation take time out to reassess the situation.

Perform a dropped objects visual inspection for each stage of this document.
Verify that the power unit’s zone rating is compatible with its intended use in the
7 workplace or on the rig floor as well as the ATEX explosion-proof requirements prior -
to operating the power unit.

8 Visually inspect the unit for transit or other damage.

L
Verify that all accessories have been sent with the power unit. Ensure that fit-for-
9 purpose fire fighting equipment is in place and verified prior to the start of -
operations.

© 2016 Weatherford All Rights Reserved Proprietary and Confidential – Trade Secret 1
 Page 4 of 6 1

Power Unit Various Manufacturers Diesel Zone 2 - 4 Cyl - SOP (FULL SOP)
Document Document
Document Level Revision No. Revision Date Prepared By Approval
Number Classification

GL-TRS-OEPS-L4- L4 Technical Work TRS Technical TRS GBU

Controlled 12 July 24, 2019
564 Instruction Committee Approval Board

G Where possible, diesel storage and transfer equipment should be stored out of direct sunlight.

10 Verify the fluid levels are correct. If not, top off with the appropriate fluids:

• Engine Oil 15 / 40, or as is applicable for the temperature range on location. -

• Diesel

• Air Starter Lubricant, if applicable. -
• Antifreeze 50 - 50º -
• Hydraulic Oil - Castrol Vita, AWS 32, or the oil meeting zoning requirements. -

+ Do not carry out any adjustments, repairs, or maintenance unless the systems are isolated from the power source.

11 Check the hydraulic oil filter status indicator. -

Prior to starting, if possible, ensure that the unit is earthed to the rig structure or
12
separately grounded by an electrode (copper rod) that is submersed 1-3 meters into
earth, depending on soil / ground conditions. Resistance to earth must be verified to
be 5 ohms or less prior to the start of work.
N
13 Ensure the fuel tank is ventilated properly to exclude accumulation of fuel vapors. -
Check if a permit to work (PTW) is required prior to starting the unit. If it is expected
14 to refuel the unit without de-energizing (while running), ensure that a PTW is issued
and operations are carried out under the permit.
N
Connect the 1-in. (25mm) ID air hose to the unit, and secure with the R-clip and
15 -
whip-line that is provided.

, Ensure that all air hose connections have been fitted with whip checks and the R-clip fittings.

Where fitted, check that the emergency shutdown (ESD) hoses are connected to
16 the power unit engine oil pressure lines and the electric solenoid cable is long -
enough to reach the selected power source.
17 Select Start at the power unit Start / Run valve. -
Turn the knurled reset knob on the fuel shut-off valve and latch into position with the
arrow pointing to Start (at approximately the 1 o’clock position). The fuel valve will
18 -
automatically rotate to the Run position once the engine oil has reached operating
pressure.
19 Set the throttle control to approximately mid-position. -
Operate the start override lever on the unit’s control panel to open the inlet air valve
20 -
and hold open.
Operate the engine starter, by depressing the starter button located on the power
21 unit’s control panel. Alternatively, on units where a direct supply is fitted to the
starter motor, open the air supply valve until the engine starts.

Hold the Start override lever in position until the engine oil pressure builds up,
22 observe the knob on the fuel shut off valve return to the Run position, then release -
the override lever.
Set the engine speed control at the desired position, and allow the engine to run for
23 -
approximately 10 minutes or until the operating temperature is reached.
Select the Run position on the Start / Run valve, and check the pre-set pressure on
24 -
both the full flow and 26 gpm (100 l/min) systems.

By observing the pressure gauge, if the pressure has not been pre-set to the correct
25 -
pressure, this should be set by adjusting the allen screw on top of the RIV valve.

, The maximum engine operating speed is 1,800 rpm. Pump damage will occur due to prolonged overspeed.

Before turning off the engine, shift the throttle control lever to the minimum, and
26 allow the engine to idle at low speed for at least 1 minute. Return the Start / Run -
valve to the Start position, before pulling the Stop lever on the control panel.

© 2016 Weatherford All Rights Reserved Proprietary and Confidential – Trade Secret 1
 Page 5 of 6 1

Power Unit Various Manufacturers Diesel Zone 2 - 4 Cyl - SOP (FULL SOP)
Document Document
Document Level Revision No. Revision Date Prepared By Approval
Number Classification

GL-TRS-OEPS-L4- L4 Technical Work TRS Technical TRS GBU

Controlled 12 July 24, 2019
564 Instruction Committee Approval Board

The audible alarm will sound when the engine oil pressure drops. Depress the Horn
27 -
Mute button on the control panel to stop the horn.
To stop the engine in an emergency, select emergency stop with the emergency
28 stop lever. Do not use this facility for normal stopping. If the emergency stop has -
been used, a vacuum will have been created behind the air inlet D-valve.

G Never immediately attempt to restart the engine. Allow approximately 2 minutes for the engine to stabilize.

29 Shut down the engine when refueling. -

30 Place the unit close to the rig.


Run the hydraulic hoses to the rig floor away from any trip hazard, and connect to
31 -
the unit.

G Proper lifting technique to be used for lifting hydraulic hoses from Ground level to the rig floor. Never lift any hydraulic
hoses from ground level to rig floor when one end is connected to the unit.
Print Name: Signature:

Date: Comments:
Operational Procedures CS

+ The remote START / STOP switch is for emergency stopping only.

+ When it is necessary to restart the system, relieve the pressure at the unit.

In the event of discovering a hydraulic oil leak on any component of the rigged up power equipment (tong, spider, elevator,
+ panel), the hydraulic oil level in the HPU must be checked to ensure it is still high enough for the power unit to operate. Top
up if necessary.
32 Rig up the power unit to its operational location.
•
•
Provide good communication with the rig personnel.
Discuss a lifting plan. 
• Discuss safe handling practices.

33
Check if a permit to work (PTW) is required prior to starting the unit. If it is expected to refuel the unit without de-
energizing (while running), ensure that a PTW is issued and operations are carried out under control of the permit. N
34 Connect the ground terminal of the power unit to the main ground of the building or rig structure. -
If not already done, remove the hydraulic hoses from the power unit basket. Attach a drain hose (where applicable),
35 a low pressure hose, and a high pressure hose to the power unit and the equipment to be operated ensuring they -
are fully connected / mated. Route hoses in a manner that does not cause trip hazards.
36 Ensure that nobody is working on the equipment connected to the power unit before starting the unit. -
37 Select the flow required, full flow or 26 gpm (100 l/min) setting depending on the equipment being used. -

N
Start the power unit, and the select run position at least 10 minutes prior to start of operations to allow warmup of
38
the system.

R

39 Visually inspect the entire hydraulic system for any leaks.

L
40 Bleed all circuits by activating power tong or other operated tool hydraulic functions. -
41 Start running tubulars. -
42 Shut down every 6 hours of operating the unit, and verify all fluid levels. (Refill if required.) -
Every 12 hours check the exhaust flame arrestor for carbon build-up, and replace or clean as necessary. (Disregard
43 -
this step if a dummy is fitted or the exhaust flame arrestor is not used.)

© 2016 Weatherford All Rights Reserved Proprietary and Confidential – Trade Secret 1
 Page 6 of 6 1

Power Unit Various Manufacturers Diesel Zone 2 - 4 Cyl - SOP (FULL SOP)
Document Document
Document Level Revision No. Revision Date Prepared By Approval
Number Classification

GL-TRS-OEPS-L4- L4 Technical Work TRS Technical TRS GBU

Controlled 12 July 24, 2019
564 Instruction Committee Approval Board

The power pack MUST BE SHUT DOWN DURING REFUELING!!!

In cases where refueling energized equipment is critical to continuing field operations, the operation must be authorized

+ and carried out under the control of a work permit (PTW).

Fill / liquid flow rates should be reduced as much as practical to mitigate the potential for static buildup.
Fuel shut off valves shall be utilized for fuel refilling activities. DO NOT USE BALL VALVES!!!
Failure to comply may result in serious injuries and / or fatality.
44 Prior to shutting down the engine, relieve the hydraulic pressure. -
45 Ensure that nobody is working with the equipment connected to the power unit before shutdown. -
Before turning off the engine, shift the throttle control lever to minimum, and allow the engine to idle at low speed for
46 -
at least 1 minute. Return the Start / Run valve to the Start position before pulling the Stop lever.
47 Shut down the unit. -
Disconnect the pressure line hose, and return the line hose and drain line hose from the power unit. Disconnect the
48 -
hoses from the tooling.
Fix dust caps onto the hose ends and onto the push-pull couplings at the power unit. Store the hydraulic hoses in
49 -
the hose basket above the unit.

50
Fix the lifting equipment to the lifting points of the power unit, and remove the power unit from the operation area.
Store it in a secure area. 
Post-Operational Procedures CS Initial Comments

Before transporting the power unit, ensure the hydraulic hoses are placed and
51 -
secured. Ensure there are no loose items that can fall down during transportation.
52 Check that the lifting slings are properly secured for transportation. -

53
When Weatherford Personnel are required to pack equipment for back-loading,
perform the following best practices: 
• Provide good communication with the rig personnel. -
• Discuss a lifting plan. -
• Discuss safe handling practices. -
If there are any equipment malfunctions, record the unit asset number and fill out a
54 -
Job Report, include the following information:
• Equipment Asset Number. -
• Describe any malfunctions with the equipment. -
55 Report all known defects on the job report. -
Print Name: Signature:

Date: Comments:
I agree that all of the necessary steps in this work instruction have been completed and all parts used
Conformity Verification:
are in accordance with OEM specifications.
Accepted By (Print): Signature: Date:
Additional Comments:

5.0 Reference and Attachments

OEPS Online Global TRS Equipment Integrity Register, GL-TRS-OEPS-L4-518
SharePoint TRS Equipment Technical Library

6.0 Document Change Record

Revision Change Description
GL 12 Deleted generic dropped objects section and mapped one from Pre-Dispatch section per WISE 116697.

© 2016 Weatherford All Rights Reserved Proprietary and Confidential – Trade Secret 1