Section 4

Coiled Tubing Hydraulic System

Equipment

Table of Contents
Introduction................................................................................................................................................4-3
Unit A: Hydraulic System Safety...............................................................................................................4-4
Unit A Quiz: Hydraulic System Safety ..................................................................................................4-5
Unit B: Power Pack Basics ........................................................................................................................4-6
Pump Pressure Control...........................................................................................................................4-6
Power Pack Hydraulic Filter Maintenance.............................................................................................4-7
Unit B Quiz: Power Pack Basics............................................................................................................4-9
Unit C: Connecting and Lifting Hydraulic Equipment ............................................................................4-10
Unit C Quiz: Connecting and Lifting Hydraulic Equipment................................................................4-11
Unit D: Types of Fluid Contamination ....................................................................................................4-12
Particulate Contamination ....................................................................................................................4-12
Water Contamination (and other fluids)..............................................................................................4-12
Steps to Avoid Hydraulic Fluid Contamination ...................................................................................4-12
Unit D Quiz: Types of Fluid Contamination........................................................................................4-13
Unit E: Threaded Hydraulic Connections ................................................................................................4-14
Tapered-Threaded Pipe Connections ...................................................................................................4-14
Straight Threaded O-Ring Connections ...............................................................................................4-14
JIC Male/Female Flared Hose Connections:........................................................................................4-15
4-Bolt Flange Connections:..................................................................................................................4-15
Unit E Quiz: Threaded Hydraulic Connections....................................................................................4-16
Section 4 Self Check Test: Coiled Tubing Hydraulic System Equipment...............................................4-17
Unit A Quiz Answer Key: Hydraulic System Safety ...........................................................................4-20
Unit B Quiz Answer Key: Connecting and Lifting Hydraulic Equipment...........................................4-22
Unit C Quiz Answer Key: Types of Fluid Contamination ...................................................................4-23
Unit D Quiz Answer Key: Threaded Hydraulic Connections ..............................................................4-24
Section 4 Self Check Test Answer Key: Coiled Tubing Hydraulic System Equipment..........................4-25

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Use for Section notes…

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Introduction
Power-drive units operate all of the hydraulic
coiled tubing unit components with the
exception of the BOPs. The section will
introduce to you how they operate and give you
some examples as to how hydraulic systems are
used on a coiled tubing job. At the same time,
you’ll become familiar with safety issues and
acquaint yourself with hose packages (the
connections used to “plug” hydraulic
components into the power unit).
The coiled tubing power units are driven by a
V8 diesel engine designed for maximum HP at
maximum ambient temperature.
As all coiled tubing units operate on the
principle of Pressure × Area = Force, most
coiled tubing power units can deliver the
hydraulic pressure required to handle just about
any tubing load the injector is designed to lift.
But remember: A power package used with an
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Coiled Tubing Hydraulic System Equipment
80K unit is ideal for normal CT operations, but
always be sure that one is selected that can
handle the other loads associated with the
operation of the unit. Higher demand on the
engine, lowers the available power.
While these units supply a lot of power, adding
other hydraulic accessories used in completion
operations (access windows, tubing straightener,
additional BOP components, accumulators, etc.)
can overtax the capacity of the power unit. In
addition, jobs that require longer periods of slow
movement at high loads that may cause
overheating of the hydraulic fluid. As part of this
section, you will become familiar with the
proper cooling and maintenance of these
devices.
Coiled Tubing I

Unit A: Hydraulic System Safety
Halliburton’s top priority is safety first in
everything we do. Knowing appropriate safety
procedures come before learning the operation
of any unit or knowing how to properly do any
type of job.
A majority of the components that make up a
Coiled Tubing Unit operate hydraulically. Care
should be taken when working with hydraulic
equipment as with all phases of Coiled Tubing.
You will be exposed to more safety guidelines in
future Coiled Tubing courses. But for now, you
should know these important points.
1. Personal Protective Equipment required for
working with hydraulic systems are:
• Eye protection
• Hearing protection
• Protective clothing
• Gloves
• Steel toe shoes
• Hard hat
2. Guards must be in place during normal
operation. Guards are only removed when
equipment is being maintained or repaired.
Figure 4.1- Knowing how to work safely with
Coiled Tubing hydraulic systems protects
you, and the people around you.
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Coiled Tubing Hydraulic System Equipment
3. During maintenance or repair, equipment
must be locked out or disabled to prevent
accidental operation.
4. Be aware around high temperature hazards.
Avoid contact with high temperature
components such as the power pack engines,
exhaust systems, hydraulic pumps, valves
and hoses.
5. When working near an operating power
pack, stay away from fan blades, drive belts
and other moving parts. Some fans engage
without warning.
6. Before making repairs to hydraulic system,
shut down the power and make sure the
hydraulic pressure is bled off in all hydraulic
circuits. It is especially important for BOP’s
with accumulators that provide a reserve
supply of high pressured oil. Accumulators
can still be pressurized even if the power
pack is shut down or when pumps have been
vented. OBTAIN PERMISSION FROM
SUPERVISOR TO SHUT DOWN POWER
PACK BEFORE ANY MAINTENANCE.
7. Never disconnect hoses from a running
power pack.
8. Never intentionally spill hydraulic fluid,
diesel, motor oil, antifreeze, etc or allow
these fluids to leak onto the ground. Any
accidental spills must be cleaned up as
quickly as possible and in accordance to
Halliburton Company policy and local
environmental regulatory requirements.
REPORT ALL SPILLS TO YOUR
SUPERVISOR IMMEDIATELY.
9. Contaminated hydraulic fluids and diesel
must be disposed of properly. Never pour
these contaminated fluids back into the
hydraulic system or diesel tank.
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 Coiled Tubing Hydraulic System Equipment

Unit A Quiz: Hydraulic System Safety

1. Name the six types of safety equipment listed you should be wearing while working with hydraulic
systems.
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________

2. While all hydraulic circuits should be bled off after shut down, why is it especially important that
BOPs with accumulators be bled off?
_________________________________________________________________________________
_________________________________________________________________________________

3. At Halliburton, learning appropriate safety procedures come before:

_________________________________________________________________________________
_________________________________________________________________________________

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Unit B: Power Pack Basics

The components that make up a typical coiled
tubing power pack consists of a diesel engine, a
system of hydraulic pumps, a hydraulic tank,
hydraulic pressure controls and directional
control circuitry. Power packs supply the
necessary power to operate the equipment that
make up a Coiled Tubing unit. They are:
• Injector
• Reel
pressure setting. These are also known as
piston pumps.
The standard 6V-53 hydraulic power pack
contains the following hydraulic circuits:
• The Injector/Crane Circuit consists of 3
gear pumps mounted on the right side rear of
the gear pump drive box located on the
engine. This high flow circuit provides
power to the injector and crane.

• Control systems • The House/BOP Circuit consists of a

variable displacement pump mounted on the
• Crane back right hand side of the engine cam tower
• Cooling and charge systems and provides power to the hydraulically
operated well control equipment.
Power packs come in skid mounted, truck
• The Reel Circuit consists of a variable
mounted, or tractor mounted configurations
displacement pump mounted to the left side
depending on their required application.
rear of the pump drive gear box located on the
Valves used to control the fluid power systems engine. Its used primarily to power the reel
on a power pack can be classified into 3 groups direction, and to maintain back pressure on
according to the general function. the reel while pipe is being spooled on or
off.
1. Directional Control Valves – purpose is to
control direction of motion in cylinders,
fluid motors, or actuators.
2. Pressure Control Valves – this includes
pressure relief valves, by-pass valves, and
pressure reducing valves.
3. Flow Control Valves – primary function is
to regulate the rate of fluid flow for the
purpose of controlling the speed of motion
in cylinders and fluid motors.
Pumps commonly used on coiled tubing power
packs:
1. Fixed Displacement Pumps – Fixed
displacement pumps produce a fixed amount
of oil with each revolution of its input shaft Figure 4.2-Typical 30/38K Power Pack.
regardless of the demand pressure. The most
common fixed displacement pump is called
a gear pump. Pump Pressure Control
2. Variable Displacement Pump – Variable
displacement pumps produce variable flow Pump control on Injector/Crane circuits are
rate up to its physical size limits and controlled individually at the pump unloader

4•6 Coiled Tubing I


valve in conjunction with the pressure relief
valve. These in turn are remotely controlled
from the control house by a Double A valve. In
addition there are different pressure settings on
the unloader valves on each of the 3 pumps. You
will learn the differences between these valves
and how they operate in Coiled Tubing II. For
now it is important that you know that the set
pressure of each valve determines the maximum
pressure that is obtainable for each pump in the
single stack circuit. Only qualified personnel are
allowed to change pressure settings.
Each hydraulic pump can be turned ON
(Loaded) or turned OFF (Vented) by a series of
“Whitey Valves” located on the side of the
power pack and the control console.
Under normal operation all 3 ON (Loaded) and
OFF valves (Vented) are in the “Load” position,
indicating that all pumps are ON and fully
powering injector functions.
CAUTION: Never “Vent” (turn OFF) a pump
while the unit is in operation unless instructed
by a supervisor to do so.
CAUTION: When loading pumps at the start of
a job (after initial rig up) it is important that you
check with supervisor to assure all controls are
in the neutral position PRIOR to loading any of
the pumps.
Figure 4.3- A typical control cabin and
hydraulic power drive combination unit.
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Coiled Tubing Hydraulic System Equipment
Power Pack Hydraulic Filter
Maintenance
Suction Filters
Suction filters filter the oil going to the pump
inlets. The suction filters on typical 30/38 power
packs are located inside the hydraulic tank. They
screw onto fittings located on the bottom of the
tank.
It is recommended to service suction filters in
the yard not at a job location. Be sure to follow
the recommended maintenance interval per the
power pack’s maintenance schedule:
Follow this procedure when servicing the
suction filters:
1. Remove the bolts that secure the access
plate located on the top of the hydraulic
tank.
2. Drain hydraulic fluid from the tank. (see
note a)
3. The suction filter elements can be
unscrewed and removed once the oil is
drained.
4. Be careful not to damage the filter elements
when removing them. There’s a place on the
thread end to use a wrench if you cannot
unscrew them by hand.
5. Be careful not to drop anything in the holes
after removing the filters. Debris can go
straight into the pumps. Inspect the tank for
cleanliness and clean if necessary.
6. Filter elements can be cleaned most of the
time. Install cleaned or new suction filters.
Be sure filters are in good condition. If
elements are replaced, be sure to replace
with same micron rating.
7. Reinstall the access cover.
8. Fill the hydraulic tank with clean hydraulic
fluid. Using a clean container! Fill tank fluid
level until fluid reaches top of sight glass.
(see note a)
9. Be sure all suction valves below tank are
open before starting engine. Listen for
Coiled Tubing I

potential cavitation after starting engine. If
cavitation is suspected stop engine
immediately. Failure to do so will result in
pump failures.
NOTE:
a) Drain fluid from the hydraulic tank into a
clean container. Inspect it for cleanliness. It
is okay to reuse the same hydraulic fluid
only if it is clean. It is recommended that it
be filtered before it is re-installed.
Return Filters
Return filters clean the hydraulic fluid as it
returns to the hydraulic tank after the fluid has
done its work. These filters require replacement
servicing more often than suction filters. Follow
scheduled maintenance for your specific unit.
Return filters may be service in the yard or on
job location as needed.
Procedure for servicing return filters:
1) Remove ¼ inch pipe plug atop return filter
piping manifold where manifold enters
hydraulic tank (near return filters). This is a
siphon break.
2) Remove filter canisters from the return filter
housing. The top filter cartridge may remain
attached to the housing as you pull the
canister, if so; pull down on filter so it drops
into canister. This may require two people.
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Coiled Tubing Hydraulic System Equipment
3) Pour oil out of canister and remove filter
cartridges being careful not to loose the
spring located on bottom of the canister
under the second filter. (dispose of oil and
filters properly).
4) Clean canister and install new filter
cartridges with the spring at the bottom. (see
note a)
5) Reconnect the return filter canisters to the
filter housings being careful that the O-ring
remains in place and does not become
pinched.
6) Apply some type of “never seize” lubricant
to the threads of all 4 bolts that retain the
filter canister. Start all 4 bolts by hand
before beginning to tighten.
7) Tighten the 4 bolts in even increments to
avoid cocking the 4 bolt flange that secures
the canister. Do not over tighten the 4 bolts.
Caution: some of these 4 bolt flanges are
aluminum and can break very easy if
cocked. They could also become stripped if
over tightened.
8) Replace the ¼ in. pipe plug.
NOTE:
Use proper micron filter replacement cartridges.
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Unit B Quiz: Power Pack Basics

1. There are two types of pumps used on a power pack. Name each and describe their function.
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________

2. ____________________________ filters can be serviced in the yard or on location, while

_________________________ filters must always be serviced in the yard.
3. Give a brief description how pump control is maintained on Injector/Crane Circuits:
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________

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Unit C: Connecting and Lifting Hydraulic Equipment
As with raising and connecting any type of
equipment in place above ground, appropriate
lifting and safety procedures must be followed.
Presented here are just a few of the items you
should be aware of and will learn more about in
future courses:
Connecting
• Be sure that hose connections are clean
before making any connection. Use
hydraulic fluid to clean hose ends and
always install thread protectors on larger
quick disconnects ends after disconnecting
them. This keeps the connections clean and
prevents damage to their threads.
• Always lift hydraulic hoses from the
swedged end connection behind the quick
disconnect. Attach a lifting (choker) slings
to hoses no further than 5 feet away from a
hose end. This could weaken or kink the
hose’s interior liner and cause hose failure
when the hose is pressurized.
• Always use a crescent wrench to turn
winged connections when they become too
difficult to turn by hand. DO NOT USE A
HAMMER! The only connection tightened
in this way is a Weco hammer union and
Weco’s are not hydraulic system-type
connections!
• DO NOT use a punch and hammer to off-
seat a quick disconnect poppet to release
trapped pressure in hose. This action WILL
damage the poppet guide and may cause
severe hydraulic malfunction once the hose
is connected to the hydraulic system.
• After unit rig up, be sure that all threaded
quick disconnect connections are tight
before starting the power pack. Threaded
quick disconnects may appear tight but may
only be partially connected or not at all.
Also, all case drain hoses and system return
4 • 10
Coiled Tubing Hydraulic System Equipment
hoses must be connected to the power pack
BEFORE start up.
Figure 4.4- Typical hose package that is
lifted into place on the rig.
Lifting
• Never lift equipment with a chain. Always
use the properly rated “designated” lift sling
for when raising a piece of equipment.
• Always attach a tag line while lifting loads
to keep them from rotating as they are
raised. This will also help to control the
positioning of load.
• Alert other personnel in the area before
moving a load. NEVER stand under or near
lifted loads suspended by a crane or
immediately before or after it has been
raised.
• Be prepared to react as the crane operator
moves the load into position. Also, when
spotting a piece of equipment, always push
it away from you to avoid being injured if
you should slip or if the load falls suddenly.
• An experienced signalman is used to signal
the crane operator on how to position the
suspended load if radio communication sets
are not available.
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Unit C Quiz: Connecting and Lifting Hydraulic Equipment

1. During rig up, why is it important to make sure all threaded quick disconnects are tighten before
starting the power pack?
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________

2. When attaching a lifting sling, how far away from the end is allowable when placing it? Why should
it be under this distance?
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________

3. Why is it smart to use a tag line when lifting a load?

_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________

4 • 11 Coiled Tubing I

Unit D: Types of Fluid Contamination
Particulate Contamination
Particle contamination occurs when foreign
material enters the hydraulic system. If
operations personnel are not careful, foreign
matter can enter the hydraulic system at various
points such as through contaminated quick
disconnects, replacement parts, or through
contaminated fluid added to the hydraulic tank.
Contamination that enters downstream of the
power pack filters can do severe damage to the
system hydraulic components BEFORE the
filters ever get a chance to remove the
contamination. This is why it is important to
clean quick disconnects before connecting them.
A small amount of contamination can bring the
entire system down in within minutes and cause
considerable damage in time an money.
Water Contamination
(and other fluids)
Water accumulation is a common problem.
Water attacks the anti-wear additives that are in
most hydraulic fluids. If this happens, the pumps
and other hydraulic components will wear out
more quickly. Water can enter the system
through fill ports that are left open, through
BOPs (blow out preventors), and through
condensation of humid air in the hydraulic tank.
The first two of these can be controlled. Several
options for controlling the third situation are
being considered as of this writing.
Another way water can enter into the system is
by leaving the pour cap off of a 5 gallon pail or
55 gallon drum of new oil. Always immediately
replace the pour cap after taking oil out of a pail
or drum. This will prevent rainwater; wash down
water or water spray from contaminating new
oil, preventing the filters from doing their job.
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Coiled Tubing Hydraulic System Equipment
Sometimes the simplest thing you can do will
prevent the most damage.
Steps to Avoid Hydraulic Fluid
Contamination
While keeping fluids clean on the job site should
be a “no-brainer,” you can follow these steps to
ensure hydraulic, and other fluids you will be
using are not contaminated:
• Clean hydraulic connections before making
them up.
• Install protector caps for large quick
disconnects.
• Use clean containers when draining or
adding fluid to the hydraulic tank.
• Close the filler cap on the hydraulic tank
after adding fluid.
• Ensure that filter cap o-rings are in place
after servicing filters
• Follow suction and return filter servicing
procedures (do not take short cuts!).
• Use clean hydraulic fluid in a hydraulic
tank.
• Never add a mismatched or non-approved
hydraulic fluid into the tank.
• Never disable the tank filler port filter.
• Depending on the type of connections you
are using, always use Teflon tape properly
(see Unit E). Teflon is a source of
contamination and is known to jam
hydraulic components.
NOTE:
Teflon tape should never be used on hydraulic
fitting: Use hydraulic thread sealants such as
Loctite 5431 or Perma Lok LM012.
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Unit D Quiz: Types of Fluid Contamination

1. List at least 7 ways to prevent hydraulic fluid contamination.

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_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________

2. Which is the most common way fluids can become contaminated? Why?
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4 • 13 Coiled Tubing I

Unit E: Threaded Hydraulic Connections
There are basically 4 types of connections used
on hoses in conjunction with Halliburton Coiled
Tubing units:
• Tapered-threaded pipe connections
• Straight threaded, o-ring connections
• JIC male/female hose connections
• 4-bolt flange connections
Being familiar with these connections and with
their proper use can keep you safe and all
equipment functioning properly.
Tapered-Threaded Pipe
Connections
Pipe threaded connections have “tapered” male
and female threads. It is the interfacing and
crushing of the two threads that make the
hydraulic seal. Pipe threads become less
effective in sealing the more often they are
reused. Teflon tape is often used to help make
the pipe threads seal.
Figure 4.5- Tapered Threaded Pipe
Connection
Correct use of Teflon tape:
4 • 14
Coiled Tubing Hydraulic System Equipment
1. Clean male and female threads to remove
the old Teflon tape.
2. Start the tape 2 threads BELOW the open
end of the connection.
3. Wrap the tape in a clockwise direction or the
same direction as you would tighten.
4. Make sure you apply two layers as you wrap
your way toward the end.
5. Never start the Teflon tape at the end.
6. Never use Teflon tape on straight threaded
or JIC type connections.
Straight Threaded O-Ring
Connections
Straight threaded connections (aka, SAE o-ring
connections) have a “straight” thread to connect
the male and female ends. The thread-in for this
type of connection does not do the sealing
(unlike a pipe thread). Straight threaded
connections use an o-ring located at the end of
the male thread to make the hydraulic seal so
Teflon tape isn’t necessary. These use –900
series o-ring sizes.
Figure 4.6- Straight Threaded O-Ring
Connection
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JIC Male/Female Flared Hose after makeup as well as making it difficult to

repair. When you disconnect a flange, it’s
Connections: always a good idea to replace the o-ring with a
new one before reconnecting.
The JIC (Joint Industrial Council) type-
connection uses a smooth tapered 37° male and
female connector to make a hydraulic seal. JIC
connectors are often used for connecting hoses
to permanent connections on hydraulic valves
and manifolds. JIC connections are easy to
recognize, you can see the 37° smooth taper at
the end of the male connection. Teflon tape is
not necessary for JIC type connections.

Figure 4.8- 4-Bolt Flange Connection

Figure 4.7- JIC Flared Hose Connection

4-Bolt Flange Connections:
Flange connections are used for large, high flow
connections 1 inch or larger. Flanges use an o-
ring on the flange face to make the hydraulic
seal. The flange is held in place with 4 bolts. It is
important not to scratch the o-ring surface when
positioning a flange as this may cause it to leak
The flange must fit flat against its mating
surface for the o-ring to seal properly. It’s also a
good idea to use a thread anti-seize compound
on the 4 bolts to allow easier removal of the
bolts the next time. It is also a good practice to
fill the heads of socket head cap screw bolts with
silicone sealant to prevent corrosion of the
internal hex. The bolt head will be in good
condition the next time the flange is removed.

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Unit E Quiz: Threaded Hydraulic Connections

1. List and describe each of the 4 connections typically used with Coiled Tubing Units.
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________

2. Of the 4 listed, which use an O-Ring to seal its connection? Which use teflon tape?
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________

3. Knowing that teflon tape is used for properly sealing some connections, list at least 4 ways to use it
correctly.
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________

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Section 4 Self Check Test:

Coiled Tubing Hydraulic System Equipment
Answer each question below by filling in the blank or marking the correct answer. Refer to the page
number after each question if you need help or to check your answers.

1. The 4 types of hydraulic connections used in coiled tubing are:

_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________

2. On a Power Pack, _________________________filters clean the hydraulic fluid as it goes back to the
hydraulic tank; _____________________ filters cleans the oil going to the pump inlets.
3. Basically, “Loading” a pump means that the hydraulic pump is turned _________ and “venting” a
hydraulic pump means that it is turned __________.
4. List the 3 groups of valves used to control the fluid power systems.
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________

5. (A) A ______________________ is an example of a Fixed Displacement Pump.

(B) A ______________________ is an example of a Variable Displacement Pump.

6. (A) Name two ways hydraulic fluid could become contaminated.

_________________________________________________________________________________
_________________________________________________________________________________

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(B) Of the two ways, ______________________ specifically attacks the wear additives in most
hydraulic fluids.

7. _________________________________ are connections used most often on high flow, 1 in. or larger
hydraulic lines.

8. Name the components that typically make up a power pack unit.

_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________

9. On a standard 6V-53 hydraulic power pack, there are 3 main types of “circuits.” Name and describe
each type.
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_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
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_________________________________________________________________________________

10. A Power Pack can either be controlled at the ______________________________ or remotely

controlled from the __________________________________.
11. List 4 ways you can protect yourself while working with hydraulic systems.
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
12. Power Packs supply the power necessary to operate the equipment on a coiled tubing unit. Name
each.
_________________________________________________________________________________
_________________________________________________________________________________

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_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________

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Unit A Quiz Answer Key: Hydraulic System Safety

1. Name the six types of safety equipment listed you should wear while working with hydraulic systems.
• Eye protection
• Hearing protection
• Protective clothing
• Gloves
• Steel toe shoes
• Hard hat

2. While all hydraulic circuits should be bled off after shut down, why is it especially important that
BOPs with accumulators be bled off?
Accumulators can still be pressurized even if the power pack is shut down or when pumps have
been vented.

3. At Halliburton, learning appropriate safety procedures come before:

Knowing appropriate safety procedures come before learning the operation of any unit or
knowing how to properly do any type of job.

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Unit B Quiz Answer Key: Power Pack

1. There are two types of pumps used on a power pack. Name each and describe their function.
Fixed displacement pumps – Produce a fixed amount of oil with each revolution of the input
shaft regardless of demand pressure. The most common fixed displacement pump is the gear
pump.
2. Return filters can be serviced in the yard or on location, while suction filters must always be
serviced in the yard.
3. Give a brief description how pump control is maintained on Injector/Crane Circuits:
Pump control on injector/crane circuits are controlled individually at the pump unloader valve
in conjunction with the pressure relief valve. These are remotely controlled from the control
house by a double a (or similar) valve.

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Unit C Quiz Answer Key: Connecting and Lifting Hydraulic Equipment

1. During rig up, why is it important to make sure all threaded quick disconnects are tighten before
starting the power pack?
Threaded quick disconnects may appear tight but may only be partially connected or not at all.

2. When attaching a lifting sling, how far away from the end is allowable when placing it? Why should
it be under this distance?
Attach a lifting (choker) slings to hoses no further than 5 feet away from a hose end. This could
weaken or kink the hose’s interior liner and cause hose failure when the hose is pressurized.

3. Why is it smart to use a tag line when lifting a load?

Always attach a tag line while lifting loads to keep them from rotating as they are raised.

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Unit D Quiz Answer Key: Types of Fluid Contamination

1. List at least 7 (out of 10) ways in preventing hydraulic fluid contamination.

• Always clean hydraulic connections before making them up.
• Always install protector caps for large quick disconnects.
• Always use clean containers when draining or adding fluid to the hydraulic tank.
• Always close the filler cap on the hydraulic tank after adding fluid.
• Always make sure that filter cap o-rings are in place after servicing filters
• Always follow suction and return filter servicing procedures (do not take short cuts!).
• Always use clean hydraulic fluid in a hydraulic tank.
• Never add a mismatched or non-approved hydraulic fluid into the tank.
• Never disable the tank filler port filter.
• Depending on the type of connections you are using, always use Teflon tape properly.
Teflon is a source of contamination and is known to jam hydraulic components.

2. Of all of the ways fluids can become contaminated, which is the most common? Why?
Water accumulation is a common problem. Water attacks the anti-wear additives that are in
most hydraulic fluids. If this happens, the pumps and other hydraulic components will wear out
more quickly.

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Unit E Quiz Answer Key: Threaded Hydraulic Connections

1. List and describe each of the 4 connections typically used with Coiled Tubing Units.
Tapered-Threaded Pipe Connections
Pipe threaded connections have “tapered” male and female threads. It is the interfacing and
crushing of the two threads that make the hydraulic seal.
Straight threaded connections (aka, SAE o-ring connections)
These have a “straight” thread to connect the male and female ends. The thread-in for this type
of connection does not do the sealing (unlike a pipe thread). Straight threaded connections use
an o-ring located at the end of the male thread to make the hydraulic seal.
The JIC (Joint Industrial Council) Connections
These type of connections use a smooth tapered 37° male and female connector to make a
hydraulic seal. JIC connectors are often used for connecting hoses to permanent connections on
hydraulic valves and manifolds.
4-Bolt Flange Connections
These type of Flange connections are used for large, high flow connections 1 inch or larger.

2. Of the 4 listed, which use an O-Ring to seal its connection? Which use teflon tape?
4-Bolt Flange Connections
Straight threaded connections (aka, SAE o-ring connections)

3. Knowing that teflon tape is used for properly sealing some connections, list at least 4 ways (out of 6)
to use it correctly.
1. Clean male and female threads to remove the old Teflon tape.
2. Start the tape 2 threads BELOW the open end of the connection.
3. Wrap the tape in a clockwise direction or the same direction as you would tighten.
4. Make sure you apply two layers as you wrap your way toward the end.
5. Never start the Teflon tape at the end.
6. Never use Teflon tape on straight threaded or JIC type connections.

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 Coiled Tubing Hydraulic System Equipment

Section 4 Self Check Test Answer Key:

Coiled Tubing Hydraulic System Equipment
1. The 4 types of hydraulic connections used in coiled tubing are:
Tapered-Threaded Pipe Connections
Straight threaded connections (aka, SAE o-ring connections)
The JIC (Joint Industrial Council) Connections
4-Bolt Flange Connections

2. On a Power Pack, Return Filters clean the hydraulic fluid as it goes back to the hydraulic tank;
Suction Filters cleans the oil going to the pump inlets.

3. Basically, “Loading” a pump means that the hydraulic pump is turned ON and “venting” a hydraulic
pump means that it is turned OFF.

4. List and describe the 3 groups of valves used to control the fluid power systems.
Directional Control Valves
Directional Control Valves – purpose is to control direction of motion in cylinders, fluid motors,
or actuators.
Pressure Control Valves
Pressure Control Pumps–produce variable flow rate up to its physical size limits and pressure
setting. These are also known as piston pumps.
Flow Control Valves
Flow Control Valves – whose primary function is to regulate the rate of fluid flow for the
purpose of controlling speed of motion in cylinders and fluid motors.

5. (A) A Gear Pump is an example of a Fixed Displacement Pump.

(B) A Piston Pump is an example of a Variable Displacement Pump.

6. (A) Name two (out of 10 listed) ways hydraulic fluid could become contaminated.
Particulated Contamination
Water Contamination
(B) Of the two ways, Water Contamination specifically attacks the wear additives in most hydraulic
fluids.

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7. 4-Bolt Flange Connections are connections used most often on high flow, 1 in. or larger hydraulic
lines.

8. Name the components that typically make up a power pack unit.

The components that make up a typical coiled tubing power pack consists of a diesel engine, a
system of hydraulic pumps, a hydraulic tank, hydraulic pressure controls and directional
control circuitry.

9. On a standard 6V-53 hydraulic power pack, there are 3 main types of “circuits.” Name and describe
each type.
• The Injector/Crane circuit consists of 3 gear pumps mounted on the right side rear of the
gear pump drive box located on the engine. This high flow circuit provides power to the
injector and crane.
• The House/bop circuit consists of a variable displacement pump mounted on the back right
hand side of the engine cam tower and provides power to the hydraulically operated well
control equipment.
• The Reel circuit consists of a variable displacement pump mounted to the left side rear of
the pump drive gear box located on the engine. Is used primarily to power the reel
direction, and to maintain back pressure on the reel while pipe is being spooled on or off.

10. A Power Pack can either be controlled at the Well Head or remotely controlled from the Control
House.

11. List 4 (out of 6) ways you can protect yourself while working with hydraulic systems.
• Eye protection
• Hearing protection
• Protective clothing
• Gloves
• Steel toe shoes
• Hard hat

12. Power Packs supply the power necessary to operate the equipment on a coiled tubing unit. Name
each. (5)
• The Injector
• The Reels
• The Control Systems
• The Crane
• The Cooling and Charge Systems

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