MN 006 0509 010 0509 011.desbloqueado

DOCUMENT NUMBER: MN-006-0509-010--0509-011
Users Guide
10,000 PSI Pressure Testing Skid
Part No. AM805UU0028
Hydraulically Powered/Off-Skid Fluid Supply Provision
Revision Information
Disclaimer
Lee Specialties Ltd. has made every effort to ensure that this document contains accurate and current
information, however, the document is intended to be used in conjunction with a complete training
program and on-site supervision and Lee Specialties Ltd. does not warrant or guarantee that the
information contained herein is either complete or accurate in every respect, and the reader hereby
protects, indemnifies and holds harmless Lee Specialties Ltd. together with its officers, employees and
agents from and against all liability for personal injury, death or property damage to any person
arising directly or indirectly from the use by the reader of the information contained in the document.
Contact Information
If you have any questions that are not covered by the contents of this manual please let us know:
Lee Specialties Ltd.
7739 Edgar Industrial Way
Red Deer, Alberta
Canada T4P 3R2
telephone: +1.403.346.4487
facsimile: +1.403.347.3312
e-mail: enquiries@leespecialties.com
web site: www.leespecialties.com
Copyright Information
Copyright Lee Specialties Ltd.
Revision Date Released Description of Changes Reviewer(s)/Approver(s)
0 July 2003 First release
1 November 2005 Format updates, content additions to
Specification section, provision to draw from
an off-skid fluid supply
M. Bourassa, J. Svederus, B. Thomas
Confidential
This document and the proprietary information herein are the property of
Lee Specialties Ltd. It shall not be disclosed nor copied, in whole or in part,
without the written consent of Lee Specialties Ltd.
Unauthorized transmission, reproduction, transcription, or retrieval system
storage in any form is prohibited.
USERS GUIDE TABLE OF CONTENTS
LEE SPECIALTIES LTD., 2005 MN-006-0509-010--0509-011 REV 1
III
Table of Contents
Section 1: About This Document 1
Section 2: Safety 3
2.1 General Safety 3
2.2 Personal Safety 4
2.3 Hydraulic Safety 4
2.4 Environmental Safety 5
Section 3: System Description & Specifications 7
3.1 Overview 7
3.2 Operators Control Panel 10
3.3 Skid Controls 11
3.3.1 Flow Control Valve 11
3.3.2 External Fill Valve and Port 12
3.3.3 Testing Fluid Directional Valves 12
3.3.4 Testing Fluid Tank Valves 13
3.3.5 Hand Pump 13
3.3.6 Pressure Hose Bleed-Off Valves 14
3.4 10,000 PSI Intensifier Pump 15
3.5 Specifications 16
Section 4: Operation 19
4.1 PreOperation Checklist 19
4.2 Maintenance During Operation 20
4.3 Start Up Procedures 21
4.3.1 Start the Engine 21
4.3.2 Connect the Pressure Supply and Return Hoses 22
4.3.3 How to Use the Charge Pump to Fill the Testing Fluid Tanks from an External Source 22
4.3.4 How to Pump Testing Fluid from One Tank to the Other 22
4.3.5 How to Use the Hose Reel Functions 23
4.4 Pressure Test 24
4.4.1 Pressure Test with Testing Fluid Drawn from Skid Tanks 24
4.4.2 Pressure Test with Fluid Drawn from the External Fill Port 25
4.5 Shut Down Procedures 26
TABLE OF CONTENTS USERS GUIDE
MN-006-0509-010--0509-011 REV 1 LEE SPECIALTIES LTD., 2005
IV
Section 5: Maintenance 27
5.1 Maintenance Schedules 27
5.1.1 Daily Maintenance 27
5.1.2 100 Hour Maintenance 28
5.1.3 Six Month Maintenance 29
5.1.4 Annual Maintenance 29
5.2 Maintenance Procedures 29
Appendix A: Technical Information A-1
Hydraulic Schematic with Parts Information A-2
Hose List A-3
Technical Drawings with Parts Information A-5
Appendix B: OEM Reference Material B-1
USERS GUIDE 10,000 PSI PRESSURE TESTING SKID
1
Section 1: About This Document
This document contains the following information about the 10,000 PSI Pressure Testing Skid:
general safety information
set up, operation and take down procedures
maintenance schedules and procedures
The complete documentation package also contains the following:
hydraulic schematic with parts information
hose list
technical drawings with parts information
third-party reference information where appropriate
ABOUT THIS DOCUMENT USERS GUIDE
2
This page has been left blank intentionally.
3
Section 2: Safety
2.1 General Safety
Safety should never be taken lightly. The potential for accidents or fatal injuries is always
present when dealing with the high pressures of hydraulic systems. All personnel should be
aware of the dangers of working with hydraulic systems and take the appropriate precau-
tions. This will help to ensure the safety and well-being of all persons within your operation.
Whether on site or in the shop, you are obligated to incorporate safety practices into your reg-
ular work routine.
Where appropriate in this manual, relevant safety notices have been highlighted to draw your
attention to any possible hazards. These notices do not replace proper training on equipment
or well site safety procedures.
Table 2-1: Safety Symbols
Symbol Definition
DANGER! This symbol and paragraph
indicate a risk of serious injury or death
to personnel.
WARNING! This symbol and paragraph
indicate a risk of severe damage to
equipment.
CAUTION: This symbol and paragraph
indicate a risk of moderate injury to
personnel or damage to equipment.
NOTE: This paragraph indicates useful
information that will allow the user to
complete tasks quickly and efficiently.
SAFETY USERS GUIDE
4
2.2 Personal Safety
Wear appropriate clothing for the job. This may include hard hats, fire retardant
clothing, gloves, and CSA approved safety footwear. Check local policies on per-
sonal protective equipment (PPE).
Wear safety glasses, goggles, and/or face shields when potential eye hazards
exist. Any airborne dust, liquid, gaseous or chemical compounds, or high-pres-
sure air can be hazardous to your eyes.
Earplugs and/or industrial ear muffs are highly advised where sound levels
might reach damaging levels.
Wear a self-contained breathing apparatus when working around smoke, vapor,
fumes, gases, or areas with insufficient oxygen.
Do not wear jewelry (watches, rings, necklaces), loose-fitting clothing, or any-
thing that could be caught in the moving parts of machinery. Other items that
can become caught in moving equipment include scarves, gloves, belts, and
shoelaces.
Ensure that long hair and beards are tied back and secured such that they will
not fall into or be caught in moving equipment.
Ensure that all personnel handling hazardous materials used in wireline and
testing operations are aware of the possible dangers.
Use approved equipment when handling hazardous materials. Improper han-
dling or the incorrect equipment may cause serious injury or even death.
All personnel must be properly trained for every job, including the proper use of
equipment, knowledge of procedures, etc. Improper or insufficient training can
lead to the endangerment of all persons on a job site.
Ensure that everyone on a work site is aware of any potential dangers from
equipment or from the location.
2.3 Hydraulic Safety
Hydraulic systems are built to store energy and can generate extremely high
pressures that exert force upon other pieces of equipment. Serious injuries or
even death can result if any personnel do not follow appropriate safety proce-
dures.
Check all hoses and fittings for wear or damage before you attempt to operate
any equipment. Replace any parts that seem questionable. Failure to correctly
service equipment could result in serious injuries.
Connect all lines and hoses correctly. An incorrect connection can cause the
reverse of an intended action. A sudden, unexpected action could result in seri-
ous injury.
Never attempt to service or adjust any piece of equipment while it is under pres-
sure! Always shut down the equipment and unload pressure from the system
before performing any kind of maintenance.
Never use your hands to try and detect a pinhole leak. Always use a piece of
wood or cardboard, and wear safety glasses or a face shield.
Tighten all connections before you apply system pressure. Completely relieve all
pressure before disconnecting any hydraulic lines. Fluid under pressure can be
strong enough to penetrate steel.
Do not weld, solder, or use any type of torch near a pressurized line. The heat
could rupture the hose and ignite the fluid within, causing serious burns.
Be aware that even solar and ambient heat can cause thermal expansion of
hydraulic fluid in a closed system. This can result in blown seals or unexpected
equipment operation.
USERS GUIDE SAFETY
5
2.4 Environmental Safety
Please dispose of all hydraulic fluids properly. Incorrect disposal of wastes can harm the envi-
ronment and ecology of a given area. Your local environmental agency can advise you of the
proper procedures.
Always use proper containers when draining fluids. Do not use food or beverage containers
or anything at may mislead someone to drink from it. Do not pour the fluids onto the ground,
down a drain, or into a stream, pond, or lake. Observe relevant environmental protection reg-
ulations when disposing of petroleum products.
DANGER! Be Aware! Be Alert! Be Safe!
SAFETY USERS GUIDE
6
7
Section 3: System Description & Specifications
3.1 Overview
The 10,000 PSI Pressure Testing Skid is a compact and durable device used for safe and effi-
cient hydrostatic pressure testing of wellhead equipment in the shop or field.
The skid is powered by a 20hp diesel engine. A 48 cc hydraulic gear pump and an 18 cc piston
pump attached to the engine provide hydraulic flow. The gear pump provides hydraulic flow
to the hose reels and the charge pump, and the piston pump provides hydraulic flow to the
intensifier pumps. The charge pump moves the testing fluid to the intensifier pumps and is
also used to fill the testing fluid tanks from an external source and to pump testing fluid
between the fluid tanks.
The system uses two hydraulically driven intensifier pumps to pump the pressure testing
fluid to the equipment being tested. A high volume pump is used to fill equipment and
increase system pressure up to 1,000 psi, and a high pressure pump is used to increase system
pressure to a maximum of 12,000 psi.
The skid displays hydraulic and equipment system pressure separately at the operatorss
panel, in both metric and imperial units. A relief valve is installed to protect the high volume
pump in the event that the pumps discharge ball valve leaks. The relief valve will begin to
relieve pressure at 1,750 psi.
The unit has four lifting brackets, one on each corner, that can be used to lift the unit from
above. A forklift can also be used to lift the unit.
Figure 3-1: 10,000 PSI Pressure Testing SkidTop View
SYSTEM DESCRIPTION & SPECIFICATIONS USERS GUIDE
8
Figure 3-2: Hose Reels
1. High Pressure Fluid Supply Hose
2. Valve Control Hydraulic Hose
3. High Pressure Fluid Return Hose
Figure 3-3: Testing Fluid Tanks
1. Testing Fluid Tank 1
(45 US gallons/170.3 L)
2. Testing Fluid Tank 2
(74 US gallons/283.9 L)
Figure 3-4: Diesel Engine and Hydraulic Filter
1. Hydraulic Fluid Filter
2. Yuken Piloted Relief Valve
3. Kubota Diesel Engine
USERS GUIDE SYSTEM DESCRIPTION & SPECIFICATIONS
9
Figure 3-5: 12 Volt Battery
10
3.2 Operators Control Panel
Figure 3-6: Operators Control Panel
Table 3-1: Control and Gauge Descriptions for the Operators Control Panel
Item Name Description
1 Pilot for relief valve
(large Yuken control)
Adjusts the hydraulic pressure for the hose reels/charge pump
hydraulic circuit.
2 HYDRAULIC REGULATOR
rotary control
Adjusts the hydraulic pressure for the intensifier pump hydraulic
circuit.
3 HYDRAULIC PRESSURE
gauge
Displays the hydraulic fluid pressure.
4 PRESSURE gauge Displays the fluid pressure at the hose.
5 ENGINE SPEED rotary
control/pull knob
Controls the engine speed.
Turn the control counter-clockwise to increase engine speed.
Turn the control clockwise to decrease engine speed.
6 ENGINE STOP pull knob Stops the engine. Pull to operate.
7 ENGINE START/ENGINE
PREHEAT spring-return-
to-neutral switch
PREHEAT activates the glow plugs. START starts the engine.
The glow plugs should be engaged before the engine is started. The
time required to preheat depends on the ambient temperature.
Refer to the Kubota diesel engine manual for details.
8 WORK LIGHTS switch Activates the skid work lights. The lights draw power from the 12VDC
batter for the diesel engine.
9 EMERGENCY STOP pull
knob
Stops the engine by closing the air supply.
Pull the button firmly to stop the engine.
10 OIL PRESSURE gauge Displays the engine oil pressure.
11 VOLTAGE gauge Displays the 12VDC battery voltage.
12 ENGINE SPEED gauge Displays the engine speed in rpm.
13 ENGINE TEMP. gauge Displays the engine temperature.
11
3.3 Skid Controls
This section describes the skid controls that are not on the operators control panel.
3.3.1 Flow Control Valve
The flow control valve, located below and to the left of the operators control panel, controls
the rate of hydraulic flow from the gear pump on the engine to the 4-bank spool valve on the
operators control panel. The 4-bank spool valve contains controls for the charge pump and
the supply, return, and valve supply hose reels. Use the flow control valve to control the
speed of rotation for the charge pump and hose reels. Increasing the flow will increase the
pressure out of the charge pumps.
14 CHARGE PUMP
ON/OFF lever
Controls hydraulic flow from the gear pump to the charge pump.
15 SUPPLY
IN/OUT lever
Directs hydraulic flow to the SUPPLY hose reel so the operator can
spool out or reel in the high pressure fluid supply hose.
16 RETURN
IN/OUT lever
Directs hydraulic flow to the RETURN hose reel so the operator can
spool out or reel in the high pressure fluid return hose.
17 VALVE SUPPLY
IN/OUT lever
Directs hydraulic flow to the auxiliary hose reel so the operator can
spool out or reel in the hydraulic hose.
18 HIGH PRESSURE/HIGH
VOLUME lever
Directs hydraulic flow from the charge pump to either the high
volume or high pressure intensifier pump.
Figure 3-7: Flow Control Valve
Table 3-1: Control and Gauge Descriptions for the Operators Control Panel
Item Name Description
12
3.3.2 External Fill Valve and Port
The external fill valve and port allows the operator to supply testing fluid to the skid from an
external source. The testing fluid can be directed either to the fluid tanks or directly to the
intensifier pumps.
3.3.3 Testing Fluid Directional Valves
There are two fluid direction valves on the testing fluid circuit. One directs testing fluid to the
intensifier pumps from the external fill port (normally closed). The other valve directs testing
fluid from the charge pump to the intensifier pumps.
Figure 3-8: External Fill Valve and Port
1. External Fill Port with
Camlock Cover
2. External Fill Valve
Figure 3-9: Testing Fluid Direction Valves
1. External Fill Port to Intensifier Pumps
(normally closed)
2. Charge Pump to Intensifier Pumps
13
3.3.4 Testing Fluid Tank Valves
The fluid tank suction valves determine from which fluid tank testing fluid will be drawn.The
fluid tank fill valves determine to which tank testing fluid will be directed.
3.3.5 Hand Pump
The hand pump, located to the right of the operators control panel, provides hydraulic pres-
sure to the auxiliary hydraulic hose. To fill the hydraulic reservoir, open the access port,
which is the black lid below the handle grip.
Figure 3-10: Testing Fluid Tank Valves
1. Fill Valve for Tank 1
2. Fill Valve for Tank 2
3. Suction Valve for Tank 1
4. Suction Valve for Tank 2
Figure 3-11: Hand Pump
Figure 3-12: Relief Valve on the Hand Pump
Note: Remove the handle of the
hand pump and use the notched
end to loosen the relief valve.
14
3.3.6 Pressure Hose Bleed-Off Valves
There are bleed-off valves on both the high-pressure fluid supply and return hoses. Use these
valves to release pressure from the supply or return lines.
DANGER! Fluid under high pressure can cause serious
injury. Always use caution when working with
high pressure fluids.
Figure 3-13: Bleed-Off Valve for the Pressure Supply Hose
Figure 3-14: Bleed-Off Valve for the Pressure Return Hose
15
3.4 10,000 PSI Intensifier Pump
The 10,000 PSI Intensifier Pump is designed for grease seal and pressure testing applications.
The pump is capable of 0.6 gpm @ 60 strokes/minute and a maximum operating pressure of
10,000 psi.
The high pressure intensifier pump can be used in all environments with the following restric-
tions:
Maximum temperature: 40C (104F). In extremely hot weather, the pump must
be monitored for oil overheating.
Minimum temperature: 40C (40F). Before using in cold temperature, allow
the hydraulic oil to circulate and warm up.
The high pressure intensifier pump is used primarily with wireline or slickline to create a
grease seal when running downhole tools. The pump can also be used for the following appli-
cations:
Any situation where fluid needs to be pumped at high pressure and there is a
hydraulic fluid supply available.
Utilization as a test station on skids and/or trucks.
The general hydraulic supply requirements for the high pressure intensifier pump are as fol-
lows:
Pump capable of 2000 psi and 11 gpm.
Pressure must be adjustable from approximately 100 2000 psi to control grease
or testing fluid pumping pressure.
Figure 3-15: High Pressure and High Volume Pumps
Hydraulic Motors
1. High Pressure Pump
2. High Volume Pump
16
3.5 Specifications
Table 3-2: 10,000 PSI Hydraulic Pressure Tester Specifications
Specification Group Specification Details
Operating Parameters Max. operating pressure 10,000 psi (68.95 MPa)
Temperature range 40C (104F) to 40C (40F)
In extremely hot weather, the pump must be
monitored for oil overheating.
Before using in cold temperature, allow the
oil to circulate and warm up.
Skid Information Length 92.0 in. (233.7 cm)
Width 54.0 in. (137.2 cm)
Height 47.0 in. (119.4 cm)
Weight 3000 lb. (1364 kg)
Engine
Refer to the Kubota diesel
engine manual for more
information.
Lee Part No. AM810UU0223
Manufacturer Kubota
Type Vertical, water-cooled, 4-cycle diesel
engine, 3-cylinder
Model D902
Horsepower 20.4 hp @ 3600 rpm
(15.2 kW @ 3600 rpm)
Gear Pump Lee Part No. PM810UU0121
Manufacturer Caproni
Type 38 cc (per revolution)
Volume and Flow dependent on engine speed
Piston Pump Lee Part No. PM810UU0171
Manufacturer Rexroth
Type 18cc variable displacement piston pump
Charge Pump Lee Part No. PM810UU0325/PM810UU0352
Manufacturer Ace
Type Non-positive displacement centrifugal pump
Volume and Flow 10 US gal/min. @ 120 psi with 5000 rpm
(37.7 Lpm @ .8 MPa)
Hydraulic Motors for the
High Pressure and High
Volume Pumps
Lee Part No. PM631UU0001
Manufacturer Lee Specialties Ltd.
Type Reciprocating
Quantity 2
17
High Volume Pump Lee Part No. AM628UU0003
Type Piston pump
Intensification ratio 1.2: 1
Max. continuous
operating pressure
1000 psi (6.89 MPa)
Volume and Flow 4.6 US gal/min. @50 spm (17 Lpm)
High Pressure Intensifier
Pump
Lee Part No. AM627UU0003
Type Piston pump
Hydraulic supply Pump capable of 2000 psi and 11 US gpm;
pressure adjustable from 100 to 2000 psi
(13.79 MPa and 41.64 Lpm; adjustable from
0.69 MPa to 13.29 MPa)
Intensification ratio 6.9:1 (hydraulic to grease)
Max. continuous
operating pressure
10,000 psi (68.95 MPa)
Volume and Flow 0.6 US gal/min. @ 60 strokes/min.
(2.3 Lpm)
Hand Pump Lee Part No. AM810UU0217
Manufacturer TR Engineering
Pressure 5000 psi (34.5 MPa)
Fluids
*Refer to the Kubota diesel
engine manual for more
information.
Hydraulic fluid ATF Dexron III
Engine fuel* Diesel fuel oil No. 2-D
Engine oil* MIL-L-2104C or be above CD grade (API
classification)
Coolant* 1:1 (50%) solution of pure water and anti-
freeze
Testing fluids Pure water and/or methanol
DO NOT leave water in the pressure tester if
temperatures are below freezing.
Fluid Tank Volumes Hydraulic oil tank 22 US gallons (83.3 L)
Fuel tank 13 US gallons (49.2 L)
Testing fluid tank 1 45 US gallons (170.3 L)
Testing fluid tank 2 75 US gallons (283.9 L)
Hoses Supply pressure hose 150 ft. (45.7 m)
Return pressure hose 200 ft. (70 m)
Hydraulic valve control
hose
200 ft. (70 m)
Table 3-2: 10,000 PSI Hydraulic Pressure Tester Specifications
Specification Group Specification Details
18
19
Section 4: Operation
4.1 PreOperation Checklist
This section contains information on operating procedures for the 10,000 PSI Pressure Testing
Skid.
NOTE: Refer to the Kubota diesel engine manual for more information about the operation of
the engine.
1. Verify the equipment: When the pressure testing skid arrives on site, check to
ensure that all required components, fluids and hoses required to operate the
equipment are present.
2. Place the equipment: The placement of the unit on site will be determined by the
site manager according to the local safety requirements, job requirements and
operating conditions of the site.
3. Inspect the equipment: Perform the following inspections before you operate the
equipment. See also Table 4-1, Maintenance Tasks Required During Operation,
on page 20 and Table 5-1, Daily Maintenance Tasks, on page 27.
WARNING! Failure to perform these checks could result in
equipment shut down or malfunction.
a. Perform a visual and tactile (feel) inspection for broken or loose equipment.
Replace components or correct problems before you operate the equipment.
b. Perform a visual and tactile (feel) inspection for loose fasteners.
c. Inspect all hose connections to ensure that they are correctly and securely fas-
tened.
d. Inspect all safety guards and shields. If any guard or shield is missing or dam-
aged, DO NOT operate the equipment until after the guard or shield is
repaired or replaced.
e. Inspect the water separation wells for the hydraulic fluid and fuel tanks (if
applicable) and drain them if necessary.
f. Verify all fluid levels:
hydraulic fluid
engine oil
engine coolant
engine fuel
testing fluid
OPERATION USERS GUIDE
20
4.2 Maintenance During Operation
Perform the following inspections and tasks during the operation of the 10,000 PSI Pressure
Testing Skid.
WARNING! Failure to perform these checks could result in
equipment shut down or malfunction.
Table 4-1: Maintenance Tasks Required During Operation
Maintenance Point Task
Hydraulic fluid tank Monitor level. Fill when necessary.
Keep this tank full to ensure maximum hydraulic
pressure. The sight glass is on the side of the tank.
Hand pump reservoir Monitor level. Fill when necessary.
Testing fluid Monitor levels. Fill when necessary.
Test pressure Monitor level at gauge on the operator's panel.
Engine temperature* Monitor the gauge at the operators panel.
Engine oil pressure* Monitor the gauge at the operators panel.
Engine speed* Monitor the gauge at the operators panel.
Engine fuel* Monitor fuel levels. Fill when necessary. The sight
glass is on the side of the tank.
* Refer to the Kubota diesel engine manual for more information.
USERS GUIDE OPERATION
21
4.3 Start Up Procedures
See 3.2 Operators Control Panel on page 10 and 3.3 Skid Controls on page 11 for a
description of the controls used in the following procedures.
4.3.1 Start the Engine
1. Release the latch on the left side of the operators control panel lid and open the
control panel. If required, turn on the skid work lights. See Figure 3-6 Opera-
tors Control Panel, on page 10 for a description of the controls.
NOTE: The work lights draw power from the 12VDC battery for the diesel
engine.
2. On the operators control panel, ensure all directional control levers are in the
central/neutral position.
3. Ensure that the HYDRAULIC REGULATOR control is at its lowest pressure set-
ting. Rotate the regulator control counterclockwise until there is no tension felt
at the control.
WARNING! If the HYDRAULIC REGULATOR control is at a
high setting at startup, then the unit will deliver
testing fluid at a high pressure immediately.
This can over-pressure both the skid equipment
and the equipment being tested.
4. Ensure the ENGINE SPEED control is at its lowest position.
NOTE: Turn the control clockwise until it stops rotating, or push the orange
knob and push the control all the way down towards the panel.
5. Open the fuel block valve on the fuel tank.
6. Ensure the engine EMERGENCY STOP switch is in the operational position.
7. Ensure the ENGINE STOP control on the operators panel is in the down posi-
tion.
8. At the operators panel, turn the ENGINE START/PREHEAT switch to
PRE-HEAT and hold it in position for approximately 5 seconds.
NOTE: The PREHEAT control engages the glow plugs for the engine. In cold
temperatures, hold the switch for a longer period of time. Refer to the Kubota
diesel engine manual for details.
9. Turn the ENGINE START/PREHEAT switch to ENGINE START.
CAUTION: Do not engage the ENGINE START button for more
than 10 seconds at a time. If the engine does not
start, preheat the engine and try again.
10. Once the engine has started, allow it to idle at low rpm.
11. Check all enginerelated gauges to ensure the engine is working normally.
NOTE: Refer to the Kubota diesel engine manual for details about normal oper-
ating parameters.
12. While the engine is idling, inspect the entire system for leaks.
DANGER! NEVER use your hands or any other body part to
test for leaks. Fluids under high pressure can
cause serious injuries. If you find any leaks, shut
down the system and correct the leaks before
you continue operations.
Once the diesel engine is running, set up the skid unit for the desired operation.
22
4.3.2 Connect the Pressure Supply and Return Hoses
This procedures assumes that the diesel engine is running.
1. Spool out the high pressure supply and return hoses and connect them to the
equipment to be tested.
NOTE: See 4.3.5 How to Use the Hose Reel Functions on page 23.
2. Spool out the auxiliary hydraulic hose and connect it to the pilot operated relief
valve.
4.3.3 How to Use the Charge Pump to Fill the Testing Fluid
Tanks from an External Source
This procedure assumes that the diesel engine is running. See 3.2 Operators Control Panel
on page 10 and 3.3 Skid Controls on page 11 for a description of the controls used in this
procedure.
NOTE: This procedure describes how to fill the pressure testing fluid tanks ONLY. When you
fill a testing fluid tank, the charge pump needs to be operated. In order to operate the charge
pump, fluid is required from one of the tanks to prime the pump.
1. Connect the external testing fluid source to the external fill port on the skid.
2. Open the external fill port valve.
3. Open the fluid suction valve for the tank that will prime the charge pump.
4. Open the fill valve for the tank to be filled.
5. Close both testing fluid directional valves that are near the intensifier pumps.
6. Increase the engine speed until the ENGINE SPEED gauge reads approximately
1400 rpm. Turn the ENGINE SPEED rotary control counterclockwise to
increase engine speed.
NOTE: The throttle control is equipped with a full speed bypass that can be
engaged by pressing the orange button and pulling up on the knob.
7. At the operators panel, move the CHARGE PUMP control to the ON position to
engage the charge pump.
8. When the charge pump starts to operate, close the testing fluid suction valve.
9. Use the flow control valve if necessary to adjust the charge pump speed.
10. Monitor the testing fluid tank levels.
11. When the testing fluid tanks are full, set the CHARGE PUMP control to the OFF
position.
4.3.4 How to Pump Testing Fluid from One Tank to the Other
1. Open the fluid suction valve of the tank from which fluid will be drawn.
2. Open the fill valve of the tank that will be filled.
3. Close both fluid directional valves that are near the intensifier pumps.
4. At the operators panel, move the CHARGE PUMP lever control to the ON posi-
tion to start fluid mixing.
5. Watch level indicators and stop the charge pump when the required movement
is achieved.
23
4.3.5 How to Use the Hose Reel Functions
This procedure assumes that the diesel engine is running. See 3.2 Operators Con-
trol Panel on page 10 and 3.3 Skid Controls on page 11 for a description of the
controls used in this procedure.
1. Set the flow control valve to its lowest flow setting.
2. Rotate the hose reel/charge pump pressure regulator control counter-clockwise
until there is no pressure felt at the control. This unlabeled control is attached to
the left-hand side of the operators control panel.
NOTE: This ensures that the control is at its lowest pressure setting.
3. Set the required HOSE REELS control lever to the IN or OUT position.
4. Use the flow control valve to increase hydraulic flow to the hose reel circuit
selected.
NOTE: The hose reel will spool in or out as indicated by the control lever posi-
tion.
5. Rotate the hose reel/charge pump pressure regulator control clockwise to
increase hydraulic pressure to the hose reel circuit as required.
6. When the required hose has been spooled out, set the HOSE REELS control level
to the center neutral position.
24
4.4 Pressure Test
description of the controls used in the following procedures.
4.4.1 Pressure Test with Testing Fluid Drawn from Skid Tanks
This procedure assumes that the diesel engine is running and that the testing fluid will be
drawn from one of the testing fluid tanks on the skid.
1. Ensure the fluid directional valve from the charge pump to the intensifier pumps
is open.
2. Ensure the fluid directional valve from the external fill port is closed.
3. Close the tank fill valves.
4. Open or close the fluid suction valves on the fluid tanks as required for the cur-
rent job.
5. Ensure the bleed-off valves for the pressure supply and return hoses are closed.
6. Set the CHARGE PUMP control lever to ON.
7. Ensure the hydraulic pressure regulator and flow control valves for the charge
pump are set correctly.
8. Move the HIGH PRESSURE/HIGH VOLUME control lever to select which inten-
sifier pump to operate.
NOTE: Only one intensifier pump can be operated at one time. The high volume
pump will fill the equipment quickly and pressure it to approximately 1000 psi,
and the high pressure pump will increase pressure to a maximum of 10,000 psi.
9. Adjust the HYDRAULIC REGULATOR control to adjust the output flow of the
selected intensifier pump.
Turn the control clockwise to increase output pressure.
Turn the control counterclockwise to decrease output pressure.
10. When the desired system pressure has been reached, decrease the hydraulic
pressure slightly.
11. Monitor the test PRESSURE gauge for the duration of the pressure test.
12. See 4.5 Shut Down Procedures on page 26 when the pressure test is complete.
25
4.4.2 Pressure Test with Fluid Drawn from the External Fill Port
This procedure assumes that the diesel engine is running and that the charge pump will be
used.
1. Connect the external fluid source to the external fill port.
2. Open the external fill valve.
3. Ensure the fluid directional valve from the external fill port to the intensifier
pumps is closed.
NOTE: This valve is located near the intensifier pumps. See Figure 3-9 on
page 12.
4. Ensure the fluid directional valve from the charge pump to the intensifier pumps
is open.
NOTE: This valve is located near the intensifier pumps. See Figure 3-9 on
page 12.
5. Close the tank suction valves.
6. Close the tank fill valves.
7. Ensure the bleed-off valves for the pressure supply and return hoses are closed.
8. Set the CHARGE PUMP control lever to ON.
9. Ensure the hydraulic pressure regulator and flow control valves for the charge
pump are set correctly.
10. Move the HIGH PRESSURE/HIGH VOLUME control lever to select which inten-
sifier pump to operate.
NOTE: Only one intensifier pump can be operated at one time. The high volume
pump will fill the equipment quickly and pressure it to approximately 1000 psi,
and the high pressure pump will increase pressure to a maximum of 10,000 psi.
11. Adjust the HYDRAULIC REGULATOR control to adjust the output flow of the
selected intensifier pump.
Turn the control clockwise to increase output pressure.
Turn the control counterclockwise to decrease output pressure.
12. When the desired system pressure has been reached, decrease the hydraulic
pressure slightly.
13. Monitor the test PRESSURE gauge for the duration of the pressure test.
14. See 4.5 Shut Down Procedures on page 26 when the pressure test is complete.
26
4.5 Shut Down Procedures
description of the controls used in the following procedure.
1. When the test has been successfully completed, pump the hydraulic hand pump
to operate the pilot relief valve.
NOTE: The relief valve will release the pressure from the test equipment.
2. Turn the HYDRAULIC REGULATOR control fully counterclockwise until there
is no tension felt at the control.
3. Move the HIGH VOLUME/HIGH PRESSURE pump control to the center/neutral
position.
4. If required, set the CHARGE PUMP charge pump control to the OFF position.
5. Use the bleed-off valves on the high pressure fluid supply and return hoses to
release pressure in the line.
DANGER! Use caution when working with high pressure
hydraulic systems. DO NOT stand in front of the
valve.
6. Disconnect and reel in all hoses.
DANGER! Ensure that all pressure has been released from
the system before you disconnect any hoses.
7. Use the ENGINE SPEED control to reduce the engine speed.
NOTE: Allow the engine idle before you shut it off.
8. Pull out the ENGINE STOP control to stop the engine.
9. Close the fluid suction valves on the testing fluid tanks.
10. Close the fluid fill valves on the testing fluid tanks.
11. Close the fluid directional valves to the intensifier pumps.
27
Section 5: Maintenance
This section contains maintenance schedules and procedures for the 10,000 PSI Pressure Test-
ing Skid. See also Table 4-1, Maintenance Tasks Required During Operation, on page 20.
WARNING! Failure to perform required equipment
maintenance could result in equipment shut
down or malfunction.
5.1 Maintenance Schedules
5.1.1 Daily Maintenance
Perform the following inspections and tasks at the beginning of every operating day and
before you start the engine.
Table 5-1: Daily Maintenance Tasks
Engine oil level* Inspect for correct level. Fill if necessary.
See Fluids on page 17.
Engine fuel level* Inspect for correct level. Fill if necessary.
Engine coolant level* Inspect for correct level. Fill if necessary.
Engine belts* Inspect for correct fit. Tighten if necessary.
* Refer to the Kubota diesel engine manual for more information.
Hydraulic fluid level Inspect for correct level. Fill if necessary.
Keep full to ensure maximum hydraulic pressure.
Inspect for water contamination, dirt, foreign
particles.
Hoses Inspect for kinks, leaks, pinholes, or other defects.
Inspect hose ends remove and replace if any
problems are found.
DANGER! Do not use hands or any other body
part to test for leaks! Use a piece of wood or
cardboard.
Pillow block bearings on
reels
Inspect for adequate lubrication. Lubricate if
necessary with EP2 grease.
See Figure 5-1, Figure 5-2 and Figure 5-3.
Testing fluid levels Inspect for correct level. Fill if necessary.
MAINTENANCE USERS GUIDE
28
5.1.2 100 Hour Maintenance
Perform the following inspections and tasks every 100 operating hours.
Table 5-2: 100 Hour Maintenance Tasks
Mounting bolts Inspect for wear and tightness. Tighten if necessary.
Pillow block bearings on
the hose reels
Lubricate with EP2 grease.
See Figure 5-1, Figure 5-2 and Figure 5-3.
Engine oil* Replace; see Fluids on page 17.
Engine oil filter* Replace.
Engine air cleaner* Clean or replace.
Engine fuel filter* Clean or replace.
*Refer to the Kubota diesel engine manual for more information.
Figure 5-1: Lubrication Point for the Bearing on the High Pressure Fluid Supply Hose Reel
Figure 5-2: Lubrication Point for the Bearing on the High Pressure Fluid Return Hose Reel
USERS GUIDE MAINTENANCE
29
5.1.3 Six Month Maintenance
5.1.4 Annual Maintenance
5.2 Maintenance Procedures
For maintenance procedures for the Kubota diesel engine, refer to the Kubota diesel engine
manual.
Figure 5-3: Lubrication Point for Bearing on the Auxiliary Hose Reel
Table 5-3: Six Month Maintenance Tasks
Hydraulic system fluid filter Replace (10 micron filter is recommended). See
Figure 3-4 Diesel Engine and Hydraulic Filter, on
page 8 for the hydraulic filter location.
Table 5-4: Annual Maintenance Tasks
Hydraulic system fluid Replace. See Fluids on page 17.
MAINTENANCE USERS GUIDE
30
USERS GUIDE TECHNICAL INFORMATION
A-1
Appendix A: Technical Information
This appendix contains the following reference information:
hydraulic schematic with parts information
hose list
technical drawings with parts information
TECHNICAL INFORMATION USERS GUIDE
A-2
Hydraulic Schematic with Parts Information
A-3
Hose List
Table A-1: 10KPSI Hydraulic Pressure Tester Hose List
Description Hose Part No.
Hand pump to reel A111A2
Jumper hose between Yuken regulators A111A3
Yukentank return A146A1
Pressure regulatorYuken valve A146A3
Pressure gaugepiston pump A147A1
Charge pump hydraulic motor to case drain A148A1
Centrifuge hydraulic motor case drain A148A1
PumpYuken control valve (pressure) A150A3
Case draintank B133B1
Valve reel out B145B1
Valve reel in B146B1
Return reel out B156.5B3
Return reel in B156B3
Charge pump supply B164B1
Supply reel in B168.5B1
Supply reel out B169B1
Piston pumpcontrol valve (2 hoses) C136C3 & C124C4
Flow control supply to control valve C131C1
Control valvehigh volume pump C135C1
Control valvefilter housing C137C4
4bank spool return C138C1
Flow control valvehigh pressure pump C147C1
Pumpflow control inlet C151C3
Centrifuge hydraulic motor return to valve body C152C1
4bank spool supply C153C1
Charge motor return C156C1
Flow controlfilter C160C3
Cooler bypass back to tank D119D2
Into cooler from thermostat D113D1
Cooler return to T D113D3
Return from high pressure pumphigh volume pump D116D3
Supply to gear pump from tank D118D3
Cooler returnfilter housing D160D1
Return from high pressure pumpthermostat D162D3
A-4
Pump discharge to tank return manifold E115HC1
Input to pumps from charge pump E236HC1
Between high pressure pumps (supply) HC6.5HC1
Manifold to manifold suction HC20.5HC1
Between tank return valves HC8.25HC1
Tank suction right side HC10HC1
Tank suction left tank HC21HC1.25
Tank suction manifold bypass - remote suction HC20.5HC1.25
Table A-1: 10KPSI Hydraulic Pressure Tester Hose List
Description Hose Part No.
A-5
Technical Drawings with Parts Information
A-6
A-7
A-8
A-9
A-10
A-11
A-12
A-13
A-14
A-15
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A-16
USERS GUIDE OEM REFERENCE MATERIAL
B-1
Appendix B: OEM Reference Material
This appendix contains the following reference information:
Kubota diesel engine manual
OEM REFERENCE MATERIAL USERS GUIDE
B-2

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