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DOCUMENTNUMBER: MN-006-0509-010--0509-011

Users Guide

10,000 PSI Pressure Testing Skid

Part No. AM805UU0028

Hydraulically Powered/Off-Skid Fluid Supply Provision

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Revision Information

Disclaimer

Lee Specialties Ltd. has made every effort to ensure that this document contains accurate and currentinformation, however, the document is intended to be used in conjunction with a complete trainingprogram and on-site supervisionand Lee Specialties Ltd. does not warrant or guarantee that theinformation contained herein is either complete or accurate in every respect, and the reader herebyprotects, indemnifies and holds harmless Lee Specialties Ltd. together with its officers, employees andagents 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 WayRed Deer, AlbertaCanada T4P 3R2

telephone: +1.403.346.4487facsimile: +1.403.347.3312e-mail: [email protected] 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 ofLee 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 systemstorage in any form is prohibited.

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USERSGUIDE TABLEOFCONTENTS

LEESPECIALTIESLTD., 2005 MN-006-0509-010--0509-011 REV1III

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 113.3.2 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 194.2 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

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TABLEOFCONTENTS USERSGUIDE

MN-006-0509-010--0509-011 REV1 LEESPECIALTIESLTD., 2005IV

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

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USERSGUIDE 10,000 PSI PRESSURETESTINGSKID

LEESPECIALTIESLTD., 2005 MN-006-0509-010--0509-011 REV11

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

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ABOUTTHISDOCUMENT USERSGUIDE

MN-006-0509-010--0509-011 REV1 LEESPECIALTIESLTD., 20052

This page has been left blank intentionally.

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Section 2: Safety

2.1 General Safety

Safety should never be taken lightly. The potential for accidents or fatal injuries is alwayspresent when dealing with the high pressures of hydraulic systems. All personnel should beaware 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 yourattention to any possible hazards. These notices do not replace proper training on equipmentor 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.

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SAFETY USERSGUIDE


2.2 Personal Safety

Wear appropriate clothing for the job. This may include hard hats, fire retardantclothing, 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 levelsmight 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 thatcan become caught in moving equipment include scarves, gloves, belts, andshoelaces.

Ensure that long hair and beards are tied back and secured such that they willnot fall into or be caught in moving equipment.

Ensure that all personnel handling hazardous materials used in wireline andtesting 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 canlead to the endangerment of all persons on a job site.

Ensure that everyone on a work site is aware of any potential dangers fromequipment or from the location.

2.3 Hydraulic Safety

Hydraulic systems are built to store energy and can generate extremely highpressures 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 operateany equipment. Replace any parts that seem questionable. Failure to correctlyservice equipment could result in serious injuries.

Connect all lines and hoses correctly. An incorrect connection can cause thereverse 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 systembefore performing any kind of maintenance.

Never use your hands to try and detect a pinhole leak. Always use a piece ofwood 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 bestrong 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 unexpectedequipment operation.

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USERSGUIDE SAFETY


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 theproper procedures.

Always use proper containers when draining fluids. Do not use food or beverage containersor 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!

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SAFETY USERSGUIDE



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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 pistonpump attached to the engine provide hydraulic flow. The gear pump provides hydraulic flowto the hose reels and the charge pump, and the piston pump provides hydraulic flow to theintensifier pumps. The charge pump moves the testing fluid to the intensifier pumps and isalso used to fill the testing fluid tanks from an external source and to pump testing fluidbetween the fluid tanks.

The system uses two hydraulically driven intensifier pumps to pump the pressure testingfluid to the equipment being tested. A high volume pump is used to fill equipment andincrease system pressure up to 1,000 psi, and a high pressure pump is used to increase systempressure to a maximum of 12,000 psi.

The skid displays hydraulic and equipment system pressure separately at the operatorsspanel, in both metric and imperial units. A relief valve is installed to protect the high volumepump in the event that the pumps discharge ball valve leaks. The relief valve will begin torelieve pressure at 1,750 psi.

The unit has four lifting brackets, one on each corner, that can be used to lift the unit fromabove. A forklift can also be used to lift the unit.

Figure 3-1: 10,000 PSI Pressure Testing SkidTop View

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SYSTEMDESCRIPTION& SPECIFICATIONS USERSGUIDE


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

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USERSGUIDE SYSTEMDESCRIPTION& SPECIFICATIONS


Figure 3-5: 12 Volt Battery

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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 rotar y

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.

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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, controlsthe rate of hydraulic flow from the gear pump on the engine to the 4-bank spool valve on theoperators control panel. The 4-bank spool valve contains controls for the charge pump andthe supply, return, and valve supply hose reels. Use the flow control valve to control thespeed of rotation for the charge pump and hose reels. Increasing the flow will increase thepressure 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

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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 anexternal source. The testing fluid can be directed either to the fluid tanks or directly to theintensifier pumps.

3.3.3 Testing Fluid Directional Valves

There are two fluid direction valves on the testing fluid circuit. One directs testing fluid to theintensifier pumps from the external fill port (normally closed). The other valve directs testingfluid 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

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3.3.4 Testing Fluid Tank Valves

The fluid tank suctionvalves determine from which fluid tank testing fluid will be drawn.Thefluid tankfillvalves 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.

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3.3.6 Pressure Hose Bleed-Off Valves

There are bleed-off valves on both the high-pressure fluid supply and return hoses. Use thesevalves to release pressure from the supply or return lines.

DANGER! Fluid under high pressure can cause seriousinjury. Always use caution when working withhigh pressure fluids.

Figure 3-13: Bleed-Off Valve for the Pressure Supply Hose

Figure 3-14: Bleed-Off Valve for the Pressure Return Hose

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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 of10,000 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 mustbe monitored for oil overheating.

Minimum temperature: 40C (40F). Before using in cold temperature, allowthe hydraulic oil to circulate and warm up.

The high pressure intensifier pump is used primarily with wireline or slickline to create agrease 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 ahydraulic 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

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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

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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 dieselengine 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 i f

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

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Section 4: Operation

4.1 PreOperation Checklist

This section contains information on operating procedures for the 10,000 PSI Pressure TestingSkid.

NOTE: Refer to the Kubota diesel engine manual for more information about the operation ofthe engine.

1. Verify the equipment: When the pressure testing skid arrives on site, check toensure that all required components, fluids and hoses required to operate theequipment are present.

2. Place the equipment: The placement of the unit on site will be determined by thesite manager according to the local safety requirements, job requirements andoperating conditions of the site.

3. Inspect the equipment: Perform the following inspections before you operate theequipment. See also Table 4-1, Maintenance Tasks Required During Operation,

on page 20and 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 isrepaired or replaced.

e. Inspect the water separation wells for the hydraulic fluid and fuel tanks (ifapplicable) and drain them if necessary.

f. Verify all fluid levels: hydraulic fluid engine oil engine coolant engine fuel testing fluid
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OPERATION USERSGUIDE


4.2 Maintenance During Operation

Perform the following inspections and tasks during the operation of the 10,000 PSI PressureTesting Skid.

WARNING! Failure to perform these checks could result inequipment shut down or malfunction.

Table 4-1: Maintenance Tasks Required During Operation

Maintenance Point Task

Hydraulic fluid tank Monitor level. Fi ll 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 operator s 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.

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USERSGUIDE OPERATION


4.3 Start Up Procedures

See 3.2 Operators Control Panel on page 10and 3.3 Skid Controls on page 11for adescription of the controls used in the following procedures.

4.3.1 Start the Engine1. 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 10for a description of the controls.

NOTE: The work lights draw power from the 12VDC battery for the dieselengine.

2. On the operators control panel, ensure all directional control levers are in thecentral/neutral position.

3. Ensure that the HYDRAULIC REGULATORcontrol is at its lowest pressure set-ting. Rotate the regulator control counterclockwise until there is no tension feltat the control.

WARNING! If the HYDRAULIC REGULATOR control is at a

high setting at startup, then the unit will delivertesting fluid at a high pressure immediately.This can over-pressure both the skid equipmentand the equipment being tested.

4. Ensure the ENGINE SPEEDcontrol is at its lowest position.NOTE: Turn the control clockwise until it stops rotating, or push the orangeknob 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 STOPswitch is in the operational position.

7. Ensure the ENGINE STOPcontrol on the operators panel is in the down posi-tion.

8. At the operators panel, turn the ENGINE START/PREHEAT switch toPRE-HEATand hold it in position for approximately 5 seconds.NOTE: The PREHEATcontrol engages the glow plugs for the engine. In coldtemperatures, hold the switch for a longer period of time. Refer to the Kubotadiesel engine manual for details.

9. Turn the ENGINE START/PREHEATswitch 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 tr y 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 totest for leaks. Fluids under high pressure cancause serious injuries. If you find any leaks, shutdown 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.

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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 theequipment 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 reliefvalve.

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 Panelon page 10and 3.3 Skid Controls on page 11for a description of the controls used in thisprocedure.

NOTE: This procedure describes how to fill the pressure testing fluid tanks ONLY. When youfill a testing fluid tank, the charge pump needs to be operated. In order to operate the chargepump, 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 SPEEDgauge reads approximately1400 rpm. Turn the ENGINE SPEEDrotary control counterclockwise toincrease engine speed.NOTE: The throttle control is equipped with a full speed bypass that can beengaged by pressing the orange button and pulling up on the knob.

7. At the operators panel, move the CHARGE PUMPcontrol to the ONposition 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 PUMPcontrol to the OFFposition.

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 PUMPlever control to the ONposi-tion to start fluid mixing.

5. Watch level indicators and stop the charge pump when the required movementis achieved.

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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 10and 3.3 Skid Controls on page 11for a description of thecontrols 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-clockwiseuntil there is no pressure felt at the control. This unlabeled control is attached tothe 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 REELScontrol lever to the INor OUTposition.

4. Use the flow control valve to increase hydraulic flow to the hose reel circuitselected.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 toincrease hydraulic pressure to the hose reel circuit as required.

6. When the required hose has been spooled out, set the HOSE REELScontrol levelto the center neutral position.

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4.4 Pressure Test

See 3.2 Operators Control Panel on page 10and 3.3 Skid Controls on page 11for adescription 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 bedrawn from one of the testing fluid tanks on the skid.

1. Ensure the fluid directional valve from the charge pump to the intensifier pumpsis 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 theCHARGE PUMP

control lever toON

.7. Ensure the hydraulic pressure regulator and flow control valves for the charge

pump are set correctly.

8. Move the HIGH PRESSURE/HIGH VOLUMEcontrol lever to select which inten-sifier pump to operate.NOTE: Only one intensifier pump can be operated at one time. The high volumepump 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 REGULATORcontrol to adjust the output flow of theselected 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 PRESSUREgauge for the duration of the pressure test.

12. See 4.5 Shut Down Procedures on page 26when the pressure test is complete.

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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 beused.

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 intensifierpumps is closed.NOTE: This valve is located near the intensifier pumps. See Figure 3-9 onpage 12.

4. Ensure the fluid directional valve from the charge pump to the intensifier pumpsis open.NOTE: This valve is located near the intensifier pumps. See Figure 3-9 onpage 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 theCHARGE PUMP

control lever toON

.9. Ensure the hydraulic pressure regulator and flow control valves for the charge

pump are set correctly.

10. Move the HIGH PRESSURE/HIGH VOLUMEcontrol lever to select which inten-sifier pump to operate.NOTE: Only one intensifier pump can be operated at one time. The high volumepump 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 REGULATORcontrol to adjust the output flow of theselected 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 PRESSUREgauge for the duration of the pressure test.

14. See 4.5 Shut Down Procedures on page 26when the pressure test is complete.

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4.5 Shut Down Procedures

See 3.2 Operators Control Panel on page 10and 3.3 Skid Controls on page 11for adescription 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 REGULATORcontrol fully counterclockwise until thereis no tension felt at the control.

3. Move the HIGH VOLUME/HIGH PRESSUREpump control to the center/neutralposition.

4. If required, set the CHARGE PUMPcharge pump control to the OFFposition.

5. Use the bleed-off valves on the high pressure fluid supply and return hoses torelease pressure in the line.

DANGER! Use caution when working with high pressurehydraulic systems. DO NOT stand in front of the

valve.

6. Disconnect and reel in all hoses.

DANGER! Ensure that all pressure has been released fromthe system before you disconnect any hoses.

7. Use the ENGINE SPEEDcontrol to reduce the engine speed.NOTE: Allow the engine idle before you shut it off.

8. Pull out the ENGINE STOPcontrol 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.

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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 equipmentmaintenance could result in equipment shutdown or malfunction.

5.1 Maintenance Schedules

5.1.1 Daily Maintenance

Perform the following inspections and tasks at the beginning of every operating day andbefore 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. Fi ll 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 5-2and Figure 5-3.

Testing fluid levels Inspect for correct level. Fill if necessary.


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MAINTENANCE USERSGUIDE


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 5-2and 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

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USERSGUIDE MAINTENANCE


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 enginemanual.

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 8for the hydraulic filter location.

Table 5-4: Annual Maintenance Tasks


Hydraulic system fluid Replace. See Fluids on page 17.

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MAINTENANCE USERSGUIDE



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USERSGUIDE TECHNICALINFORMATION

LEESPECIALTIESLTD., 2005 MN-006-0509-010--0509-011 REV1A-1

Appendix A: Technical Information

This appendix contains the following reference information:

hydraulic schematic with parts information

hose list technical drawings with parts information

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TECHNICALINFORMATION USERSGUIDE

MN-006-0509-010--0509-011 REV1 LEESPECIALTIESLTD., 2005A-2

Hydraulic Schematic with Parts Information

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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

Centr ifuge 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

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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.

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Technical Drawings with Parts Information

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SECTION

A-A

SCALE

1/2

L

ee

S

p

ecialties

Ltd

.

RedDeer,Alberta,Canada,Ph(403)346-4487

UnlessOtherwiseIndicated:AllDim

ensionsinInches.125rmsFinishMin.

W

eight:

of

Drawing:

CheckedBy:

DecimalTolerances:x.xxx0

.005

Concentricity:0.005TIR

x.xx

0.01

FractionalTolerances:

1/64

ExclusivePropertyOfL

eeSpecialtiesConsideredConfidentialAndMayNotBeCopiedOrReproducedW

ithoutWrittenConsentOfLeeSpecialtiesLimited

Material:

CheckDate:

Revision:

Designer:

Date:

Sheet:

R

EVISION

HISTORY

REV.

DES

CRIPTION

DATE

APPROVED

15ksiSidePortPilotedCheckValve

1

AM552UU0003.iam

15KsiPilotedChec

kValveAssembly

1

0

SKM

09/26/2004

AA

1

1

AM678WB0086

BonnetforBOP

EqualizingValve

2

1

PM552UU0009

MainBodyw/1/2"NPT

3

1

PM625UU0034

3/4"BallBearing

4

1

PM625UU0033

CheckValveSeat(11/4"APISeat)

5

1

PM625UU0016

CheckValveCage

6

1

PM678UU0130

ValveBodySideBleedoff-Autoclave

7

1

PM552UU0005

PistonEndCap

8

1

PM552UU0007

Plug

9

1

PM552UU0008

Piston

PartsList

ITEM

Q

TY

PARTNUMBER

D

ESCRIPTION

8.38

6

8

21 7

9

3

4

5

SMALLEY

W

AVESPRINGC

125-H8

218ORING

206ORING

W

/BACKUP

210ORIN

G

119O-Ring

225O-Ring

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USERSGUIDE OEM REFERENCEMATERIAL

LEESPECIALTIESLTD., 2005 MN-006-0509-010--0509-011 REV1B-1

Appendix B: OEM Reference Material

This appendix contains the following reference information:

Kubota diesel engine manual

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OEM REFERENCEMATERIAL USERSGUIDE


Documents

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