CHAPTER 9 DIESEL POWER UNIT

CONTENTS

INTRODUCTION .................................................................................................................... 2
THE TONG’S HYDRAULIC CIRCUIT ...................................................................................... 2
TRANSPORTING POWER UNIT ............................................................................................ 2
PRE - START UP CHECKS .................................................................................................... 3
DAILY CHECKS .................................................................................................................... 4
RIGGING UP POWER UNIT ................................................................................................... 4
STARTING THE POWER UNIT............................................................................................... 5
POWER UNIT WITH A SPRING STARTER......................................................................... 5
POWER UNIT WITH AN AIR STARTER .............................................................................. 5
OPERATING THE POWER UNIT............................................................................................ 5
RIGGING DOWN THE POWER UNIT...................................................................................... 6
DIESEL HYDRAULIC POWER UNIT TROUBLE SHOOTING TIPS .......................................... 7
OPERATIONAL AND HAZARD IDENTIFICATION ................................................................ 10

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INTRODUCTION
The power sources that Weatherford uses to drive tongs vary in accordance with the regulatory
requirements of the region where they are operated, but they are typically 4 or 6 cylinder Deutz
diesel internal combustion engines. The engine is mounted in a metal housing that is attached to
mobile skids, or the metal housing is mounted on a trailer. The housing contains all the parts and
safety features that make the diesel engine work properly including the:
• fuel tank
• controls and gauges
• starter
• emergency shut down system
• spark arrestors.

THE TONG’S HYDRAULIC CIRCUIT

The hydraulic power unit is more than just a power source for the tong. The housing that contains
the power source also houses most of the building blocks that make up the tong’s hydraulic circuit
including the:
• reservoir that contains hydraulic fluid
• pump
• pressure control valves
• flow control valves
• pipework that connects the parts.

TRANSPORTING POWER UNIT

If the power unit is to be transported, ensure that it is secured properly to avoid transportation
damage and that it has current lifting certification. If in doubt then contact your supervisor.

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PRE - START UP CHECKS

Before starting the hydraulic power unit, you MUST ensure that the unit is in a Zone 2, Div 2 area
or less restrictive zone and establish if a Permit To Work is required.
Before starting the unit perform the following checks.

? Check the… For proper functioning, the… If it is not, then…

1. Hydraulic fluid Tank must not be more than ¾ full. Fill the tank / drain the tank.
level
2. Diesel fuel level Tank must contain sufficient fuel. Fill the tank, and check often.
Low levels of fuel may cause the
engine to suck up sediments and
debris.
3. Engine oil level Oil must reach the “full” line on the Add engine oil until it reaches the
dipstick. Low levels of engine oil “full” line on the dipstick.
can cause the engine to seize.
4. Fuel line Fuel line should be primed with Prime the system using the manual -
diesel fuel. priming pump.
5. Air lines Airline must have the correct Replace the fittings, seals, and
fittings, seals and safety pins. safety pins with the correct parts.
6. Pipe work Pipe work must be free of leaks, Change out pipe work.
corrosion, or other damage.
7. R.I.V. valve (if R.I.V. valve should be open while Open the valve.
equipped) starting the Power Unit.
8. Flow control Position of the valve must agree Refer to the power tong
valve with the requirements of the power specifications in order to set the
tong. valve properly.
9. Tank return line Ensure valve is open to tank. Open the valve
10. Chalwyn valve (if Valve must be open. Check the atmosphere for gas leaks.
equipped), or, Replace the valve if it is faulty.
Emergency shut
off
11. Spring start (if Mechanism must coil properly and Remove the obstruction. Replace
equipped) spin with out obstruction. the spring mechanism if it is faulty.
12. Air start (if Air start Mechanism must be free Clean out moisture trap, replace
equipped) of moisture and rust. rusted parts.
13. Spark arrester Spark arrester must be free of Clean spark arrester every 12 hrs, or
carbon and rust. as operation demands. Replace
spark arrester.
14. Slave cylinder (or Slave cylinder should have Lubricate it.
regulator valve) sufficient lubrication.
15. Drive belts Drive belts must be free of Change out defective belts.
damage.
16. Spare fan belts Spare fan belts must be protected Stow spare belts inside the Power
from the elements, and damage Unit tool box.
from moving parts.

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? Check the… For proper functioning, the… If it is not, then…

17. Spare filter for oil Spare filters must be protected Stow spare filters inside the Power
and diesel fuel from the elements. Unit tool box.
18. Attached hoses Hoses must be free of damage. Change out defective hose, and or,
The seals and fittings at each end fittings / /seals.
of the hose must also be free of
damage.
19. Stowed hoses Hoses should be stowed with dust Affix dust caps to the ends.
caps on their ends. This protects
the fluid inside from contamination
and stops the fitting from being
damaged.
20. Fuel container Fuel container must be full to Fill container when empty. DO NOT
eliminate contamination. store on Power Unit, when unit is
running.

DAILY CHECKS
Daily checks should include:
• Visually inspecting the unit for damage.
• Ensure the spark arrestor is clean and clear of carbon build up
• Ensuring that fan belts and guards are in good condition.
• Checking of fluid levels are correct if not top up with:
o Diesel Engine Oil 15/40
o Diesel Fuel Oil
o Air Starter Lubricant, Air Cleaner Bowl
o Hydraulic Oil Tellus 68
In addition to functioning properly, Weatherford hydraulic power units must look presentable.
They should:
• have good paintwork, showing unit weight
• be free of rust and other environmental damage
• carry the Weatherford name and logo.
If the unit does not operate properly or if it does not look presentable, fill out a Equipment Fault
Report.

RIGGING UP POWER UNIT

ENSURE YOU HAVE A HYDRAULIC CIRCUIT BEFORE ATTEMPTING TO START UNIT.
Power Units should be rigged up in a Zone 2, Div 2 area or less restrictive zone.
Note: If rough weather is expected, or cyclonic conditions prevail it may be necessary to weld
the Power Unit to the deck.
Ensure cover is folded up and secured as to not interfere with safety features or cause a fire
hazard, if the slings are removed coil these up and place on top of the folded up cover. Hoses
should be routed in such a way as to eliminate trip hazards, crossing over doorways and
minimising abrasion throug h cut outs and over kick rails.

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If a JAM dump valve is to be used ensure that it is tied off correctly and no load is on the fittings
or the pipe work.
Use whip checks and “R” clips on all airlines and always connect the low-pressure (1¼”) line first.
Ensure a hydraulic circuit is complete before starting the unit. Once started, allow diesel motor to
warm up and the hydraulic oil to circulate unloaded prior to first connection.
Ensure slave cylinder (governor) is set correctly by rotating tong till the Power Unit revs up,
release lever and unit should return to idle. Alternatively operate the tong back up lever until the
unit revs then bleed pressure off and unit should return to idle. If not adjust spring load as
necessary by screwing in or out.

STARTING THE POWER UNIT

POWER UNIT WITH A SPRING STARTER
1. With the crank handle removed function spring release lever to remove any tension in the
spring.
2. Fit crank handle and wind slowly in a clockwise direction with the spring engager button
depressed until engagement is felt.
3. Release the spring engager button and continue to crank in a clockwise direction until
resistance is felt.
4. Prime the injectors and the pump manually, ensure that the RIV is wound out.
5. Remove crank handle and throw the spring release lever, the Power Unit should start.
Failure to remove the crank handle can result in personal injury.
6. If the Power Unit doesn’t start repeat steps A) through to E).
POWER UNIT WITH AN AIR STARTER
Connect airline utilising “R” clips and whip checks.
1. Make sure the starter valve is closed and turn on air supply.
2. Prime the injectors and the pump manually, ensure that the RIV is wound out.
3. Give a short burst of air, the Power Unit should start.
4. If the Power Unit doesn’t start repeat steps C) through to D).
Note: If the temperature is below 0 Deg C Aero-start may be required.

OPERATING THE POWER UNIT

Once the Power Unit running open the flow valve to the tong’s flow requirements. Screw in the
R.I.V. until the required operating pressure is reached this will normally be 2000 - 2200 PSI.
Have the tong operator function the tong to ensure correct pressure and flow are met . Ensure
slave cylinder (governor) is set correctly and operating by rotating tong till the Power Unit revs up,
release lever and unit should return to idle. Alternatively operate the tong back up lever until the
unit revs then bleed pressure off and unit should return to idle. If not adjust spring load as
necessary by screwing in or out. The slave cylinder may not work correctly if the oil is cold so
allow time to warm up.

Once the Power Unit is running, periodically check the unit and maintain a full tank of fuel. This
can be done at crew change and shift changes.

If the temperature exceeds 30 Deg C it will be necessary to divert flow to the radiator and not
directly to the tank, if this is done then fluid will also bypass the filter element. Ensure that before

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the direct to tank valve is closed that flow through the radiator is established. Leave the direct to
tank valve slightly cracked open in case of blockages.

RIGGING DOWN THE POW ER UNIT

• Ensure lift rams etc are fully closed.
• Check all power unit shutdown devices
• Unscrew the RIV (unloader valve)
• Use the fuel shut off located behind the injector pump to stop the engine.
• When rolling up hoses start with the high pressure (1”) then the low pressure (1.¼”) and so
on in that order.
• Ensure that all hose ends are lubricated, protected from the environment. Dust caps are
fitted to all fittings.
• Roll up the airline and place this on last.
• Fill up Diesel fuel tank to reduce contaminants. Check all other fluid levels.
• Fit cover.
• Re-fit slings ensuring they are in good condition and that all safety clips / pins are installed
on the shackles.

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DIESEL HYDRAULIC POWER UNIT TROUBLE SHOOTING TIPS

? Symptom… Possible cause… Corrective action…

1. Hydraulic pump Filter (suction) is not clean, restricting Remove the filter and replace or clean
makes excessive fluid flow to the pump. element.
noise.
Viscosity of the oil is too high. Change oil.
Air is leaking into the hydraulic Check the oil level in the reservoir. The
system. intake on the suction filter must be well
below the level of the hydraulic oil.
Check all fittings on the intake side of the
hydraulic pump. To check the suction line
fittings, pour oil over the point of
connection while the pump is running. If
the noise stops, then the source of the air
leakage is at this point. Tighten the fittings
until the noise stops.
Loose or worn-out parts. Replace with new parts.
2. Hydraulic system Relief valve setting is too high and Reset the relief valve to the proper
over heating. the discharge pressure is in excess of reading.
normal operating conditions.
Incorrect oil viscosity (too high or too Change oil.
low).
Excessive internal leakage. Check parts for wear, and repair or
replace if necessary.

Check contamination in hydraulic system,

white oil = water.

High degree of friction. Check moving parts inside pump for

tightness and proper fit. Repair, if
necessary.
Leakage in pump, check-valve, un- Repair or replace valve.
loader valve, or relief valve.
3. Hydraulic system Heat exchanger not working or Check to make sure coolant or air is
over heating inadequate for system. flowing without clogging or backing-up.
Level of hydraulic oil in reservoir is Fill to 4 inches from top of reservoir and
low. maintain at this level.
Power Unit is operating closed centre Contact manufacturer for adaptor.
hydraulic system.
4. Excessive wear of Abrasive contaminants in oil. Change the oil. Flush the system, and
moving parts. replace the filters. Install a larger filter, if
possible.
Alignment of moving parts is off. Re-align as necessary.
Operating pressure is set to high. Adjust the relief valve to manufacturers
tong specifications.
Viscosity is to low at operating Change oil to a higher viscosity.
temperature.
Leakage of air into the system. Check for air leaks and tighten all
connections. Bleed existing air out of
system.

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? Symptom… Possible cause… Corrective action…

5. Flow rate (tong Intake line to pump is plugged. Check suction filter and clean or replace, if
speed) is to low. necessary.
Level of hydraulic oil in reservoir is too Fill to 4 inches from top of res ervoir and
low. maintain at this level.
Air leakage in intake line to pump. Check fittings for tightness and adjust as
necessary.
Pump rotation is in wrong direction. Verify replacement pump specification and
operation.
Oil viscosity too high. Change oil (check manufacturer’s
specifications for proper grade).
Oil viscosity too low (overheating). Change oil to proper grade.
Damaged or worn pump parts. Inspect the parts and replace as
necessary.
Oil bypasses through valves to Check relief valve for proper operation.
reservoir.
Check position of directional valves to see
if open or closed.
6. Engine fails to start. Fuel tank empty. Fill up tank and vent injector pump and
lines.
Shut-off valve closed. Chalwyn valve Open shut off valve and reset if necessary.
stuck.
Tap Chalwyn valve with suitable tool.
Check atmosphere for gas.
Strainer in fuel lift pump is blocked. Clean strainer.
Dump 20 litres of fuel from bottom of tank
to clear contaminants.
Fuel filter is blocked. Renew filter, then vent injector lines and
pump.
In extreme winter, use winter grade fuel.
Check all fuel line connections for
Fuel lines leaking.
tightness.
Air starter is seized. Pour light oil into airline. CRC etc.
7. Engine is difficult to Grade of motor oil is too viscous. This Choose a grade of motor oil to suit the
start. particularly applies in winter. temperature conditions.
Fuel supply may be inefficient. In Replace fuel filter and then vent the
winter blockage by clouding. injectors and pump.
Clean strainer and fuel lift pump.

Check fuel line connections for tightness.

Use winter grade fuel.

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? Symptom… Possible cause… Corrective action…

8. Engine gives poor Fuel supply not sufficient. Replace fuel filter and then vent the
performance. injectors and pump.
Clean strainer and fuel lift pump.
Check fuel line connections for tightness.

Valve clearance is out of adjustment, Readjust valve clearances.

valve spring broken.
Fit new valve spring.
Have it inspected by specialists. Use fuel
Injector nozzle needle sticking.
oil additive in concentrated dose.

Inefficient compression due to either Have compression rings and pistons

sticking or broken compression rings inspected by specialists.
or incorrect valve clearance. Readjust the valve clearance.
9. Engine overheats, Cooling fans on cylinders and Clean cooling fans, particularly the vertical
causing the cylinder heads are very dirty (Deutz). ones in the cylinder heads.
temperature
indicator to display Injector is defective. Have it inspected by specialists.
“STOP” or “RED” Injection pump delivery is out of Have it inspected by specialists.
NOTE: Shut down adjustment.
the engine
immediately. Insufficient cooling air input to blower Make sure air can enter the blower freely.
Blower V-belt is broken (Deutz). Replace the V-belts.
Low coolant level or incorrect coolant. Correct the coolant level or type of
coolant.
Leaking coolant hoses or Tighten or replace as necessary.
connections.
Engine fan belts slipping. Inspect and repair.
10. Engine oil pressure Leaks in lubricating oil system or low Check oil level and connections on pump,
to low. oil level. lines, filter, pressure gauge, and cooler for
NOTE: Shut down tightness.
the engine Excessive main bearing clearance. Have adjusted by a specialist.
immediately.
11. Charging indicator Dynamo speed too low. Check V-belt tension.
lamp lights while Dynamo not charging battery Have inspected by specialist.
engine is running. because dynamo or regulator / cut
out defective.
12. Engine smokes Too much oil in the sump. Drain oil until the level reaches the top
badly. mark on the dipstick.
Oil level in the oil bath air cleaner is Pour off the oil until the level is at the
too high. mark.
Inefficient compression due to either Have compression rings and pistons
sticking or broken compression rings inspected by specialists.
or incorrect valve clearance.
Re-adjust the valve clearance.

Injector pump out of timing or worn Have it inspected by specialists.

components.
Spark arrester is blocked with carbon. Clean out spark arrester.

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? Symptom… Possible cause… Corrective action…

13. V-belts continually Tension jockey wheel out of Re-align to run true.
breaking. alignment with crank pulley.
Incorrect size V-belts fitted. Check for correct fitting V-belts.

OPERATIONAL AND HAZARD IDENTIFICATION

Please refer Chapter 1 – Operational and Hazard Identification for hazards involved in the
operation and handling Weatherford equipment.

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