IPS Coiled Tubing Unit Stem Sheet

Information

Document No.
Location
Unit Number
Conducted on
Prepared by
Picture of Unit.

Power pack/wet kit

1.1 Coolant level: Insure level to base of fill neck, check "services required" if you add more than a half gallon
1.2 Engine oil level: Insure oil level is at full mark on the dip stick. Replace at 300hrs. Or when ever contamination is present.
1.3 Hydraulic oil level: Fill tank to appropriate level. Drain any condensation before filling.
1.4 Air intake piping: no unplugged holes, loose or missing clamps, & no visible leaks.
1.5 Cooling fan belt condition & tension: Inspect for cracks, frays, & excessive stretch or wear. Replace if needed.
1.6 Radiator: no leaks, no fin contamination to cause air flow restriction, steam clean as requires, shroud intact and mounting bolts tight.
1.7 Oil & Fuel filter condition: Replace at 300 hrs or when rusted, leaking, dented, or bad fuel is present.
1.8 Fuel, Air,& Hyd. Tank condition: Inspect all for rust, dents, cracks, leaks, vents, caps, and valve defects.
1.9 Air, Fuel, Hyd. Hoses: Inspect all hoses for damage, wear, leaking, excessive rust, or cracks. Replace as needed.
1.10 BOP Accumulator: N2 precharge pressure should be 1400psi. Check with system bled off to 0 psi and leave bleed valve open to Hyd. Tank.
1.11 Engine oil pressure: Not less than 15 psi with engine at idle, not less than 50 psi with engine running full throttle.
1.12 Gauges & Indicators: Must work from zero to full gauge range within limits of system being measured.
1.13 Hyd Quick couplings: Check for leaks, excessive corrosion, non-standard size/style will require repair or replacement and retest.
1.14 Air compressor @ full charge: 115-125 psi, must hold post SD for minimum of 30 minutes with valves open, not > than 10% loss allowed.
1.15 Air intake filter: Indicator should be below 25 in. Vacuum with engine running at full throttle, replace filter if indicator is in red area or if 25 in. Or more of vacuum is measured with engine running at full throttle, retest after replacing filter.
1.16 Coolant temperature: OEM spc of 200 deg. Operating temperature.
1.17 Check for exhaust leaks: Check for any leaks and /or defects. Repair or replace if needed
1.18 Fuel/Oil/Coolant Leaks: Observe very closely all hoses, piping, couplings, pump, and radiator for visible leaks of principle engine liquids, none are to be allowed.
1.19 Air compressor mounting: Bolts tightened to OEM specs.

Generator

2.1 Coolant level: should be visible in sight glass @ min./cold.
2.2 Engine oil level: Insure oil level is at the full mark on the dip stick. Replace at 300 hrs. Or when ever contamination is present.
2.3 Oil & Fuel filter condition: Replace at 300 hrs or when rusted, leaking, dented, or bad fuel is present.
2.4 Air Filter: Replace at oil change or if contaminated to restrict air flow.
2.5 RV Adjustment: Insure that all RV adjustment stems, locknuts, knobs secure, threads are free & lubricated.

Control Cabin

3.1 Structure: Framework, skid, pollution pan, expanded metal, guarding; no cracks at welds, severely corroded members, deep gouges, rips/tears; correct before pass
3.2 Windshield/door: Main/side/rear glass not cracked or broken, seal not leaking, wiper system functional "if applicable" repair before pass
3.3 Cabin lift system: Hydraulic cylinders and control valves functional, no leaks, no broken handles, cabin support struts functional, repair all before pass.
3.4 Gauges and indicators: Must work from zero to full gauge range within limits of system being measured, calibrated for recorder.
3.5 Hose condition, all air/Hyd: Cracks, damages outer jackets, exposed wire braids, excessive rust on ends and leaks unstoppable by tightening requires replacement.
3.6 Engine kill system: "normal" kill button when depressed must immediately shut off fuel supply and kill engine completely.
3.7 Throttle operation: idle to full rev functionality via twist type air assist control valve.
3.8 Hydraulic quick couplings: No leaks or deep corrosion, non-standard style/size require repair or replacement. Verify proper tag #
3.9 Priority System Accumulator: Check and verify N2 precharge pressure is at 1400 psi, check and service with circuit bled to 0 psi and with the bleed open to tank.
3.10 Stripper supply pump: Suction oil filter clean, pump delivery function, pressure test to 5000 psi.
3.11 Basic control system: Injector in/out hole, reel back tension, chain traction/tension, reel brake set/release, injector brake set/release, normal & emergency engine kill must function.
3.12 Injector Brake safety system: while injector is rotating shut down Diesel engine; injector brake must set automatically when engine shut down, verify by noting/timing the loss of the brake release pressure at the console.
Initial brake release pressure
Time to fully dump in seconds
3.13 Weight indicator: Calibration current, gauge functional.
3.14 Circulation pressure: Calibration current, gauge functional.
3.15 Well head pressure: Calibration current, gauge functional.

Injector Head

4.1 Hoses and plumbing: No exposed wire braids, leaks, drips, contact with moving parts or rust/corrosion on hose ends. Secure hoses with tie wraps where possible.
4.2 Connections: Snaptites must not leak @ 0-max operating pressures, must be numerically labeled and be of the correct size and gender, no deep seated corrosion.
4.3 Gauges: All gauges must function with +/- 5% accuracy throughout range. No cracked faces or damaged ind. pins.
4.4 Dampener Accumulators: N2 precharge; tension - 100 psi, traction - 300 psi. No leaks
4.5 Traction/tension rams: no leakage allowed from rod seals, no deep seated rust, test low and high pressures.
4.6 Motors & Counterbalances: no visible external leaks, cracks, broken fittings or frame contact allowed. Mounting bolts must be tight.
4.7 Load cells: Properly mounted, purged, inflated to proper height under drive case load. Limit pins/bolts work freely and are adjusted properly to allow adequate travel/support.
4.8 Guide Arch: Rollers/turnbuckles free, no excessive wear, bearings greased. Alignment assembly free/greased.
4.9 Stripper assy: Disassembled, cleaned, replace element and non extrusion ring. Inspect all brass for wear. Pins/caps fit freely, piston travels freely in both directions.
4.10 Structural condition: No cracked welds, no deep seated corrosion allowed on frame members, fall arrestor pad eye is un damaged, pivot points pins/pad eyes are not ceased & do not exhibit excessive plat < .060".
!!!!!!!!!!!!!WARNING!!!!!!!!!!!!!!! Physical inspection of grippers, rollers, bearings, chains may not be performed while the machine is rotating or energized.
4.11 Drive Chains: All link pin retainer are securely fastened. All links must be clean and free of sand/grit/dirt.
4.12 Gripper blocks: Dies must match dressed CT OD dimension, retainer bolt must be secure, surface of dies must not have extrusions that may damage pipe, elastomer pads must be in good condition.
4.13 Shaft/Sprockets/bearings: Observe while chains rotate slowly & after greasing. No wobble/jumping or alignment instability, no inordinate noises such as "popping, cracking, groaning, or grinding", no play; up/down allowed in bearings with chain tension released.
4.14 Chain Lubrication system: oiler tank full of clean lubricant, air pressure set to 20-40 psi, nozzles must be unobstructed, test while chain are rotating.
4.15 HP Hydraulic filters: Inspect bypass indicators during rotation, replace as needed or every 300 hrs.
4.16 Traction & Tension cylinders: Rams must be fully retracted then extended with max. Hyd pressure, no leaks from rod seal or piston seal bypass allowed.
4.17 Motor brake function: Brake must hold with 4200 psi Hyd. Pressure in HI & 2100 psi Hyd. Pressure in LO both in & out of hole directions. No motor shaft seal leaks allowed.
4.18 Stripper pressure test: Test 250 psi 5 minutes. First & MAWP for 5 minutes. Next no leaks. Record with calibrated meter, sign and attach chart. Note dress dimension, test Hyd. System to 5000 psi with out any leaks.
Maintenance coordinator comments
Injector dress dimension inches OD CT
Stripper dress dimension inches OD CT
Injector chain running feet

Hose Reel

5.1 1-1/2" hose & connections: No exposed and rusted wire braids, threaded connection not leaking, main connectors not leaking under power, securing blocks and chains present and chains secured.
5.2 Hydraulic Swivel: Must rotate freely, no leaks under power, no damage from impact, threaded connections tight and leak free.
5.3 Reel Bearings: no inordinate noises such as popping, cracking, groaning, or grinding. Bearings greased and mounting bolts tight & secure.
5.4 Hydraulic drive assy: Motor not leaking from shaft seal, sprocket/shaft key not sheared, sprocket teeth not excessively worn. Clean chain and lube.
5.5 Hydraulic control valve: Insure that it is in working order. Handle not broken or missing pin retainers, spool free and not leaking, Snaptites not leaking, & mounting is secure.
5.6 Structural condition: no cracked welds, guards in place securely, no deep seated corrosion on frame members & all bolts tight and in place.

Trailer

6.1 Landing gear: greased no cracks on pins or pads
6.2 Slack adjusters: greased
6.3 All lights: Insure all lights are functional and working properly
6.4 Tires: in good condition

Miscellaneous

7.1 Equipment labeling: IPS decals on all skids and in good condition
7.2 First Aid: mounted and stocked
7.3 Blood Borne pathogen kit: present and stocked
7.4 Full body harness: 2 stocked and in good condition. Only retractable lanyards being used.
7.5. Fire extinguisher: mounted stocked and current inspection.
7.6 Tie down straps: 2 each stocked
7.7 Spill control: properly stock with absorbent pad and emergency containment kit