Jet 04 Basic Oilfield v1-1 April 02 2007 4127828 01 PDF
Jet 04 Basic Oilfield v1-1 April 02 2007 4127828 01 PDF
Jet 04 Basic Oilfield v1-1 April 02 2007 4127828 01 PDF
Basic Oilfield
Equipment
Version 1.1
JET Manual 04 Basic Oilfield Equipment
InTouch content ID# 4127828
Version: 1.1
Release Date: January 31, 2007
Owner: Well Services Training & Development, IPC
Schlumberger private
Document Control
Revision History
Rev Effective Date Description Prepared by
Other company, product, and service names are the properties of their respective owners.
Table of Contents
1.0 Introduction 7
1.1 Learning objectives 7
1.2 Safety warning 7
2.0 Basic Engines and Transmissions 9
2.1 Types of engines 9
2.1.1 Electric motors 9
2.1.2 Gasoline engines 9
2.1.3 Diesel engines 10
2.2 Engine comparisons 11
2.2.1 Internal combustion engines 11
2.2.2 Intake and combustion 11
2.2.3 Compression 11
2.2.4 Horsepower and torque versus rpm 11
2.3 Diesel engines—Schlumberger’s main prime movers 12
2.3.1 Stroke cycles 12
2.3.2 Diesel engine components 13
2.4 Transmissions 19
2.4.1 Clutches 20
2.4.2 Manual gearbox 21
2.4.3 Power shift transmission 22
2.4.4 Torque converter 22
2.4.6 Drivelines 24
2.4.7 Routine maintenance of transmissions 24
3.0 Basic Pneumatic Systems 25
3.1 Types of pneumatic systems 25
3.2 Parts of pneumatic systems 26
3.3 Pneumatic systems components 26
3.3.1 Compressor 26
3.3.2 Blowers 28
3.3.3 Air reservoirs (tanks) 29
3.3.4 Governors (pressure regulator) 29
3.3.5 Pressure-relief valves 30
3.3.6 Check valves 31
The objective of JET manual 04, Basic Oilfield • explain the principles of operation and
Equipment, is to familiarize personnel with components of different types of pneumatic
the equipment used in pumping services. The systems and compressors
training will provide a better understanding
• explain the principles of operation of
of Schlumberger equipment design and
electricity, electrical circuits, batteries, and
performance and reduce service incidents and
circuit components
operating failures.
• explain the principles of operation and
Schlumberger has in place the Standard maintenance for various types of hydraulic
Equipment Maintenance (STEM) program to system components
help outline the procedures needed for the • describe the process for each of the
preventive maintenance of all Schlumberger following:
units. The program consists of the STEM I,
STEM II, and STEM III inspection procedures; ○ STEM I Auxiliary Posttrip
each is done at various intervals. ○ STEM I Diesel Engines
• Nomex coveralls
• hard-toed boots
• hard hat
• safety glasses
and, if needed:
• gloves
• goggles
• dust mask
• ear protection.
| Introduction
2.0 Basic Engines and Transmissions
In this chapter, you will learn about the basic Advantages of electric motors
types of engines used at Schlumberger,
The advantages of using electric motors include
including electric motors, gasoline engines,
the following:
and diesel engines. The chapter compares
the three types and provides details about
• no exhaust emissions: Electric motors
diesel engines, the principal engine used
are noted for their environmentally clean
at Schlumberger. Detail is also given about
operation because they produce no
transmissions.
exhaust emissions.
• size: Electric motors are very compact
2.1 Types of engines relative to their power output and, therefore,
Schlumberger equipment uses electric motors, can easily be adapted to areas where a
gasoline engines, and diesel engines. These normal engine will not fit. Electric motors
are sometimes called prime movers, which are also very quiet and operate with little
are power plants or sources of energy that vibration.
transform a natural energy source into motive Disadvantages of electric motors
power.
Electric motors are the best option for most
Schlumberger applications, but they have some
2.1.1 Electric motors serious disadvantages:
Schlumberger uses electric motors on offshore
• initial high cost: They are more expensive
skids (Fig. 2-1).
than most other power sources, costing
three times more than comparable
horsepower diesel engines.
• power requirements: Electric motors require
a power plant or electrical power supply,
which is often not available.
• packaging requirements: Electric motors
are limited by their packaging. They are
highly inflexible and must be precisely
mounted or installed.
Turbocharger
A turbocharger is a blower, powered by engine
exhaust gases, that forces air into the intake
manifold at higher than atmospheric pressure
to increase engine power and performance
(Fig. 2‑10).
Emergency
kill
Plunger
Fine mist
Figure 2-13 Mechanical Fuel Injection
Routine maintenance
Figure 2-16. Transmission
The routine STEM (standard equipment
maintenance) procedure for diesel engines The transmission, in most cases, is connected
should include checks of the following: to the back of the engine and sends power from
the engine to other mechanisms. The engine
• fuel system: First check the fuel level. Then runs best at certain rpm ranges. The function
look for leaks in the lines and connections. of the transmission is to ensure that the power
Drain a small amount of fuel from the is delivered to the wheels or pumps while the
reservoir (making sure not to spill any) engine is kept within the optimal range.
to remove any water that may be in the
system due to condensation or impure fuel. Transmissions are divided into manual and
• air system: Ensure that air can flow automatic. Manual transmissions are equipped
unrestricted to the engine by checking the with a clutch and a gearshift. The automatic
vacuum restrictor gauge. transmission does not have this component,
and when it has been put into drive, it
An engine is connected to the transmission Spring pressure holds the clutch engaged.
via the clutch (Fig. 2‑17). The clutch provides When engaged, the clutch springs exert full
a smooth connection and disconnection of pressure on the clutch plate, holding the clutch
engine power flow to the transmission. It is disk against the flywheel.
located between the engine and transmission
assemblies. The force required to activate or control
clutches may be supplied by actuators that are
• electrical
• mechanical
• pneumatic.
Electric clutches
Electric current flowing through a field coil
activates electric clutches. The current engages
and disengages the clutch.
• standard
• over-center.
Standard clutches
With standard clutches, foot motion on the
clutch pedal moves through the linkage to the
clutch-release-bearing fork (Fig. 2‑18). This Figure 2-19. Over-Center Clutch
pushes the release bearing against the clutch
release levers, disengaging the clutch. Some Pneumatic
clutches use springs, which serve as aids in
The pneumatic, or air-actuated, clutch is a
disengaging, and as return springs when the
double-positioned air cylinder hooked to the
clutch is engaged.
shaft that engages and disengages the clutch.
Driven-plate
Driving surface assembly
Pressure plate
2.4.2 Manual gearbox
Clutch cover
Ring gear
Clutch spring
A manual gearbox is a train of gears that
Flywheel Throwout transfers and adapts engine power to the drive
bearing
wheels or pump of the machine. An operator
Pilot-bearing
Throwout
Pedal must engage the clutch and position the gear
collar lever to select speed ratios for various travel
Crank shaft speeds or to reverse the direction of travel.
Transmission
main gear
The gears have two or more parallel shafts
Clutch shaft arranged to
Release lever Lever pivot point Throwout lever
To differential
Gear
selector
fork
From engine Idle gear
Main shaft
sump area.
Governor-driven
gear
2.4.3 Power shift transmission Lockup
clutch Control valve body
Modulated lockup valve Oil filter
(optional)
A power shift transmission has positive control Converter-driven power
takeoff drive gear
on the gears and stays in one gear. This type MT 653DR
of automatic transmission is typically used for
pumping (Fig. 2‑21). Figure 2-22. Torque Converter in Relation to the Whole
Transmission
Power shift transmissions are typically used in
fracture pumps, among others, when pumping. The automatic transmission of an automobile
These controls are such that the transmission uses a torque converter to shift gears in
will not down-shift once set, allowing the response to torque requirements. A gear train is
operator control of the pump speed. used with the torque converter to provide extra
speed ranges. Acting as a clutch, the torque
Automatic transmissions have no clutch that converter connects and disconnects power
disconnects the transmission from the engine; between the engine and the gear train. As a
they use a torque converter. transmission, the converter gives many more
The figure below shows the torque converter in Journal and bearing
Stub yoke
relation to the whole transmission. Flange yoke
Sleeve yoke
Tubing
End yoke
2.4.5 Couplings
A coupling connects two ends of shafts in the Slip u-joint
Slip tub shaft
Permanent u-joint
same line, transmitting power (or torque) from
one shaft to the other. This connection results Figure 2-23. Direct Couplings
in synchronized rotation for the shafts at the
same rpm. Flexible couplings
If two shafts joined by a coupling are not in
Shafts are joined with a coupling for the perfect alignment, stresses are induced due to
following reasons: bending. These stress greatly reduce the life
of shafts and cause an additional load on the
• to join units that are in different locations bearings that support the shafts. Consequently,
or that are more convenient to handle as a flexible coupling (Fig. 2‑24) is typically used
smaller units to join shafts of two units, such as a motor and
• to join standard units to accomplish a a pump. Flexible couplings not only permit axial
special purpose and radial misalignment, but they also provide
vibrational dampening and overload protection.
• to allow for misalignment of the shafts One drawback of flexible couplings is the
• to reduce the transmission of shock or requirement for close-proximity mounting.
vibration
The vee of a flexible joint is a universal joint,
• to rapidly connect or disconnect the shafts
like the drive shaft in a car. The joint ends of the
as required by the operation of the machine
Pneumatics deals with the use of compressed systems are found on many Schlumberger
or pressurized gas or air as a source of power. trucks and are used to power brakes (Fig. 3‑2),
Air is extremely compressible, elastic, and horns, and cab tilt controls, and to start deck
capable of absorbing large amounts of potential engines.
energy. Once compressed, it exerts an outward
force, much like a coiled spring.
Parts of a compressor
A compressor includes these basic
components:
• intake valve
• discharge valve
• piston
• rod
Figure 3-5. Compressor Unit
• flow line to and from the governor
Belt-driven compressors are powered by a • unloader poppet
dedicated diesel engine or may be connected
to a hydraulic motor mounting on the engine of • plunger
a truck. • air filter
Meshed gear assemblies are driven by a • line to the reservoir or tank for holding
directly geared mounting to the truck engine. the compressed air.
The compressor components for a
Power take-offs, also called PTOs, also are high‑pressure/low-volume system are nearly
powered by the truck’s engine, but not by identical to those of a low-pressure/high-volume
a direct connection. Found on most bulk system. The only difference is the position of
equipment, this type of compressor requires a the intake or suction valve. On a high-pressure
method of engaging or disengaging the power system, this valve is typically mounted on the
source. This is typically accomplished manually side of the compression chamber, whereas on
or through the use of a clutch. a low-pressure system it is mounted on top of
the chamber next to the discharge valve.
Compressors are sometimes cooled by
the engine’s cooling system. Either air or Compressor cycle
a combination of water and antifreeze can
serve as the coolant, according to the type A compressor goes through stages, during a
of compressor and engine used. Other air complete cycle:
compressors are cooled only by air, and these
have a fan connected to them to circulate air • intake stage, when air is drawn into the
across the outside of the cylinders. cylinder or chamber
• compression stage, when air is
The engine may also lubricate the compressor. compressed in the chamber and
The compressor is connected by a hose to the discharged to the reservoir
engine’s lubrication system, allowing the oil to
• unloading stage, when any unnecessary
flow into the top of the compressor and down
pressurized air is unloaded.
through system components. In a meshed
Compression
Air is compressed in
the chamber and discharged
,OW PRESSURE to the reservoir.
(IGH
VOLUME
COMPRESSOR
Unloading
Any unecessary pressurized
air is unlocked.
Water
separator
Drain
3.3.9 Lubricators
Figure 3-16. Lubricator
After the compressed air leaves the dryer, it
passes through the air lubricator (Fig. 3‑16).
The air lubricator injects a fine mist of oil 3.4 Applications
into the air, which lubricates downstream
components. High-pressure/low-volume pneumatic systems
are used in many ways. Here are the most
On air systems used for fluidizing bulk materials common applications:
such as cement, this lubrication method is not
used because the downstream components • brakes
do not require lubrication and because the oil • tractor protection valves
would contaminate (clog) the fluidizing systems
used on most bulk handling equipment. • front brake limiting valves
• clutches
The lubricator has an adjustable regulator that
• gear shifts
should be checked regularly to ensure that the
unit is providing adequate oil or lubrication per • power divider lock control
volume of air. There is also a sight glass that
• parking brakes
provides a quick visual check of oil level. It is
the operator’s responsibility to add oil when • dash gauge warning buzzer
needed. • air cylinders
It is important to service the lubricator regularly • pumping equipment.
to ensure equipment longevity.
Schlumberger uses electricity to power starter The water is equivalent to the current (the
motors, lighting systems, instruments, data electrons). The knob is the switch. The water
acquisition systems, ignition systems and pipe is the circuit (Fig. 4‑2).
even to control valves in hydraulic systems.
This section covers some of the basic terms
and components used in electrical systems.
Most of these electricity basics deal with direct
current (DC). DC circuits are the foundation
of Schlumberger mobile and skid-mounted
equipment.
Negative Positive
terminal terminal
Wire Insulation
conductor Figure 4-2. Water Pipe Circuit
Incandescent
lamp
When you turn on the water, you switch the
current on to allow the current to flow. The
Conductor current flows because of the potential pressure
difference: on one side of the valve of the
faucet there is no pressure, and on the other
side there is water pressure. This difference
Switch makes up the voltage, or electromotive force,
sometimes referred to as EMF.
Note:
Electricity is not just something
supplied by batteries and used up AMPS
in a light bulb. It is a form of energy
that circulates and requires a Figure 4-3. Examples of Amperage
complete circuit to flow.
Conventional current
When Ben Franklin discovered electric current,
he had no idea that electrons existed. Having a
Refer to the Figures 4-1 and 4-2 for a
positive attitude, he arbitrarily said that current
comparison of a basic electrical circuit and a
flowed from positive to negative. Much later,
water pipe circuit.
scientists discovered that current was a flow
of electrons and that the electrons traveled in
4.2 Electric current the opposite direction, that is, from negative to
positive. In the late 1960s, only a few textbooks
Current is the flow of electrons in an electric and school curricula taught negative-to-positive
circuit. Flowing water is a good analogy current flow. In fact, today most of the world is
of electricity. When water flows through a still using Franklin’s conventional current flow
pipe or down a stream, there is a current. theory, that is, positive to negative, to explain
Sometimes the current flows faster than and dissect electrical circuits. No matter which
normal, and sometimes it flows more slowly. If way the current flows, it still produces the same
you measured how fast the water current was amount of work (Fig. 4‑4).
flowing through a pipe with a flowmeter, you
would measure the flow by so many gallons per
minute.
Electrons Return of
4.3 Voltage flow
through Electrons
electrons
the circuit
Water flows through a pipe because of water due to
pressure. Water pressure forces the water voltage
pressure
to flow. Likewise, electromotive force is the
Positive
pressure that forces electrons to flow through ions
a circuit. Electromotive force is also known as
voltage. The basic unit of electromotive force
is the volt (V). In formulas, volt is sometimes
abbreviated E (for energy). Figure 4-6. Battery Components
Ohm’s Law: E = I x R
Battery maintenance
• Keep the battery terminals clean and clear
To ensure that plenty of power is available of buildup that can corrode the cables.
when needed, proper battery maintenance is • Check to ensure that terminal connections
essential. Keep batteries fully charged at all are tight.
times. If there is a drop or lack of power when
starting, charge a battery to its full capacity • Check the condition of the entire cable, not
when possible. just the area near the battery, to verify that
there are no exposed wires or cracks in the
Use this checklist for routine secondary insulation.
(rechargeable lead/acid) battery maintenance: • Protect the battery from extreme
temperatures.
• Check the fluid levels in the battery
periodically, and use distilled water to • Do not overcharge a battery.
replenish the fluid. • Do not let two-way radio and computer
batteries run down completely.
• Frequently charge and discharge nickel
cadmium (NiCd) batteries to prevent
memory effect. This effect is a condition in
which the batteries do not recharge above
the level of their first recharge, which could
be below their full capacity.
To check an automobile battery, turn on the
lights and start the engine. If the lights go out or
dim excessively, the battery may be weak and
Fuses must be replaced with the proper type, System pressure passes through the gauge
current, and voltage rating (Fig. 4‑19). saver to the Martin Decker gauge, which is set
to close the circuit when it reaches a certain
level. A needle on the gauge responds to
system pressure, and when the needle makes
contact with the preset contact, the circuit
closes.
Rate
Pressure
4.12 Safety
Always follow these safety procedures when
you work with electrical systems:
Hydraulics, the study of the behavior of liquids, 5.1 Why use hydraulic power?
explains how forces are created and how the
tremendous potential of fluid power can be Schlumberger uses hydraulic power for tasks
effectively applied. such as mixing, proportioning, and agitating
in cement mixers and liquid- and dry-additive
Pascal’s law states, “Pressure applied on a systems. These are auxiliary circuits or systems
confined fluid is transmitted undiminished in all that support downhole operations.
directions, and acts with equal force on equal
areas, and at right angles to them.” Keeping Hydraulic devices are used for these
Pascal’s law in mind, what would you expect applications because they offer a number of
to happen if a piston was forced into a bottle advantages:
that was completely filled to the rim with water?
The bottle would break because the liquid is • produce high power output but are light and
practically incompressible and transmits the small
force applied at the piston throughout the • require minimum day-to-day maintenance
container. This is a simple example of hydraulic because the same hydraulic fluid used to
force (Fig. 5‑1). drive the system is also used to lubricate
the parts inside the hydraulic system
• are simple to operate
• can be operated at varying speeds
• are reversible
• can be stalled without damage when
overloaded and will start up immediately
when the load is reduced
• can be hooked up in a variety of
configurations as needed for the most
efficient operating.
Hydraulic systems are significantly less efficient
than direct-drive systems because of internal
friction that produces heat. They also tend
to leak internally. However, they require less
day‑to-day maintenance than direct‑drive
systems, though they require a qualified
technician for major repairs. Nevertheless, for a
Figure 5-1. Hydraulic Force in a Bottle coiled tubing unit and its spatial restrictions and
power transfer requirements, hydraulic devices
provide the best load distribution and packaging
available (Fig. 5‑2).
• a screwdriver.
The auxiliary posttrip inspection involves these
25 areas:
• engine performance
• coolant and oil leaks
• mounting for loose bolts and cracks
• proper operation of the neutral safety
switch.
5.3.7 Instrumentation
Verify that all gauges operate properly and can
be clearly read (Fig. 5‑10). Figure 5-11. Hydraulic System
• the gasket
• the latches
• the roll-over vent valve.
Figure 5-20. Caps
STEP 02 Check the previous STEM I STEP 05 Inspect the fuel system. Inspect
inspection to make sure that earlier problems the filters, hoses, and lines for leaks, rubbing,
have been repaired. chafing, and loose connections. Fill the tank to
within 50 mm [2 in] of the top (90% capacity) to
STEP 03 Inspect the oil level. It should allow for fuel expansion. In cold environments,
be up to the full mark. Add as needed. If the use winter-grade diesel fuel. Ordinary fuel may
oil looks gritty, watery, diluted (diesel in oil) cloud and clog the fuel filters.
or milky, check with a mechanic; a STEM II
inspection may be required. When adding oil, STEP 06 Inspect the belts. Also inspect
make sure to use the correct type and viscosity. the shrouds and guards. Belts should yield
Do not mix these, if possible, and do not overfill 12 mm to 19 mm [1/2 in to 3/4 in] under thumb
the oil level. Ensure that the correct dipstick is pressure. Inspect the belts for cracking and
being used for a particular engine; the wrong fraying. Check the condition of the pulley
dipstick can make a big difference. for loose bearings. A belt that is too tight is
destructive to the bearings of the driven part. A
loose belt will slip.
STEP 04 Inspect the exhaust system. Look a. Make sure the coolant temperature
for leaks and excessive noise. Look for leaks remains in the operating range for the
around the exhaust manifold gaskets, muffler, engine.
and muffler piping. If the engine has not been
used in a long time, drain any accumulation b. Check the oil pressure as often as
of fluid from the exhaust manifold. Avoid possible during the job. If the oil
excessive idling. Prolonged engine idling will pressure gauge shows a large drop in oil
result in the temperature of the engine coolant pressure, possible engine failure may be
falling below the specified operating range. imminent. Let the field supervisor or field
A low operating engine temperature causes engineer in charge know immediately,
incomplete combustion of fuel in the cylinders. and then switch to an alternate power
Incomplete combustion may cause lacquer or source if available.
gummy deposits to form on the valves, pistons,
and rings. It also causes rapid accumulation STEP 02 Check how the unit is operating.
of sludge within the engine. When prolonged Continuously check the unit for unusual
engine idling is necessary, keep the engine noises, vibrations, leaks, or smoke. Note any
running at a minimum of 900 rpm. operating problems on the STEM I inspection
form or Driver’s Trip Report. Remember to idle
STEP 05 Inspect the automatic the engine for 5 minutes before shutting the
transmission fluid level. If necessary, run engine down. Doing this allows the internal
through the gears with the unit on level ground, components to cool, which can prevent serious
and then read the fluid level on the dipstick. internal damage.
The unit should be at a normal operating
temperature. After the job, do the following:
Note:
STEP 01 Inspect the oil level. Wait until the
engine has cooled, and check the oil level and
Disengage the drive mechanism condition. Top off the oil if necessary. Use the
(transmission or PTO), and allow appropriate type of oil with the correct viscosity.
the engine to idle for 5 minutes Be sure the engine oil level has not risen during
before shutting down. the job. An increase in the level could indicate
contamination by fuel, water, or coolant.
10 psi.
Note:
The correct hazard class and
STEP 11 Visually inspect the unit. Inspect
under and around the unit for leaks from the
ID number for placarding each
tanks, C-pumps, and hydraulic lines. Note any
of Schlumberger’s hazardous
discrepancies on the STEM I inspection form or
materials should be available in
Driver’s Trip Report.
each location. This information
should also be noted on the During a job, check the following:
Loading Sheet for each unit.
The quality of a cement job is only as good Before a job and before applying air to a
as the bulk cement delivery to the mixer. vessel, do the following:
Therefore, it is very important for the bulk
system operator to understand how his
equipment works and how to keep it maintained
STEP 01 Review the previous STEM I
inspection report.
so that it works well on every job.
Here are the general configurations of STEP 02 Perform the STEM I chassis
pressurized and gravity silos. The following inspection, if applicable.
steps will ensure that the bulk system being
used (gravity surge can, pressurized silo, STEP 03 Make sure the maximum working
pressurized bulk truck) are in good operating pressure is stenciled on the tank.
condition when a job begins.
STEP 04 Make sure the tanks are labeled
correctly.
Note:
Make sure the equipment has
received the proper STEM I Note:
inspection, and confirm that the Improper labeling of bulk tanks
correct bulk equipment is being can cause an operating failure by
taken to location. Double-check mixing cement from the wrong tank
the loading tickets and/or service during a job.
order, the STEM I checklists, and
the unit’s number to ensure that the
correct piece of equipment is being
dispatched to the job. STEP 05 Inspect the check valves, relief
valves, and gauges. Ensure that the check
valve(s) and pressure-relief valve(s) are present
and free of corrosion or dirt. Verify the test
When working around cement pressure date on the pressure-relief valves. Inspect the
vessels, the operator must wear the following pressure gauges. The recommended pressures
PPE (and have the minimum safety equipment): are 0 to 60 psi, fluid filled, with a 6.5-cm [2.5-in]
face.
• goggles
Pressure-relief valves must be inspected
• dust mask.
every month and every year for every job, as
Cement dust is very abrasive to the eyes, specified in WS Safety Standard 27: Inspection
nose, throat, and lungs. Because it is caustic, it and Testing of Pressure Relief Valves and
can burn the skin if handled improperly. Use it Gauges, InTouch Content ID# 3313707. The
carefully. valves should be green-tagged, with the test
date noted on the tag.
While applying air to a vessel, do the step 03 Use a combustible gas detector.
following: Analyze the O2 in the air.
STEP 02 Inspect for leaks. Inspect hoses, step 05 Use an air mover to change air
caps, manifolds, and manhole covers. If leaks out frequently.
are found, bleed pressure completely from the
tanks and then repair the equipment.
step 06 Do not block the entry or exit
while a person is inside a tank.
STEP 03 Check the pressurized system
(bulk truck, pressurized silo, and pressurized
surge can):
step 07 Shut down and lock any
power‑driven equipment (compressors) before
a. Pressurize the empty tank to 5, 10, entry.
and 15 psi. Record how long it takes to
pressure up. If the compressor is cycling
in and out, the compressor is keeping up
with the delivery of the product. If the air
pressure is dropping on the product tank
and the compressor is cycling, there is a
restriction in the air lines or pads.
The batch mixer requires regular and specific near the joint between the dished head and the
maintenance. This piece of equipment plays cylindrical section.
a very important role in the completion of a
cement job. It must be maintained properly to If it is necessary to enter the tank, make sure
avoid service incidents and operating failures. the unit cannot be turned on by someone else.
Many problems can be directly attributed to Review the lockout procedure for this.
improper cleanup of the unit after a job.
STEP 06 Inspect the paddles and paddle
Always take the time to properly clean up the shafts for looseness. Grease the bearings
batch mixer. It is much easier to wash up wet where required.
cement than to chip out set cement.
Some batch mixers may be chain driven
The following steps outline the basic STEM I through a gear drive. If so, make sure that the
inspection of the batch mixer. Though there are chain has a little slack in it and that the guards
many different types of batch mixers in use, covering the chain are in good condition. The
these steps are applicable to all of them. clutch operating the chain should be able to
be greased through a nipple on the end of
Before a job and before starting an engine, the shaft. If the shaft does not have a grease
do the following: nipple, manual greasing is required.
STEP 01 Review the previous STEM I There may also be a sight glass or dipstick
inspection report. to check the oil level in the paddle’s gearbox.
Some gearboxes have a simple plug in the
side to check the oil level. If in doubt, ask your
STEP 02 Do the STEM I diesel engine supervisor. Top off the oil if necessary.
inspection.
STEP 05 Inspect the tanks. Look inside STEP 07 Inspect the piping. Look for
the tanks for cement buildup. If you see excess cement buildup. Verify butterfly valve action.
cement, clean it out. Ensure that all access If the action is stiff or if you can see damage,
hatches have gratings in place. If the mixer has repair the problem. Ensure that the blanking
a closed top, make absolutely sure that there caps are secure on all 4-in openings.
is no buildup of set cement in the upper corner
STEP 02 Verify unit operation. Make sure STEP 04 Make sure the load is secure for
all functions of the batch mixer are working the trip back to the district. Note any problems
correctly. or maintenance requirements on the STEM I
inspection form or Driver’s Trip Report.
After a job, do the following:
Safety Standard 17: Storage and Handling of Standard S013: Mechanical Lifting, InTouch
Oxidizers, InTouch Content ID# 3313693 Content ID# 3260276
80 | References
13.0 Check Your Understanding
1. The global consistency of fuel is one of 4. Which three of the following are functions
the advantages of using gasoline engines of a diesel fuel management system?
as a prime mover. A. holds a supply of diesel fuel
A. true B. uses high pressure to inject fuel into the
B. false cylinder
C. meters the quantity of fuel required for
2. Match each fuel system component with each cycle of the engine
its description. D. carries fuel to various components of
Components the engine through a network of hoses
and pipes
___ A. shut-off valve
E. controls the rate at which fuel is
___ B. reservoir
injected
___ C. fuel pump
___ D. injectors 5. Match each routine maintenance
Description system with the corresponding routine
1. holds and supplies fuel for use by the maintenance.
engine system
2. transfers fuel from the tank to the ___ A. air system
engine ___ B. fuel system
3. terminates the flow of fuel from the tank ___ C. oil system
to the engine
___ D. coolant system
4. calculates the right amount of fuel and
directs it into the cylinder under high
pressure Routine maintenance
1. Check fluid level; check fan for damage;
3. In a two-stroke engine cycle, each down check radiator for leaks.
stroke is a power stroke. 2. Ensure that pressure is maintained;
A. true check for leaks in hoses and
connections.
B. false
3. Check oil level and condition by looking
at the dipstick.
4. Check coolant level; look for leaks in
lines and connections; check filters to
make sure they are not clogged.
Description Description
1. The piston moves downward and draws 1. Used only in liquid additives, or LAS,
air into the cylinder. applications, such as fracturing.
2. Both valves are closed and the piston 2. Used to power brakes, horns, cab tilt
moves upward, squeezing the air into a controls, and deck engines.
tiny space until it becomes hot. 3. Used to convey and fluff bulk material
3. The piston moves upward to push out such as sand and cement.
the burned gases.
4. The buildup of burning gases forces the 10. Match each part of a pneumatic system
piston down. with its position on the diagram below.