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TEXVEN ENERGY SERVICES LLC TS-80-SS2 SKID-MOUNTED

COILED TUBING UNIT CONTROL CABIN AND POWER PACK
OPERATION & MAINTENANCE MANUAL

TABLE OF CONTENTS
SECTION III – MAINTENANCE

1. Periodic Maintenance Schedule .................................................................... 3

1.1 Maintenance Benefits ......................................................................................... 3
1.2 Maintenance Actions .......................................................................................... 3
1.3 Scheduled Maintenance ..................................................................................... 4
1.4 Maintenance Instructions .................................................................................... 4
1.4.1 Daily Maintenance Instructions .................................................................... 4
1.4.2 Periodic Maintenance for Trailer (if applicable) ........................................... 7
1.4.3 Weekly Maintenance Instructions ................................................................ 7
1.4.4 Monthly Maintenance Instructions ............................................................... 7
1.4.5 Extended Maintenance Instructions............................................................. 9
1.5 Corrosion Check ............................................................................................... 10
1.6 Servicing ........................................................................................................... 11

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COILED TUBING UNIT CONTROL CABIN AND POWER PACK
OPERATION & MAINTENANCE MANUAL

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COILED TUBING UNIT CONTROL CABIN AND POWER PACK
OPERATION & MAINTENANCE MANUAL

1. Periodic Maintenance Schedule

If the operator has ANY QUESTIONS about the safe use or

maintenance of the unit—ASK THE SUPERVISOR—NEVER
GUESS—ALWAYS CHECK.

1.1 Maintenance Benefits

• Best Performance — Your equipment is ensured of its best performance and
reliability when a scheduled maintenance program is followed. A small cost
and effort expended for a preventive maintenance program yields improved
performance, efficiency, and reliability.
• Benefits — These benefits are realized by:
o Understanding the nature of preventive maintenance.
o Following the lubrication and maintenance schedule that has been
established.
• Intended Use — This equipment is intended to be used according to its
designed purpose only. A program of regular preventive maintenance can
assure the reliability of the equipment in all operating conditions. A complete
log of all maintenance and repairs should be kept to help pinpoint future
problem areas. Corrective action can then be taken to prevent breakdowns
during operation of the equipment.

1.2 Maintenance Actions

• Preventive — The nature of maintaining the equipment calls for actions which
will prevent major repair work. These actions can be performed at an opera-
tor level, and can usually be categorized into (1) adjusting, (2) servicing, and
(3) treating for corrosion.
• Adjusting — The action of correcting misalignments, testing for the proper
setpoints (calibrating), and tightening loose components.
• Servicing — Servicing is the action of maintaining the proper amounts (levels)
of lubricating grease, oil, coolant, fuel, etc. Servicing also encompasses
replacing filter elements, as well as performing minor repair work. An
example of minor mechanical repair work is replacing a gasket or seal, etc.
An example of minor electrical repair work is replacing a light bulb or fuse,
etc. Minor repair work can be accomplished by operator-level personnel and
by use of this manual. Major mechanical repair work should be performed by
an authorized mechanic as a precaution against damaging the equipment or
injuring personnel. Likewise, major electrical or electronic repair work should
be performed by authorized technicians.

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COILED TUBING UNIT CONTROL CABIN AND POWER PACK
OPERATION & MAINTENANCE MANUAL

• Treating for Corrosion — This necessary, ongoing process consists of

thorough cleaning, lubrication, and assurance of protective finish integrity.
Equipment located where high humidity or high temperatures are prevalent
require extra awareness and inspections.
• Information — All preventive actions should be referenced in the specific
equipment manuals in the vendor publications section.
• Record Keeping — Records of maintenance activities should be maintained
at all times. This information is invaluable to service technicians when
troubleshooting or repairing the equipment.

1.3 Scheduled Maintenance

General Instructions Engine fluids and lubricants should be checked before and after
each operation. Refill or replace as necessary. Fluid capacities are approximate based
on manufacturer’s data. Capacities on individual units may vary due to custom changes.
Filters should always be changed with the fluids they protect to ensure long equipment
life and dependability.
Visually inspect all fittings and hoses before, and after, each operation. Tighten any
loose fittings and replace any worn hoses, as necessary to ensure unit longevity and
dependability.
Perform maintenance on items daily, weekly, or when the hour meter registers the
recommended scheduled hours of operation.
Guideline Because operating requirements for this data unit will vary, this maintenance
program should be used as a guideline in conjunction with an ongoing operational
analysis program.

1.4 Maintenance Instructions

1.4.1 Daily Maintenance Instructions

Daily maintenance is operational level service to the unit. These maintenance
procedures are part of the before and after operation checklists and operating
procedures.

NOTE: While performing service on equipment, always park equipment on

level ground and tag unit, ‘Out of Service.’

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COILED TUBING UNIT CONTROL CABIN AND POWER PACK
OPERATION & MAINTENANCE MANUAL

Preparation Maintenance Tasks

Check Data Unit Connections

1. Verify that all electrical interconnections and fuel lines are in place and
secure.
2. Proceed with maintenance or return unit to service.

Check Enclosure Lights and Battery System

1. Check all lights of the skid assembly and all connections for electrical system
and proper positioning after being transported.
2. Verify that batteries are charged, in place, and connections secure.
3. Verify that all electrical interconnections to remote control panel are in place
and secure.
4. Proceed with maintenance or return unit to service.
Post-Operation Maintenance Tasks

Check Fuel System

1. Check all fuel hoses and connections of the generator assembly, including
the tank connections to fuel filter assembly, and tank interconnections for
secure and proper positioning.
2. Verify that clamps are in place. Look for any signs of leaks or seepage
around connections.
3. Verify fuel level with fuel tank sight gauge. Fill, as required.
4. Check fuel tank isolation valves for proper positioning.
5. Proceed with maintenance or return unit to service.

Check Cooling System

System under pressure could cause severe injury. Partially open

the filler cap to relieve pressure prior to complete removal of the
cap. If the cooling system of a hot engine has been drained, do not
fill until the engine cools. A sudden change in temperature may
cause damage to the engine.

1. Check all coolant hoses and connections for secure and proper positioning
after being operated. Make a visual check for cooling system leaks. Look for
any signs of leaks or seepage around connections.
2. Allow system to cool down before opening filler cap.
3. Verify coolant level through overflow tank on radiator assembly. Fill as
required.

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COILED TUBING UNIT CONTROL CABIN AND POWER PACK
OPERATION & MAINTENANCE MANUAL

4. Inspect radiator core for damage or blockage from dirt and/or debris. Check
by shining backlight through coil. A dirty or damaged coil will not allow much
light through fin assembly. Clean as required.
5. Proceed with maintenance or return unit to service.

Check Engine Oil Level

1. Check engine oil level with the sump mounted dip stick with the engine warm.
2. The dipstick should show a level between ADD and FULL. The oil level with
the engine stopped should be at the FULL mark.
3. Fill as required with recommended type lubricating oil. Refer to the
Operator’s Manual in Section VI OEM Publications of this manual.

Do not overfill the engine sump at any time or serious equipment

damage can occur.

Use only specified lubricants. Refer to the Operator’s Manual in

Section VI OEM Publications of this manual.

4. Proceed with maintenance or return unit to service.

Check Air System

Do not operate the generator unit with a dirty air intake system or
serious equipment damage can occur.

1. Check air intake filters for any large debris in the assembly pre-filter.
2. Brush or wipe assembly clean of dust.
3. Proceed with maintenance or return unit to service.

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COILED TUBING UNIT CONTROL CABIN AND POWER PACK
OPERATION & MAINTENANCE MANUAL

1.4.2 Periodic Maintenance for Trailer (if applicable)

The trailer wheel lug nuts must be re-torqued to 450-500 ft-lb after
the first 100 miles of operation.

1. Inspect the wheels for any loose lug nuts; if necessary tighten to 450-500 ft-lb
of torque.
2. After the first 100 miles the wheel lug nuts must be re-tightened to
450-500 ft-lb of torque.
3. Make sure the trailer wheel lugs are torqued to 450-500 ft-lb every six
months.
Refer to the Master Maintenance Schedule in Section III – Maintenance of the O&M
Manual for Trailer periodic maintenance information.

1.4.3 Weekly Maintenance Instructions

Clean the Unit

1. Verify that all electrical connections are secured properly.
2. Spray down outside of unit with water and brush off dirt and debris. Carefully
clean up any corrosive material accumulated anywhere on the unit.

Never use diesel fuels as a cleaning agent as they are highly

flammable and can cause equipment damage.

3. If required, use a noncorrosive industrial strength cleanser mixed in a 50/50

ratio with clean water to remove buildup.
4. Wipe down all exposed controls, indicators and gauge panel.
5. Clean out the spark arrester inside muffler.

Check the Air Cleaner

Check air cleaner dust cap and clean if required.

1.4.4 Monthly Maintenance Instructions

Monthly Maintenance intervals are determined as approximately 100 hours of operation.
It is for this reason that unit operating durations and parameters are monitored and
recorded. These procedures are listed as a guideline for determining the best service
interval.
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COILED TUBING UNIT CONTROL CABIN AND POWER PACK
OPERATION & MAINTENANCE MANUAL

Clean Air Cleaner Elements

1. The air cleaner element is a dry type and should never have oil applied to it.
Avoid touching the element except when cleaning it. Instructions for cleaning
the element can be found on a label attached to the element.
2. Change the element yearly, or more often in extremely dusty conditions.
3. Wipe down housing and remove any debris accumulated around element
gasket.
4. Replace the outer housing cover and tighten by hand only.

Replace Engine Oil and Filters

1. To drain the lubricating oil, open oil drain at the bottom of the oil pan.
2. Drain oil while still warm to remove suspended debris in oil. Close oil drain.
3. Remove the filter with a filter chain wrench.
4. Clean the sealing surface of the mounting base and ensure that the entire old
gasket is removed.
5. Apply clean engine oil to the gasket of the new oil filter. Place the filter in
position and tighten until the filter gasket contacts the base. Tighten the filter
by hand for an additional 3/4 turn. Do not overtighten the oil filter.
6. The FULL level of oil on the dipstick is determined with the engine stopped,
either warm or cold. Remove the oil filler cap and fill the crankcase through
the oil filler tube only. For oil capacity and recommended oil type, refer to the
Operator’s Manual in Section VI OEM Publications of this manual.
7. Clean the oil filler cap and install into the filler tube.
8. Operate the engine at low idle for two minutes to ensure that the lubrication
system has oil and that the oil filters are filled with oil. Inspect engine for oil
leaks.
9. Stop the engine and allow the oil to drain back into the sump for a minimum
of ten minutes. Remove the oil level gauge and check the oil level. Bring
level up to FULL mark on dipstick. DO NOT OVERFILL OR ENGINE
DAMAGE CAN OCCUR!

Drain Fuel System

1. Open the drain at the bottom of the fuel oil day tank to drain off any water and
sediment.
2. Ambient temperature changes can cause condensation in partially filled fuel
oil tanks. Water accumulation can be controlled by keeping the fuel tank
filled and, if required, the use of some fuel additives.
3. Microbe growth can be eliminated through the use of some commercially
available biocides.
4. With the genset running, inspect the fuel supply lines, return lines, filters, and
fittings for leaks. Check flexible sections for cuts, cracks, and abrasions.

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COILED TUBING UNIT CONTROL CABIN AND POWER PACK
OPERATION & MAINTENANCE MANUAL

5. Verify that the fuel lines do not rub against anything that could break them.
Replace worn fuel line components before leaks occur.

Check Battery
1. Keep the battery case clean and dry and the battery connections are clean
and tight.
2. Maintain the electrolyte level by adding distilled water. Use a battery
hydrometer to check the specific gravity of the electrolyte in each battery cell.
Charge the battery if the specific gravity measures less than 1.215. Do not
overcharge the battery and stop charging the battery when the specific
gravity reaches 1.260 at approximately 81 ºF (27 ºC).
3. Check the battery charging system for the correct output.

Check Coolant System

Take a sample of the coolant and have an analysis run to determine needed ad-
ditives.

1.4.5 Extended Maintenance Instructions

Flushing and Refilling Radiator

1. Clean the cooling system every 500 hours of operational service.

2. Use a good radiator cleaning solution designated as an inner coil
cleaner/flushing agent and use in accordance with the instructions on the
container.
3. After the cleaning operation, flush the cooling system by filling the radiator
with soft water and running the genset for ten minutes, and then drain the
system completely. Once the engine has cooled, refill the radiator with
recommended coolant.
Clean Radiator

Do not use fuel oil, kerosene or gasoline as a solvent.

1. Inspect the exterior of the radiator core every 700 hours and, if necessary,
clean it with a quality grease solvent that is designated for use as a coil
cleaner.
2. Direct the solvent through the fin assembly in the opposite direction of the
normal air flow.
3. Dry with compressed air in the same manner.

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COILED TUBING UNIT CONTROL CABIN AND POWER PACK
OPERATION & MAINTENANCE MANUAL

4. Aware that periodic cleaning intervals depend on the individual unit’s

operating conditions and ambient environment, service personnel should
adjust the cleaning/maintenance regime accordingly. In certain types of
service, deposits will form more rapidly than others. Heavy deposits will
cause an increase in the pressure drop through the radiator and a decrease
in the cooling effect. Cleaning intervals can be shortened or lengthened
depending on the characteristics of the site, once the personnel have
established the optimum time frame.
Clean Control System

1. With the DC potential disconnected, the control cabinet and panels should be
blown out with air and/or wiped clean inside and out.
2. A light coat of a corrosion-preventive spray solution is recommended on
unpainted/untreated surfaces. A non-oil base cleaner/lubricant spray is
recommended as an oil base spray will eventually fog the glass covers on the
gauges/indicators, making them unreadable.
3. Inspect for any loose components, terminal screws, and soldered
connections. This inspection is especially beneficial for the skid-mounted
local control panels and electrical enclosures which are exposed to vibration
from the generator engine.
4. Inspect the vibration absorbing neoprene panel and cabinet mounts for
elasticity and resiliency. If hardened or cracked, replace immediately.

1.5 Corrosion Check

Treating for corrosion before it becomes a problem is a necessary, ongoing process.

A weekly inspection for corrosion damage consists of thoroughly cleaning and
preserving or lubricating all exposed metal surfaces. The data unit is sealed with several
coats of industrial sealant paint but this protective shell can breakdown at vibration
sensitive areas or places exposed to extreme heat for long periods of operation.
Inspection for signs of rust should always be conducted and ongoing during the course
of routine maintenance procedures. When the unit is not in service, every precaution
should be taken against corrosion.

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 TEXVEN ENERGY SERVICES LLC TS-80-SS2 SKID-MOUNTED
COILED TUBING UNIT CONTROL CABIN AND POWER PACK
OPERATION & MAINTENANCE MANUAL

1.6 Servicing

Servicing the unit is performing major repair work such as replacing a motor and/or seal,
replacing piping, troubleshooting systems, etc. An example of major electrical repair
work is repairing or changing the unit’s wiring.
Major repair work can be performed by service level personnel and by use of OEM
manuals in Section VI of this manual.

Any repairs or service (routine maintenance) performed on the data

unit must be performed by a trained service technician familiar with
electronic control systems. All such service and repairs must be
supervised by qualified management personnel and only S&S
replacement parts should be utilized.

When working on the data unit, safety glasses, approved safety

shoes and hardhat must be worn. Hammering on any part or
component may cause foreign material or steel slags to become
airborne.

It is a personal responsibility to use the proper tools when

servicing the data unit. Any special tools required are furnished
with the pump when new, and should be kept with the unit for its
routine maintenance. It is a personal responsibility to be
knowledgeable and trained in the use and handling of these tools
for all maintenance of the unit.

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COILED TUBING UNIT CONTROL CABIN AND POWER PACK
OPERATION & MAINTENANCE MANUAL

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