7. VALORIZACIÓN DE ALTERNATIVAS
7.2. SOLUCIONES INDIVIDUALES
Ref. Problem Ref. Possible Cause Remedy
3A Pumps Run Excessively 1. Air pump pressure switch bypass valve open or faulty
1. Close the bypass valve tightly
2. Reset automatic pressure switch (See Maintenance Section) to shut off air pumps at: a. 2900 PSI for units with air and electric
pumps
b. 3000 PSI for units with air pumps only 3. If air pumps continue operating, bypass valve
may be defective
a. Loosen tubing connector downstream from air bypass valve
b. If air is escaping, replace the bypass valve c. Close bypass valve tightly
4. Check pump shutoff pressure 2. Hydraulic seals in automatic
pressure switch are leaking
1. Stop pumps
2. Open manifold bleeder valve and relieve system pressure
3. Remove automatic pressure switch for inspection
4. Replace pressure switch and adjust setting 5. Close manifold bleeder valve
6. Start pumps
7. Check pressure switch settings 3. Faulty precharge valve (bladder
type separator)
1. Stop pumps
2. Open manifold bleeder valve
3. Check precharge pressure on each accumulator and record
4. Tighten each precharge valve assembly by using valve core tool
5. Precharge each accumulator with 1000 PSI of nitrogen starting with accumulator that had highest recorded pressure. This will conserve nitrogen
6. Check all precharge valves for gas leaks by placing drops of saliva across tops of valves. (Light oil may also be used.) And, if:
a. Bubbles appear, replace valve core (See Maintenance Section)
b. No bubbles appear, accumulators are ready for normal use
7. Close manifold bleeder valve 8. Start pumps
4. Four-Way valve leaking 1. Open inspection ports located at each end of reservoir
2. Observe which valve is leaking 3. Manipulate manually several times 4. If leaking persists, remove valve
5. Use special repair kits containing necessary parts for overhaul
6. The maintenance instructions supplied with the kit must be consulted for proper assembly. Improper or reverse assembly can result in high pressure and cause injury
5. Relief valve leaking 1. Open inspection ports at each end of reservoir 2. Observe relief valve return lines to see which
one is leaking
3. Note pressure reading on gauge when flow begins to check if setting is incorrect 4. Remote and replace faulty valve
Ref. Problem Ref. Possible Cause Remedy
Produced By: Entrada International, Inc. 2002
Page 53 of 91
6. Regulator Leaking 1. Open inspection ports at each end of reservoir 2. Observe regulator return lines to check if
leaking
3. Remove and replace faulty regulator 7. Bleeder Valve Leaking 1. Close manifold bleeder valve tightly
2. Check for leakage by looking through inspection ports located at each end of reservoir
3. If valve is leaking, remove and replace it 8. Leaks in Fluid System Visually inspect:
1. All piping and connections on the accumulator unit
2. All connecting lines to the BOP stack 3. Relieve all system pressure 4. Repair all fluid leaks
Ref. Problem Ref. Possible Cause Remedy 9. Loss of precharge pressure 1. Stop pumps
2. Bleed fluid system pressure by slowly opening bleeder valve
3. Listen for poppet valves to close while observing accumulator pressure gauge 4. If poppet valves do not close at precharge
pressure, and pressure continues to drop to zero, at least one accumulator has lost its precharge
5. Check and record precharge pressures of each accumulator. Those with zero precharge may have faulty bladders. To check this:
a. Tighten valve cores snugly with valve core tool
b. Precharge with 200 PSI of nitrogen. If pressure does not decrease
c. Precharge with 1000 PSI of nitrogen 6. If an accumulator does not sustain 200 PSI
precharge, the bladder is ruptured and must be replaced (See Maintenance Section.) 7. Close manifold bleeder valve 8. Start pumps
3B Pumps Shut Down at Wrong Pressure
1. Air pump pressure switch out of adjustment
1. Stop pumps
2. Close accumulator isolator valves 3. Make sure air bypass valve is tightly closed 4. Open manifold bleeder valve to relieve system
pressure
5. Close manifold bleeder valve 6. Open air pump supply valves
7. Adjust pump shutoff pressure setting (See Maintenance Section) until pump stops running when the desired fluid pressure has been reached on accumulator gauge
8. Bleed off manifold pressure through bleeder valve and repeat procedure to check accuracy of setting
9. Open accumulator isolator valves 10. Turn motor starter to AUTO position 2. Electric pressure switch out of
adjustment
Pressure switch settings have a tendency to drift and require periodic calibration. This is especially true when the equipment has been moved to a different location. To readjust the setting See Maintenance Section
Ref. Problem Ref. Possible Cause Remedy
Produced By: Entrada International, Inc. 2002
Page 55 of 91
3C Pump Cannot Reach Full Pressure 1. Faulty check valve in air pump If pump discharge pressure reaches a certain point and pump still continues to run, the check valve in the pump is stuck in open position or has been damaged: 1. Stop pumps
2. Close isolator valves with pressured up accumulators
3. Open bleeder valve and bleed off manifold pressure
4. Remove suspected air pump 5. Clean, repair, or replace as necessary 6. Reinstall pump
7. Start air pump and operate with bleeder valve open to make sure that the pump is properly primed
8. Close bleeder valve 9. Open isolator valves
10. Start pumps and pressure up system 2. Low air supply 1. Check rig main air supply gauge for proper air
supply pressure (See Installation Data Sheet.) 2. Correct air supply at rig main air compressor. 3D Pumps Produce No Pressure 1. Loss of pump prime because of low
fluid level
To restore fluid level:
1. Close accumulator isolator valves if accumulator pressure gauge shows pressure is contained
2. Stop pumps
3. Open manifold bleeder valve and bleed system pressure
4. Add fluid to at least twelve (12) inches above pump suction lines
5. Start one pump and operate at full pressure 6. Observe fluid flow through inspection ports 7. Stop pumps
8. Open isolator valves
9. Check reservoir fluid level. Add oil if needed 10. Close bleeder valve
11. Start pumps and pressure up system 2. Suction valve closed Check that pump suction valves are in full open
position.
3. Fluid Contamination 1. Close accumulator isolator valves if accumulator pressure gauge shows pressure is contained
2. Stop pumps
3. Open manifold bleeder valve
4. Open air pump supply valves and start air operated pumps
5. Observe fluid flow through inspection ports. If slight or no fluid flow is observed:
a. Stop air pumps
b. Close pump suction valve(s) c. Remove "Y" strainer plugs d. Remove strainer elements
e. Open pump suction valves and flush out debris from piping
f. Close pump suction valves g. Clean and replace strainer and plug h. Start pump and observe fluid flow through
inspection ports
i. Repeat procedure until system is clean j. Close manifold bleeder valve
k. Open accumulator isolator valves l. Start pumps
Ref. Problem Ref. Possible Cause Remedy 3E Pumps Leaking 1. Air Pumps - Plunger packing is
worn or damaged
On the older style pumps: 1. Tighten packing nut 2. If leak:
a. Stops - Check for proper plunger lubrication. The plunger should be coated with thin film of hydraulic fluid
b. Persists - Remove pump and replace 2. Electric Driven Pump - Worn
Packing
Replace packing 3. Electric Driven Pump - Damaged
Valve Cover Gasket or Loose Cover Plate
1. Stop pumps
2. Close pump suction valve 3. Remove valve cover plate
4. Remove and inspect valve cover gaskets 5. Replace gaskets if they appear to be distorted,
washed out, or compressed excessively 6. If gaskets appear to be good, invert and
reinstall
7. Replace cover plate and tighten bolts 8. Open suction valve
9. Open manifold bleeder valve 10. Turn motor starter to AUTO position 11. Operate pump and check for new leaks 12. Open air supply valves
Produced By: Entrada International, Inc. 2002
Page 57 of 91
6.4 ELECTRIC MOTOR PROBLEMSRef. Problem Ref. Possible Cause Remedy
4A Motor Fails to Start 1. Pressure Switch Faulty 1. Turn motor starter to OFF position
2. Turn off power at main generator panel or MCC 3. Remove pressure switch explosion proof cover 4. Disconnect leads from electrical pressure
switch
5. Check resistance across terminals of pressure switch with an Ohm meter. If resistance is observed, the switch is working properly 6. If no resistance is found, replace the limit
switch or, if time is limited, replace the entire pressure switch assembly (See Maintenance Section.)
7. Replace the leads from starter to pressure switch (See Starter Wiring Diagram.) 8. Turn on power at main generator panel or MCC 9. Turn motor starter to AUTO position
10. Check for proper adjustment to settings (See Maintenance Section)
11. Replace pressure switch explosion-proof housing cover
2. Starter Tripped If power supply had a thermal overload: 1. Turn motor starter to OFF position 2. Press reset button on motor starter 3. Turn motor starter to AUTO position 3. Loss of Power Supply 1. Turn motor starter to OFF position
2. Check voltage of power supply to starter at main generator panel
3. Restore power supply from main generator panel
4. Turn motor starter to AUTO position
4B Motor Runs Erratically 1. Voltage Fluctuation If pump pressure is at proper desired setting and pump stops frequently, input voltage may be too low. 1. Turn motor starter of OFF position
2. Check and correct voltage at main generator panel
3. Turn motor starter to AUTO position 2. Pressure Switch Span out of
Adjustment
If pump continues to stop and start after reaching the proper pressure setting, switch adjustment may be necessary. a.
1. Close air supply valves
2. Check that starter switch is in AUTO position.
CAUTION: ELECTRICAL CONTACTS HAVE