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Technical Manual - Revision January 2012

1. Description Qty Part Number A Part Shifting Lever Weldment 1 1037 D 20B B Part 5 16 x 1 1 2 Clevis Pin 3 09 0256 C Part Shifting Link 2 02 0120 D Part 0 093 x 1 1 8 Hitch Pin 3 E Part 3 8 NC x 1 1 2 Hex Bolt 1 09 1050 F Part 3 8 NC Hex Nut 1 09 5806 G Part Detent Spring 1 997 0 64 H Part Detent Ball 1 02 0018 J Part Shifting Shaft Bushing Weldment 1 1037 C 21 K Part Shifting Shaft 1 1037 C 20A L Part 3 8 NC x 1 Hex Bolt 4 09 1170 M Part 3 8 Lock Washer 4 09 5106 N Part Shifter Lug Weldment 1 101 0016 P Part Shifting Fork 1 1037 D 27 Q Part 7 8 UNF Hex Jam Nut 1 09 1489 R Part Bottom Bushing 1 1037 C 21B MCCOY 55 COMPLETIONS MOVING GLOBAL ENERGY FORWARD TEcHNICAL MANUAL 5 17 KT20000 20 50K Hyprautic Supports amp HANGER Lucs 5 18 Section CONTENTS TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD Supports amp HANGER Lucs KT20000 20 50K J _ Description Qty Part Number A Part 3 8 NC x 1 Hex Bolt 8 09 1170 B Part 3 8 Lock Washer 22 09 5106 C Weldment Hydraulic Discharge Line Support 1 101 2404 D Weldment Hydraulic Valve Support Post Weldment 2 101 1442 E Part Adjustable Inlet Line Support Plate 1 101 0022 F Part 3 8 Narrow Flat Washer 2 G Part 3 8 Thin Nylock Nut 2 H Weldment Hydraulic Inlet Line Support 1 101 1138 J Part 3 8
2. DRILLING amp 5 2 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD GEAR TRAIN LAYOUT 20000 20 50K Item Type Description Qty Part Number A Part Staffa HMB080 S S03 70 Hydraulic Motor 1 87 0210B Part Rineer GA125 A2 PC 082 31 0 Hydraulic Motor Optional 1 87 0150 B Assembly Pinion Idler Assembly Pp 7 10 7 11 2 C Assembly Pinion Gear Assembly Pp 7 12 7 13 1 D Assembly Rotary Idler Assembly Pp 7 8 7 9 2 E Assembly Support Roller Assembly Pp 7 4 7 5 14 F Assembly Clutch Assembly Pp 7 14 7 15 1 G Part Rotary Gear 1 1037 D 46 H Assembly Door Pivot Roller Assembly Pp 7 4 7 5 2 DRILLING amp AACCCOY TECHNICAL MANUAL 5 3 MOVING GLOBAL ENERGY FORWARD KT20000 20 50 A RS Support ROLLER 54 CONTENTS TEcHNICAL MANUAL CCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS Support ROLLER 20000 20 50K Tonc Item Type Description Qty Part Number A Part 1 4 UNF Straight Grease Fitting 1 02 0097 B Part Support Roller Shaft 1 101 3939 C Part 1 1 8 Plain Flat Washer 1 09 5041 D Part Bearing Spacer 2 101 3871 E Part Support Roller Bearing 2 02 0094 F Part Support Roller Spacer 1 1037 C 134 G Part Support Roller 1 1037 135 H Part 1 Narrow Flat Washe
3. Cylinder Series Paraki Parallel Tandem Duties i AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS TEcHNICAL MANUAL SECTION CONTENTS 7 29 KT20000 20 50 HvoRAULIC VALVE INFORMATION VA VG Valve Service Instructions INTRODUCTION Thus has been prepared t assis you in the proper maintenance of the V A2OTMAVA 3579 and VGZUTM VGSSITMI directional control valves Before work is done we you read the assembly and disassembly msinictions completely The first rule of good maintenance is cleanliness which includes a clean environment MAKE SURE YOU DISASSEMBLE AND ASSEMBLE YOUR HYDRAULIC EQUIPMENT IN CLEAN AREA Dirt is the natural enemy of any hydraulic system GENERAL INFORMATION The VA and V Cr model valves are updated versions of eur proven AJOTM and A 35TM units The WG models are cast from compacted graphite high strength iron alloy which allows the valve tobe rated to 3504 VA models are cast from iron add rated at 2500 pai These open center directional contral valves are available in parallel tandem and series circuitry As needed ihe sectional stack type construction provides flexibility for the addition of subtraction of work Sections ro existing valve bank This design also permits the combination of parallel
4. d TECHNICAL MANUAL KT 20000 20 50 8 cm 50K Lbs Ft Hydraulic Power Tong e Specifications Operation e Maintenance Assembly 2011 McCoy Corporation All rights reserved Published by McCoy Corporation Technical Publications Department m ccoyg lo E m 14755 121A Avenue Edmonton AB Canada T5L 2T2 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K This manual covers the following models TONG MODEL t DESCRIPTION Tong is equipped with Rineer 125 82 motor motor valve lift cylinder valve 80 1302 ase and chain sling Tong is equipped with Rineer 125 82 motor motor valve lift cylinder valve 80 1302 1 AP chain sling and safety door Tong is equipped with Staffa 080 motor motor valve lift cylinder valve 80 1302 2 AP chain sling and safety door 80 1303 2 Tong is equipped with Staffa 080 motor motor valve and chain sling 80 1304 2 Tong is equipped with Staffa 080 motor motor valve lift cylinder valve and chain sling NOTE Some illustrations used in this manual may not exactly match your equipment PATENTED amp PATENTS PENDING DRILLING amp TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD This page intentionally left blank KT20000 20 50K Tone Copyright 2007 2012 McCoy Corporation including its wholly owned subsidiaries McCoy all rights reserved This document i
5. 2 12 Tong Rig up amp Leveling SUSPONSION IH 2 13 TORQ 8 11 11 EE 2 15 Tong Operation Initial Start up amp 514 1 1 irdeni diviaka reari raiki 2 16 Vale ODS ALON R 2 16 Shifting 61 72 X 2 18 General Operational 2 18 Making amp Breaking Connections 2 19 Breaking A Connection 2 24 Cold Weather V 2 26 MAINNONANCE M m Section 3 General Maintenance Safety Procedures EE 3 1 Preventive Maintenance eee rrr dein in eso raa rin a aane RE YE Pa aa ER Roos 3 1 M 3 2 Adjustments a i EE 3 7 Door Latch Adjustment us 3 8 cs LAM 3 8 Shifter Detent Force 2 2 2 220 20000010000
6. dave a REPE a FR EYE XN y HT EY EUR AN Re FARE ANTES TRA FR FEN 6 1 IEEUSTRATION 6 A 3 COMPRESSION LOAD CELL 1i eiii eoi oria ania 66 864 012 244 Rye d FUR PER 65012818 60 6141 6 1 ILLUSTRATION 6 A 4 TENSION LoAD CELL EXPLODED e 6 3 ILLUSTRATION 6 A 5 COMPRESSION LOAD CELL 222 00 000000000000000000000 2222 6 4 ILLUSTRATION 6 A 6 TURN COUNTER ENCODER MOUNT 02 2 00000000000000000000000000005000000000000 sess nera 6 5 DRILLING amp AACCCOY MANUAL ix MOVING GLOBAL ENERGY FORWARD KT20000 20 50 The information presented in this document will provide setup operating and maintenance instructions for your KT 20000 tong Due to the wide variety of operating conditions these instructions must be considered guidelines rather than absolute operating procedures It is the responsibility of the user to use these guide lines together with an experienced manager to develop operating procedures that conform to all policies set forth by the operating authority ies IDENTIFICATION OF WARNINGS AND OTHER NOMENCLATURE OF IMPORTANCE USED IN THIS TECHNICAL MANUAL Farr Canada Corp uses three indicators to describe items of three degrees of importance A HAZARD to operators or equipment
7. 2 26 ILLUSTRATION 3 0 1 CAGE PLATE CAM FOLLOWER 222 222 6 00 00000000050000500000020 0000000000 0000 arra 3 2 ILLUSTRATION 3 0 2 RorARY GEAR LUBRICATION e 3 2 ILLUSTRATION 3 0 3 SUPPORT ROLLER LUBRICATION 2 2220 2 22 0 00 00000000000000008050500000000 3 3 ILLUSTRATION 3 0 4 ROTARY IDLER 22 2 2 00 0 0 00 sais assa sse 3 3 ILLUSTRATION 3 D 5 PiNION IDLER LUBRICATION we 3 4 6 a yd 3 4 3 7 CLUTCH SHAFT LUBRICATION ss 1i isse ia ria sa aae ew ava Ye ga FR Pup i EFE 3 5 ILLUSTRATION 3 0 8 SHIFTER COMPONENT LUBRICATION ACCESS we 3 5 IEEUSTRATION 3 D 9 JAW ROLLER LUBRICATION seria re sa sa sio rna to tke ga FR 140008644 164000588 666011 FEWER RH 3 6 ILLUSTRATION 3 0 10 DOOR SPRING CYLINDER LUBRICATION esses 3 6 ILLUSTRATION 3 E 1 BRAKE BAND ADJUSTMENT we 37 ILLUSTRATION 3 E 2 DOOR LATCH ADJUSTMENT 8 2 2 00 2 0000000060000000000000000000000 ieira 3 8 ILLUSTRATION 3 E 3 DOOR ALIGNMENT MEASUREMENT POINTS 2222 222 2006000000000000000000000000000000000000 3 9 ILLUSTRATION 3 E 4 DooR A
8. 2111 the Tongue the retainer 175 im rm accormpli nanga gmit ra of pne anil bald nie ihe my A rene devel pod cir imigh ele Sole dhe retainer Step 3 Detent Balls and Spring lightly coor rhe derent balls Fig 2 liens 18 dest L iden 91 and diameter ol ide sleeve 4 Fig L den 17 with raem the detent tte 152 hale m the derent n tasner Mace the on the ede ihe spring empress the halla aml hen dip on the deter sleeve Mote The sheave emat symmetrical ane end al the derve has a This chamfer mus isee ihe spani when Move lec decimi dade 16 De neulril or e daring suboeguen sep COY MOVING GLOBAL ENERGY FORWARD 7 37 TEcHNICAL MANUAL SECTION CONTENTS KT20000 20 50K VALVE INFORMATION Valve Assembly Instructions 3 Step 1 Spool Subassembly Apaly 2 3 of Logne 2629 er egurvalem to the ice hie bir ol ilie Apply clean hydraslic oil e rat value poch Carefully
9. H 5 8 5 10 Pinion Assembly a 5112 Glutch Assembly eso oia i ba ho ed e a 5 14 5 16 Hydraulic Supports amp Tong Hangers O48 MOIOILODIOIS scu ML uu LM MIR E MIA EE 5 20 Torgu Gauge MOUNTS TTE EE 5 22 Brake Band Assembly 5 24 Cage Plate Assembly 5 26 ais coi tai 5 28 Tong Door Base Assembly 5 30 Safety Door Optio R 5 32 Ghain Sling Assembly 2rd 5 34 Torque Measurement Section 6 Hydraulic Components Section 7 AACCOY 2 viii TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD List OF ILLUSTRATIONS KT20000 20 50K Tonc IREUSTRATION LAST KT 20000 TONG iiiter ena trea a nda uh Ye SRI rV Rex awe EL Rri eV dE 1 1 ILLUSTRATION 1 A 2 KT 20000 POWER TONG 1 2 DEN ag Tego APRES CPC E 2 1 ILLUSTRATION 2 1 MAJOR COMPONENT IDENTIFICATION 01 e 24 ILLUSTRATION 2 B 3 MAJOR COMPONENT IDENTIFICATION 03 222220202000 0 000000000005000000 2 5 ILLUSTRATION 2 B 2 MAJOR
10. ILLUSTRATION 2 10 RELEASING Jaws FoLLowiNG BREAK OUT amp UN THREADING DRILLING amp AACCCOY MANUAL 2 25 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Tonc SETUP amp OPERATION Breaking A Connection Continued When the tong jaws disengage align the opening in the rotary gear with the mouth of the tong and open the tong door to free the tong from the drill string Unlatch and open the tong door to free the assembly from the tubing Note that rig personnel may be required to stabilize the equipment as it completely releases from the tubing Guide the assembly away from the string and use the lift cylinder control to lower it to the drill floor if desired ILLUSTRATION 2 11 LoweRING Usine Lirr CYLINDER CONTROL p Use your rig s standard pipe handling procedures to remove and rack the freed tubing stand 4 Repeat steps e through as many times as necessary to break out and un thread the desired number of connections H EXTREME COLD WEATHER OPERATION PROCEDURES 1 Consult the power unit engine operator s manual for all cold weather operating procedures and precautions 2 Select gear and bearing lubricants that are compatible with expected climatic conditions 3 Select hydraulic fluid that is compatible with expected climatic conditions 4 Allow hyaraulic fluid to circulate for approximately 20 minutes after starting the power unit prior to activa
11. pr Lara and an nins weh iha i Y mum zb owns ptian cnn seinen valve aiti Parallel Circuits ziii pim min mcn cman cri miie F r ang Mech an be emo vanus acci wl menos menm d ny Fe sums Bra ma ye jie ahha ai Miu pey ba tior a ires h od iaaa er Fa Sem cam a Hoe Dahepan Fe Morement cl ha soced cr Tien of ho iia pen pass dni PAARL Pe ba sages iC rir ipea bn lhe opier g diacritig ie a work piane 81 Tandem Circuils hei araabia program Teen crags gne krpan culled Drop nr ceded npa Sie Tame ipm ina open Canin Vie Boia mium iye na remm passu ant a net Lum rl Bi ton ole by mi aerars Nana ao acer ang the creda Ape ue imei Fem Enn Ue miseri pra nt LR RR TEE FERT ia Cen B Fo ru Pur Typical Work Section Schematics at il Ad TES ci a 5ilandiari DA Cylinder OLA Cylinder DA Mater
12. hand seversi thra Tighten to final tongue Bf 1511 Re i gt Step 5 Relief Valves Refir all vales t tes posensans aid 15 11 Phe mew Place sends iip 1 item A ratorem Ae Tp mn fhe progr Maie certaan amie impose donne asse rni Step Install Tie Bolts aide the alte the iet cong IF cap reas nod place Wether on the screw pru bo Piare ibe valve sextiana co the pe in proper sequence 1382 Sep by hand engnge several threads the outlet ITH H a YG sene mese hie mit amd io citer em aud follow obave teszruenpee tie m reas comer Ball Torque Values 29 8 Iba 348 Ib VG20 42 ft ibs 504 in Ibs VAIS 34 Ibs 408 In Ibs 035 bs 000 In iba 150 ft 7000 COY MOVING GLOBAL ENERGY FORWARD 7 39 TEcHNICAL MANUAL CONTENTS KT20000 20 50K VALVE INFORMATION Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Pinched blown or missing Replace section seal Section sen Chl lewks between sections Stud fasteners not correctly Replace section seals and re torque forged Mounting plate
13. 22 30 Flash Point F 432 222 Colour ASTM 1 5 Neutralization Number 0 40 Rust Protection Distilled Water No Rust Sea Water No Rust Hydrolytic Stability Cu Mass Loss mg cm2 0 04 Copper Corrosion Test 1A Filterability Denison Wet amp Dry Pass Afnor Wet amp Dry Pass Cincinatti Milacron Spec Approved P69 Denison HF 0 Approved Denison P 46 Piston Pump Pass Denison T6C Vane Pump Pass Vickers 35VQ25 Vane Pump Test Pass 104 105C Vane Pump Test No Data Available Vane pump test total ring and vane wear mg 10 Oxidation Stability Turbine Oil Stability Test Life hours 2500 Rotary Bomb Oxidation Test minutes 325 FZG Spur Gear Test Failure Load Stage FLS 12 MCCOY 27 14 Sze TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD Setup amp OPERATION KT20000 20 50K Tonc Adequate setup and proper hydraulic connections are essential in ensuring reliable operation of your tong For best results and long term reliability read and obey the start up instructions in this section DO NOT ACCESS ROTATING COMPONENTS UNLESS HYDRAULIC POWER SUPPLY HAS BEEN DEACTIVATED OR ISOLATED A CLEARLY IDENTIFIED REMOTE POWER PACK EMERGENCY STOP MUST BE INSTALLED IN THE IMMEDIATE VICINITY OF THE TONG OPERATOR A SLING LOAD BEARING DEVICE SAFETY THE SUPPLIED LOAD BEARING DEVICE CHAIN SLING RIGID SLING SPREADER BAR ASSEM BLY FRAME OR ANY OTHER DEVICE THAT BEARS THE PARTIAL OR TOTAL
14. SOLUTION Inspect and repair shift mechanism as necessary POSSIBLE PROBLEM Two speed hydraulic motor if equipped is not set to correct speed SOLUTION Check motor and set to the correct speed if required POSSIBLE PROBLEM Safety door system is not properly adjusted hydraulic fluid leak past Deltrol valve SOLUTION Check and adjust safety door system POSSIBLE PROBLEM Hyaraulic fluid viscosity too high SOLUTION Ensure hydraulic fluid meets McCoy Drilling amp Completions specifications SOLUTION Ensure hydraulic fluid is appropriate for climatic conditions especially during cold weather operation POSSIBLE PROBLEM By pass valve not functioning SOLUTION Check and repair 4 4 DRILLING amp SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD TROUBLESHOOTING 20000 20 50K Tonc D FAILURE OR DIFFICULTY OF TONG TO SHIFT 1 POSSIBLE PROBLEM Bent or broken shifter handle SOLUTION Replace shifter handle 2 POSSIBLE PROBLEM Bent or broken shifter yoke SOLUTION Inspect and replace shifter yoke 3 POSSIBLE PROBLEM Frozen or hard to move shifter handle SOLUTION Grease shifter shaft 4 POSSIBLE PROBLEM Bent or broken shifter shaft SOLUTION Replace 5 POSSIBLE PROBLEM Locking nuts on shifting shaft have loosened and position of yoke has changed SOLUTION Reposition yoke and re tighten locking nuts 6 POSSIBLE PROBLEM Shifting yoke has come
15. 22 2 15 ILLUSTRATION 2 6 1 MoroR ConTROL VALVE su 2277 ILLUSTRATION 2 6 2 LIFT CYLINDER CONTROL 2 17 IREUSTRATION 256532 SHIFTING GEARS 2 18 ILLUSTRATION 2 1 MASTER LIFTING LINK 2 19 ILLUSTRATION 2 H 2 SETTING BACKING PIN To MAKE UP 1 00 0 nann 2 20 ILLUSTRATION 2 H 3 LIFT CYLINDER CONTROL 15 2 2 0 11000000000001000000000000000000000 2 2 20 ILLUSTRATION 2 H 4 OPENING Doors 221 IELUSTRATION 2 1 5 MOTOR GONTROL MAKEUP cesar sas ina aie dupl sa Fu beg ga eunt ei aaa be a TURA RR YR edge 2 22 ILLUSTRATION 2 H 6 MOTOR CONTROL RELEASING JAWS een 2 22 ILLUSTRATION 2 H 7 CYLINDER CONTROL LOWER we 2 23 ILLUSTRATION 2 H 8 SETTING BACKING PIN To BREAK OUT 2222 222 2 202000000000000000000000002000000000002000000 22 2 24 ILLUSTRATION 2 H 9 ROTATION CONTROL 0 2 2 12 02 0000000000000600000200000000000020 0000 sisse sara nnn 2 25 ILLUSTRATION 2 H 10 RELEASING Jaws FoLLowinG BREAK OUT amp UN THREADING 2 25 ILLUSTRATION 2 11 LOWERING TONG USING LIFT CYLINDER CONTROL
16. 17 1250320 SPRING OUTER ROTOR 1 8 19 1250322 1250314PC 1250314PL SPRING BUTTON NOT FOR 60 68 VANE ROTOR S VANE ROTOR L 20 1250406 1250401 1250402 STATOR 125 CID STATOR 113 CID STATOR 98 CID 1250403 STATOR 82 CID 1250400 STATOR 60 CID 21 1250404 1250410 STATOR 68 CID STATOR VANE 2 1250420 2 23 1250440 DOWEL 5 8 x 2 24 1250899 SPRING STATOR VANE REAR HOUSING A PC 25 1250817 SEAL PLATE REAR BLIND AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS TECHNICAL MANUAL SECTION CONTENTS 7 21 20000 20 50 Tone WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION Removal of Seal Plate Front and Rear Loosen and remove 6 or 3 8 16 seal plate 1 Lift up on the seal plate Protect the shaft seal from being cut by the keyway keyed shaft by placing a thin strip of metallic tape over the shaft Smooth any burrs that may tear or snag the seal 2 Remove seal plate o ring from groove in seal plate NOTE The shaft seal on a std motor is pressed into the seal plate and can be removed in the reverse manner 1 Loosen and remove 6 or 12 3 8 16 bolts from rear seal plate If motor has double ended shaft remove seal plate following same precaution as stated above for front seal 2
17. ILLUSTRATION 1 2 KT 20000 Power DimENSIONS DRILLING amp 1 2 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SPECIFICATIONS KT20000 20 50K Available Torque Staffa HMB 80 Motor 390 1000 1500 MAXIMUM RATED TORQUE 50000 LBS FT 67790 NM Available Torque Rineer GA125 Motor Available Speed Staffa HMB 80 Motor Flow USGPM LPM 10 21422 37149 High Gear RPM Available Speed Rineer GA125 Motor Hydraulic Requirements Max Length Height Staffa Motor Height Rineer Motor Overall Width Space Required on Pipe Maximum Elevator Diameter Torque Arm Length Weight Approximate Casing Jaws Available inches Recommended Spring Hanger 60 US GPM 227 LPM 3000 PSI 20 684 80 25 inches 203 8 cm doors closed 28 71 1 cm chain sling not included 25 3 8 64 5 cm chain sling not included 50 5 inches 128 3 cm 10 25 4 N A 52 inches 132 1 cm 3400 Ib 1545 kg 7 to 20 See Pg 2 12 85 0106XXH Capacity 3500 Lbs Centre line of pipe to centre line of anchor REPLACEMENT FASTENERS BOLTS NUTS SCREWS MACHINE SCREWS MUST BE GRADE 8 OR EQUIVALENT WHERE REQUIRED AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS TECHNIC
18. Jaw Die Kit 1037 JDK 561 14 3 8 Jaw Die Kit 1037 JDK 564 15 Jaw Die Kit 1037 JDK 562 16 Jaw Die Kit 1037 JDK 565 17 Jaw Die Kit 1037 JDK 568 18 Jaw Die Kit 1037 JDK 569 18 5 8 Jaw Die Kit 1037 JDK 570 19 Jaw Die Kit 1037 JDK 574 20 Jaw Die Kit 1037 JDK 575 10 3 4 Non Marking Jaw Die Kit 1037 NMJDK 550 18 Non Marking Jaw Die Kit 1037 NMJDK 568 Standard 5 Replacement Die 12 1004 2 Jaw Removal amp Die Replacement Support tong jaw assembly Remove the jaw pivot bolt Slide the jaw towards the centre of the rotary assembly to free the jaw from the cage plates Remove the flanged retaining bolts to remove the dies jaw dies may require light tapping with a hammer to free them from their slots Reverse this procedure to install new jaw dies Note that if space allows the entire jaw assembly does not need to be removed to replace the jaw dies see Illustration 2 E 1 2 12 SECTION CONTENTS TEcHNICAL MANUAL AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS SETUP amp OPERATION 20000 20 50K Tonc Jaw Removal amp Die Replacement Continued ILLusrRATION 2 E 1 Jaw REMOVAL Once the jaw has been removed the jaw dies may be replaced by removing the keeper screw above the die and tap the die from jaw using a hammer Replace the die tapping it into place if neces
19. SHAFT TYPE MODEL CODE POSITION 8 j 0 0 25 95 0 3 75 9 02 19 06 pem 7507 11 2 12 UNF 2A thread 0 95 25 Mounting face a 83 5 81 8 8 29 3 22 2 4115 Basic taper on diameter 0 0999 0 1001 per mm 0 0999 0 1001 per in 0 61 252 dia datum 165 0 6 5 min 4 54 3 75 1 Slotted nut 45 2 1 78 thick 57 15 2 25 NF Short taper with key Keyway size 19 02 19 05 0 749 0 750 wide x 10 77 10 92 0 424 0 430 deep SHAFT TYPE X MODEL CODE POSITION Clamp plate and 3 bolts supplied Bolts M12 x P1 75 x 30 0 1 18 long hex 19 0 0 75 3 holes in shaft end equi spaced on 30 0 1 18 pcd tapped to 23 0 0 9 min full thread depth Key size key supplied 19 05 19 10 0 750 0 752 sq sq 249 0 61 252 2 4115 dia datum 14 0 0 55 min l P hy Face A Dimension B Basic taper on see table see table diameter 0 0999 0 1001 rere 0 0999 0 1001 per in For front mount models Face A Front mounting face Dim B 83 31 81 43 3 280 3 206 Dim C 129 4 5 09 For dual mount models Face A Rear mounting face Dim B 250 8 248 92 9 874 9 800 Dim C 297 0 11 69 DRILLING amp COMPLETIONS AACCOY MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL SECTION CON
20. 2 High pressure shaft seals are available to special order for casing pressures of Continuous 10 bar 150 psi Intermittent 15 bar 225 psi 3 Check installation dimensions page 8 for maximum crankcase drain fitting depth 6 HYDRAULIC FLUIDS Dependent on motor see Model Code position suitable fluids include Antiwear hydraulic oils Phosphate esters HFD fluids Water glycols HFC fluids 60 40 water in oil emulsions HFB fluids 5 95 oil in water emulsions fluids a A Reduced pressure and speed limits see page 4 Viscosity limits when using any fluid except oil in water 5 9596 emulsions are 8 FILTRATION Full flow filtration open circuit or full boost flow filtration closed circuit to ensure system cleanliness of ISO 4406 1986 code 18 14 or cleaner 9 NOISE LEVELS The airborne noise level is less than 66 7 dB A DIN 70 dB A NFPA throughout the continuous operating envelope Where noise is a critical factor installation resonances can be reduced by isolating the motor by elastomeric means from the structure and the return line installation Potential return line resonances originating from liquid borne noise can be further attenuated by providing a return line back pressure of 2 to 5 bar 30 to 70 psi 10 POLAR MOMENT OF INERTIA Typical data 0 06 kg m 210 Ib in 11 MASS Approx all models 144 kg 317 Ib 11 INSTALLATION DATA C
21. 3 8 UNC x 3 4 flat head countersunk cap screws v Attach LH safety door latch plate 2 to the LH safety door latch plate using four 5 16 x 3 4 UNC head socket shoulder Screws DRILLING amp AACCODY eT 3 19 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Tonc MAINTENANCE 46 Install the safety door components continued vi Insert load plunger PN AE12 306 into LH safety door latch block ILLUSTRATION 3 H 9 SAFETY _ Loan PLUNGER INSTALLATION Attach three 1 4 NPT JIC elbows to the Deltrol safety door valve PN 08 0337M Position a 15 16 UNC valve lock nut as shown below and secure the safety door valve to the LH safety door latch block using the valve lock nut c h ILLUSTRATION 3 H 10 DELTROL SAFETY Door VALVE INSTALLATION viii Attach the safety door protector weldment PN 101 0450 to the LH safety door latch plate using four 3 8 NC x 1 hex bolts and lock washers Note that the protector has a removable top plate PN 101 1238 that is attached to the protector weldment using four 3 8 NC x 3 4 hex bolts and lock washers 47 Attach the hydraulic supports to the top plate i Attach the hydraulic valve mount weldments PN 101 1442 to the top plate near the LH rotary idler using one 3 8 UNC x 1 hex bolt and 3 8 lock washer per mount ASSEMBLY NOTE The toes on the valve mount weldments face toward the rear of the
22. 5 8 NC x 1 1 2 hex cap screws Note that the flat on the bearing cap faces toward the rear of the tong Install motor mount and motor TONGS EQUIPPED WITH THE RINEER MOTOR OPTION Install the Rineer motor mount PN 1426 7 on to the top plate Correct orientation is such that flat is against the flat on the top pinion bearing cap and the second flat is on left side directly adjacent to the clutch access panel Secure the motor mount with five 3 4 NC x 1 1 4 hex socket head cap screws and 3 4 lock washers ii Install the top clutch shaft bushing PN 1037 42 inside the centre of the motor mount iii Install Rineer hydraulic motor PN 87 0150 on to the motor mount Use caution to make sure the splines on the motor shaft are properly aligned with the grooves in the clutch shaft Secure with five 3 4 NC x 2 1 2 hex bolts and 3 4 lock washers TONGS EQUIPPED WITH THE STAFFA MOTOR OPTION i Place the motor thrust washer PN 101 3289 over the top of the splined clutch shaft followed by the motor spacer PN 1037 D 38S ii Install the motor mount PN 1037 D 7 ensuring that the flat on the motor mount is oriented toward the pinion bearing cap and the notch in the motor mount is oriented to accommodate the top shifter bushing Secure with five 3 4 NC x 1 1 4 hex socket head cap screws and 3 4 lock washers iii Install Staffa hydraulic motor PN 87 0210B on to the motor mount Use caution to make sure the sp
23. COMBINED LOAD AT 3 000 HRS 110 BEARING LIFE Radial load located at center of effective output of the shaft PUSH 16 000 14 000 12 000 10 000 8 000 Thrust Push Ibf 6 000 4 000 2 000 0 000 2 000 3 000 4 000 5 000 6 000 7 000 8 000 9 000 10 000 11 000 12 000 13 000 14 Radial Load Ibf COMBINED LOAD 3 000 HRS 110 BEARING LIFE Radial load located at center of effective output of the shaft PULL Thrust Pull Ibf O 1 000 2 000 3 000 4 000 5 000 6 000 7 000 8 000 9 000 10 000 11 000 12 000 13 000 14 000 Radial Load Ibf DRILLING amp COMPLETIONS AACCOY MOVING GLOBAL ENERGY FORWARD 7 16 Section CONTENTS TECHNICAL MANUAL HvoRaAuLIc Motor INFORMATION RINEER KT20000 20 50K Model Code M125 A2 4 15 M125 Motor Series Port Options A2 Std 2 port w 4 Bolt Flange ports A4 4 Port model w T1 TBB 000 Special Code Designator Seal Package Selection Bearing Package Selection 125 31 4 Bolt Flange ports C2 Std 2 port w O Ring Boss ports DOUBLE STK 4 PORT 30 Keyed Shaft 31 Splined Shaft 34 Double Key C4 4 Port model w Displacement Options O Ring Boss ports 35 Female Key 36 Female Spline 40
24. CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Motor INFORMATION STAFFA KT20000 20 50K DUAL MOUNT MODELS 080 MOTORS WITH TYPE F2 FM2 1 SAE PORT CONNECTION See additional views for shaft types and for types 503 504 port connection See drawing of front mount model for details of types F3 and FM3 port connection 2 rear mount holes 19 0 0 75 dia x 32 0 1 25 deep spaced as shown on 320 0 12 598 Pilot holes for dowels if required e 0 535 0 21 06 dia 26 19 1 031 4 holes see table 3 drain ports 3 4 16 UNF 2B E for bolt tappings 59 0 2 35 two normally plugged 2 2 Pipe fitting must not enter port H 21 0 0 82 more than 12 0 5 52 37 2 062 29 0 1 13 4 2 080 0 3 13 dia x 10 0 0 41 8 rear mount holes 7 8 9 UNC 2B x 32 0 1 25 deep spaced as shown on 320 0 12 598 pcd e Port flange bolt tappings thick end plate and 3 fixing bolts 1 code 61 SAE ports supplied with motor 2 positions Bas 28 5 5 9 940 331 ze 285 29889 alm Seo Eos E 285 84 0 3 31 8 5 E o 30 Flow directions for shaft 3 7 rotation shown 8 Reverse flow directions for 0 63 1 8 is opposite rotation 5 102 0 5 100 0
25. Fitting 2 02 9210 D Part DVA35 SA8 Valve 1 10 9015 MCCOY 2509 5 28 TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD HvbRAULIC ASSEMBLY 20000 20 50K Tonc Item Type Description Qty Part Number E Part Flow Control Valve 1 08 9062 F Part Outlet Valve DVA35 TR99 1 10 0086 G Part 20 Orb Plug With Machined 8 Orb Port Bushing 1 10 9068 H Part M ORB JIC 90 DEG 3 8 Fitting 1 02 9200 J Assembly 1 1 4 Hydraulic Line Return 1 Part 1 1 4 Dust Cup 1 02 9212 Part 1 1 4 Quick Coupler Fitting 1 02 9215 Part 1 1 4 M NPT F NPT 45d Fitting 1 1 1 4 NIPPLE 1 1 1 4 M ORB F NPT 90d Fitting 1 02 9202 K Part 1 2 NC x 6 1 2 Hex Bolt 4 09 1192 L Part 1 Orb Plug Fitting 1 02 9222 M Part Inlet Valve DVA35 A880 1 10 9016 N Part Hydraulic Relief Valve DVA35 MRV 2 1 10 0062 P Assembly Hydraulic Valve Handle Assembly 2 01 0409 Part Hydraulic Valve Handle 1 01 0409 HANDLE Part Hydraulic Valve Handle Links 1 01 0409 LINK Part Hydraulic Valve Pin 1 2 01 0409 PIN1 Part Hydraulic Valve Pin 2 1 01 0409 PIN2 Part C Clip 2 01 0409 CIRCLIP Part Cotter Pin 2 01 0409 COTTER DRILLING amp AACCODY 5 29 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Door ASSEMBLY DRILLING amp 5 30 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLET
26. Hex Bolt 8 09 1044 B Part Safety Door Plate 1 101 1238 C Weldment Safety Door Protector Weldment 1 101 0450 D Part Unbrako 5 16 NC x 3 4 Hex Socket Shoulder Screw 4 09 0227 E Part Load Plunger 1 AE12 306 F Part Detrol Gauge Isolator Valve GI21S 1 08 0337M G Part 15 16 Valve Lock Nut 1 09 0278 H Part LH Safety Door Latch Block 1 13 3015 J Part LH Safety Door Latch Plate 2 1 AE13 311 K Part 3 8 Regular Carbon Steel Lock Washer 6 09 5106 L Part RH Safety Door Latch Block 1 AE 13 302M M Part 3 8 UNC x 1 1 2 Hex FHCS 5 09 4050 N Part 3 8 UNC x 1 1 2 Hex Bolt 2 09 1050 P Part RH Safety Door Latch Plate 1 101 0479 Q Part LH Safety Door Latch Plate 1 101 0915 R Part 3 8 UNC x 1 Hex Bolt 4 09 1170 KT20000 20 50K AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS TEcHNICAL MANUAL SECTION CONTENTS 5 33 CHAIN SLING ASSEMBLY 20000 20 50 Tone 2 1 The 247 1 y A aj y L 4 I i D E e 5 34 Section CONTENTS TECHNICAL MANUAL COY MOVING GLOBAL ENERGY FORWARD CHAIN SLING ASSEMBLY 20000 20 50K Tonc Item Type Description Qty Part Number A Part Master Link 1 02 0517 B Part Hammer Lock Connector 4 per chain 16 02 0607 C Part 25 Link Chain Set Front 2 101 0377 Part 23 Link Chain Set Rear 2 101 0376 D Part Turnbuckle 4 02 6506 E Part 4 Link Chain Set 4 101 0378 F Pa
27. Jaw RoLLER LUBRICATION 9 Door Spring Cylinder Periodically disassemble the door spring cylinders and coat the spring and cylinder with a general purpose lubricating oil ILLUSTRATION 3 0 10 DooR SPRING CYLINDER LUBRICATION McCoy Drilling amp Completions recommends that a coating of grease be applied to the cam surface of the rotary gear prior to jaw installation DRILLING amp 3 6 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 20000 20 50K Tonc E ADJUSTMENTS 1 Brake band Adjustments The brake bands must be periodically adjusted to continue to provide smooth and efficient jaw cam action If the cage plate turns with the rotary gear the jaws will not cam properly and therefore will not bite on the tubing or casing Tightening the brake band against the cage plates will increase frictional resistance allowing jaws to cam properly and grip the casing Adjust the brake band using the adjustment nut and bolt set as shown in the illustration below Do not over tighten as this causes excessive wear to the brake bands Ensure top and bottom brake bands are adjusted at the same time TOP AND BOTTOM BRAKE BANDS MUST BE ADJUSTED SIMULTANEOUSLY Brake band Adjustment Mechanism ILLUSTRATION 3 E 1 BRAKE BAND ADJUSTMENT DRILLING amp NALCO Y ET 37 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K
28. NC x 2 Hex Bolt 16 K Part Hanger Plate 4 101 4006 L Part Hanger Weldment 4 101 3985 DRILLING amp AACCODY eT 5 19 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Options Rineer Hydraulic Motor DRILLING amp 5 20 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Motor Options 20000 20 50K Item Type Description Qty Part Number A Part Upper Motor Spacer 1 1037 D 38S B Part Thrust Washer 1 101 3289 C Part Top Clutch Shaft Spacer 1 1037 42 D Part Motor Mount Rineer 1 1426 7 E Part Staffa Hydraulic Motor 1 87 0210B F Part Staffa Manifold Block 1 87 0209 G Part 3 8 UNC x 1 1 2 Hex Socket Head Cap Screw 6 09 2051 H Part 3 4 UNC x 2 1 2 Hex Bolt 5 09 1296 4 3 4 Helical Spring Lock Washer 15 09 5118 K Part 3 4 UNC x 1 1 4 Hex Socket Head Cap Screw 10 09 2288 L Part Motor Mount Staffa 1 1037 D 7 M Part Rineer Hydraulic Motor 1 87 0150 N Part 5 8 UNC x 2 1 4 Hex Bolt 6 09 1235 P Part 5 8 Helical Spring Lock Washer 6 09 5114 DRILLING amp AACCCOY MANUAL 5 21 MOVING GLOBAL ENERGY FORWARD 20000 20 50K Tong 20 50K 2 Torque Gauce Mounts Rineer Hydraulic Motor Staffa Hydraulic Motor DRILLING amp 5 22 SEC
29. Remove seal plate o ring from groove in seal plate Press shaft and front bearing out of motor through front housing leaving rear bearing in Hyprautic Motor Repair RINEER Front bearing can be inspected in place on the shaft or pressed off to be inspected or replaced The 125 motors should be positioned as shown Suitable mount to hold the unit during main bolt removal To ensure proper orientation during reassembly use a laquer paint pen or some type of oil solvent proof marker to mark a line down the side of the motor Loosen and remove the six 5 8 11 main bolts Any bolt heads showing heavy corrosion or signs of rounding of the hex form should be replaced Turn the motor over Attach some type of plate or bar to the rear housing port pad to secure the motor for removal of remaining 5 8 11 main bolts Take precautions to ensure that no damage is done to the port face in the area where the o ring seals 7 22 CONTENTS TECHNICAL MANUAL AACCCOY MOVING GLOBAL ENERGY FORWARD Hyprautic Motor Repair RINEER 20000 20 50 WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION Remove front housing as Shown Remove o rings from housing and dowel pins from the rotating group 1 Remove rotating group from rear housing as shown Place the rotating
30. TECHNICAL MANUAL 5 25 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K CAGE PLATE ASSEMBLY DRILLING amp 5 26 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Cace PLATE ASSEMBLY KT20000 20 50K Item Type Description Qty Part Number A Part 1 2 NC x 8 Hex Bolt 2 09 1198 B Part Jaw Pivot Bolt 2 1050 C5 28 3 8 NC x 3 4 Hex Bolt 1 09 1044 D Part 3 8 Plain Washer 1 09 5006 E Part Rear Cage plate Bolt 1 1037 36 F Part Top Cage plate 1 101 1580 G Part Cage plate Spacer 3 1037 C 38 H Assembly Jaw Die Kit 20 shown See Pg 3 6 2 J Part Rotary Gear 1 1037 D 46 K Part Bottom Cage plate 1 1037 D 51 L Part Backing Pin Knob 1 02 0017 M Part Backing Pin Retainer 1 1037 B 54 1 N Part Backing Pin 1 1037 C 39A MCCOY 255 COMPLETIONS 5 27 MOVING GLOBAL ENERGY FORWARD TEcHNICAL MANUAL SECTION CONTENTS KT20000 20 50 Tone ASSEMBLY Item Type Description Qty Part Number A Assembly 1 Hydraulic Line Supply 1 Part 1 Dust Cup 1 02 9213 Part 1 Quick Coupler Fitting 1 02 9214 Part 1 M NPT F NPT 90d Fitting 1 02 9221 1 NPT PIPE NIPPLE 1 Part 1 M ORB F NPT 90d Fitting 1 02 9210 B Part DVA35 MA8 4 Way Directional Valve SAE Port 1 10 9014 C Part M ORB JIC Long 90d 1
31. WEIGHT OF THE EQUIPMENT DESCRIBED IN THIS MANUAL HAS BEEN SPECIFIED OR DESIGNED TO SUPPORT THE EQUIPMENT DESCRIBED IN THIS DOCUMENT FARR WILL NOT GUARANTEE THE ABILITY OF THE LOAD BEARING DEVICE TO SUPPORT ANY OTHER PART ASSEMBLY OR COMBINA TION OF PARTS AND ASSEMBLIES OR ANY ADDITIONS TO THE EQUIPMENT DESCRIBED IN THIS MANUAL THAT ADD WEIGHT TO THE EQUIPMENT UNLESS SUPPLIED BY MCCOY DRILLING amp COMPLETIONS MCCOY DRILLING amp COMPLETIONS DOES NOT GUARANTEE THE INTEGRITY OF MODIFIED OR DAMAGED LOAD BEARING DEVICES UNLESS THOSE MODIFICATIONS ARE PERFORMED BY MCCOY DRILLING amp COMPLETIONS McCoy Drilling amp Completions recommends following an industry accepted standard such as OSHA ASME B30 9 2006 or manu facturer s guidelines when performing any rigging and overhead lifting Use by untrained persons is hazardous Improper use will result in serious injury or death Do not exceed rated capacity Slings will fail if damaged abused misused overused or improperly maintained Only grade 80 or grade 100 alloy chain should be used for overhead lifting applications Working Load Limit WLL is the maximum allowable load in pounds which may be applied to the load bearing device when the device is new or in new condition and when the load is uniformly and directly applied The WLL must never be exceeded Working Load Limit WLL is the maximum working load for a specific minimum sling angle measured from the horiz
32. by the beam Test safety door feature if equipped Open the tong door s and attempt to rotate the cage plate at low speed low gear 2 2 in both directions makeup and breakout If cage plate begins rotating the safety door mechanism is not functional and 7 the tong must be removed from service until the safety door mechanism can be repaired If the safety door is operating correctly cage plate rotation will not be inhibited once the door is closed and latched NEVER OPERATE YOUR EQUIPMENT WITH A BYPASSED OR MALFUNCTIONING SAFETY DOOR 2 3 C While rotating the cage plate ensure that the jaws properly cam If the jaws do not cam properly the brake bands need 5 to be tightened Incrementally adjust both the top and bottom brake bands EQUALLY until proper cam action is achieved 24 When all of the previous steps completed may return your re commissioned equipment to service DRILLING amp 3 32 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD TROUBLESHOOTING 20000 20 50K Tonc 1 Adequate maintenance and proper fluid selection is essential for minimizing hydraulic related failures All troubleshooting must be per formed by a technician trained in hydraulic systems and familiar with the equipment design assembly and operation The following troubleshooting instructions are intended to be guidelines only Any faults not solved through the use of th
33. cortosim or normal wear If needed repairs should be made immediately Always refer the machine manual for the proper procedure to remove the valve from the machine Remove the valve bank from the equipment disconnecting all hoses contri handles and linkage connectors thal might be attached to the valve Plug all ports and thoroughly clean ihe exterior of the valve bank ren die peut plugs cun be remwved 7 30 Section 5 TECHNICAL MANUAL AACCCOY MOVING GLOBAL ENERGY FORWARD KT20000 20 50K HypRAULIC VALVE INFORMATION Exploded View of Work Section a Figure 1 3 net shown Parts List For Work Section em Description Oy V VGZD WAVES Part Parallel Section Smals See Figure 1 1 Square 3 381 2881 206 391 2881 200 d31 2881 4133 2 Souler Saal 1 3895 27881 200 391 2684 Ot 221 781 870 Seres Section Seals 4 Square Deals 2 34 284 206 3631 2RR1 200 3 Square Saal 1 381 2854 827 381 2881 528 Parallel and Series Section Component Parts See Figure 1 4 Back Cp Song z 441 14 a eiai d Lock wiash ars 381 3 83 028 a Back 1 347 600 70 34 10585058 Rolamar Pilotes 3 391 2183 0011 oo 2183 005 du1 2183 157 7 Back up irg 391 2881 278 32594 28814 28 351 2681 2H5 5 menda 2 91 19 1114 491 2887 217 29 1 258 1096 LI Retin
34. extremely high stress placed on the gear train frequently causes gear breakage THE SNAP BREAK METHOD IS HAZARDOUS RIG PERSONNEL AND EQUIPMENT 2 18 COY MOVING GLOBAL ENERGY FORWARD CONTENTS TEcHNICAL MANUAL SETUP amp OPERATION KT20000 20 50K H MAKING AND BREAKING CONNECTIONS THESE OPERATING PROCEDURES ASSUME THE USER HAS PROPERLY SET UP AND PREPARED THE EQUIPMENT FOR OPERATION AS PER SECTIONS 2D 2E AND 2F OF THIS MANUAL Set up and prepare your equipment for operation as per Section 2 of this manual Refer to the following sections 2 0 Hydraulic Connections 2 Tong Jaw Installation 2 1 Tong Rig up and Leveling Suspension 2 F 2 Tong Rig up and Leveling Leveling Your tong and backup assembly should be properly suspended connected to a hydraulic power source and ready to make or break connections at this point 1 Making A Connection a Ensure hydraulic power supply to the tong is energized The master link on the rigid sling must be used to suspend the tong Do not suspend the tong from any other point ILLUSTRATION 2 H 1 LiFtinG LINK THE MASTER LINK MUST BE USED TO SUSPEND THE TONG ASSEMBLY b Ensure the backing pin is in the makeup position From the front of the tong the backing pin correctly configured for makeup will be in the 10 o clock position see Illustration 2 H 2 next page If it is not simply lift up and pl
35. i Thru Key Spline Drill Motor API Thread Made in USA Data Sheet RM1255030 8 01 02 DRILLING amp AACCODY 5 TECHNICAL MANUAL 7 19 MOVING GLOBAL ENERGY FORWARD Hyprautic Motor Repair RINEER KT20000 20 50K NALCO Y MOVING GLOBAL ENERGY FORWARD SECTION CONTENTS TECHNICAL MANUAL 7 20 Hyprautic Motor Repair RINEER PART TS SUBSTITUTED IN 60 amp 68 C I D ROTATING GROUPS SERIES 125 PC EXPLODED VIEW KT20000 20 50K 19 1250317 1250323 SPRING OUTER ROTOR HD PART NO 1250117 DESCRIPTION BOLT SEAL PLATE 1250324 SPRING INNER ROTOR HD 0370410 STATOR VANE 1250442 WAVE SPRING 1250619 TIMING PLATE PC EXT SLOT 1250162 1250114 1250187 1250711 SEAL PLATE TON 3 1 2 O RING SEAL PLATE SEAL 3 1 2 BALL BEARING 60 68 CID ONLY 1250702 1250701 0370902 SHAFT SPLINED SHAFT KEYED BOLT 5 8 11 x 8 MAIN 1251158 FRONT HOUSING A PC 9 1250610 10 1250877 O RING THERMAL INNER 11 1250878 O RING MAIN O RING THERMAL MIDDLE 12 3 13 1250620 PLATE SCREW 14 1250618 PLATE TIMING PC 1250879 1250619 O RING THERMAL OUTER PLATE TIMING PC HI SPD 15 16 1250315PC 1250315PL 1250321 ROTOR S ROTOR L SPRING INNER ROTOR
36. illustration below Secure with 7 8 UNF jam nuts and 7 8 lock washers ILLUSTRATION 3 H 3 PLATE CAM FoLLOWER INSTALLATION 23 Carefully remove all the support roller shafts ensuring the support roller assemblies do not shift position as you are doing so 24 Insert three 3 8 x 1 1 2 hardened ground production dowel pins into the side body one at exact rear centre and one on either side of the front opening Position the top plate in its proper location use caution not to damage threads when aligning the top plate with the idler and support roller shafts Ensure the plate is aligned exactly horizontal to prevent binding on the dowel pins Use caution when aligning the previously installed cam followers with the rotary gear Tap plate securely into place with a rubber mallet 25 Secure the top plate with twenty seven 3 8 NC x 1 1 2 hex bolts two 3 8 NC x 1 1 4 hex bolts install these two above the removable access panel and eight 3 8 NC x 1 hex socket cap screws Note that fasteners are NOT to be installed at the chain sling hanger locations circled in red in illustration 3 H 4 on the next page DRILLING amp AACCODY TEcHNICAL MANUAL 3 15 MOVING GLOBAL ENERGY FORWARD 20000 20 50K MAINTENANCE Assembly Procedures ILLUSTRATION 3 H 4 PLATE FASTENER EXCLUSIONS 26 Install ten horizontal cam follower guides PN 1037 A 49 to the t
37. is represented by an exclamation point within a red triangle identifies items of the highest importance Failure to heed information identified by a HAZARD symbol may result in bodily injury death catastrophic equipment damage or any combination of these A HAZARD may also indicate the potential for danger ous environmental contamination This identifies a HAZARD to operators or equipment A WARNING is represented by an exclamation point within an orange triangle and contains information that will alert personnel to a potential safety hazard that is not life threatening A WARNING may also serve to alert the user to infor mation critical to the correct assembly or operation of the equipment in use This identifies a WARNING to users A CAUTION is represented by an exclamation point within a yellow triangle and highlights information that may aid the user during assembly or operation of your equipment CAUTIONS are also used to ensure common errors are not made during assembly or operation of your equipment This identifies a CAUTION to users Observance of the following is the full responsibility of the user all descriptions information and instructions set out in this manual any regulation or requirement issued by an authority or agency which may influence opera tion safety or integrity of the equipment that overrules the content of this document any legal or other mandatory regulation in force governing accident pr
38. is suspended if equipped 2 Securely support tong from the bottom Ensure the supports are capable of supporting the entire weight of the tong 3 Use crane to remove the chain sling assembly Store the chain sling in a location in which it will not be subjected to mechanical damage or corrosion 4 Remove jaw assemblies if not already done 5 Disconnect the hydraulic connections to the motor Disconnect the hydraulic connections from the safety door switch Contain hydraulic fluid spilled from disconnected lines and dispose in accordance with your company s environmental policies 6 Undo the restraints securing the inlet and outlet lines connections to their supports and use a crane to lift the hydraulic valve section away from the tong Remove the mounting posts for the valve bank Remove the inlet and outlet support brackets Remove the torque gauge mount assembly from the rear top plate of the tong Remove the four tong hangers 10 Remove the top and bottom brake band assemblies 11 Remove the tong doors i Remove the door cylinders ii Remove the thin nylock nuts and flat washers from the bottom of the two door pivot roller shafts Ensure the door assemblies are well supported when performing this next step One door at a time use a soft alloy mate rial e g brass rod etc to lightly tap the shafts up through the support roller assembly until the shafts and large washers come free at the top Use caution that the th
39. links and chains If using a compression load cell replace any component that has been crushed or otherwise distorted through compression 3 2 If applicable inspect the load cell anchor pins tension load cell only Replace the anchor pins if cracking or metal g distortion is seen If applicable the weld securing the single load cell anchor to the bridge bar main plate must be inspected compression 3 3 C load cell only If the integrity of the weld has been compromised the tong must be removed from service until the weld is repaired The load cell beam will need to be disconnected and removed so the weld is visible Before re installing the beam liberally grease the anchor pin before reinserting into the load cell beam 3 4 C Inspect load cell for damage or signs of stress Check oil level in load cell and fill if necessary refer to technical manual Section 7 or Section 8 While rotating the cage plate ensure that the jaws properly cam If the jaws do not cam properly the brake bands 3 5 need to be tightened Incrementally adjust both the top and bottom brake bands EQUALLY until proper cam action is achieved Refer to the maintenance section of the manual for instructions on properly adjusting brake bands Perform a full functional test of the tong including if applicable backup components lift cylinder and float frame com 3 6 ponents Report and correct hydraulic leaks from the hydraulic valve bank or fr
40. loose from shifting shaft SOLUTION Inspect yoke and inspect for damage If free of damage replace on shaft and tighten locking nuts 7 POSSIBLE PROBLEM Tong pops out of gear SOLUTION Ensure that detent ball amp spring assembly has been correctly set DRILLING amp AACCCOY MANUAL 4 5 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K TROUBLESHOOTING H GENERAL COMMENTS The following factors generally contribute to poor hydraulic operation and premature wear of equipment 1 Contaminated hydraulic fluid due to overuse overheating or inadequate fluid filtration 2 Unsuitable hydraulic fluid especially in extreme climatic conditions 3 Defective packing or seals in components of the hydraulic system 4 Poor or incomplete hydraulic system training Users must be fully qualified to operate the equipment and have complete under standing of the hydraulic system If your hydraulic troubleshooting procedures involve flow and pressure tests at the power unit McCoy Completions amp Drilling recom mends construction of a test rig that can easily be connected to the main suction and discharge ports of the power unit DRILLING amp 4 6 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Assemblies and Parts AACCCOY MOVING GLOBAL ENERGY FORWARD TECHNICAL ManuaL 5 1 KT20000 20 50K GEAR TRAIN LayouT
41. of the tong directly adjacent to the shifter mechanism Use a flashlight to perform a visual inspection of the gear train through the access panel and the opening of the rotary 5 gear If gear damage or chips of metal seen the tong should be removed from service and overhauled to avoid further damage Replace access panel when inspection is complete Perform a visual inspection of all fasteners and protruding body pieces example hydraulic valve mounts inlet amp outlet 6 line supports tong legs shifter handle pivot lugs Tighten or replace loose or missing fasteners Farr recommends that damaged or missing body parts be repaired or replaced as soon as possible Inspect the jaws and dies Inspect the jaw roller pins for signs of damage replace pins if necessary If the pins are welded 7 in place replace the entire jaw assembly Ensure dies are secure in the jaw replace worn dies if necessary Ensure that the jaw rollers rotate freely Check to ensure the size of the loaded jaws match the size of casing or pipe you are running Perform a visual inspection of all lifting points if visible damage is seen including cracks broken lugs distorted metal 8 etc replace damaged part s before placing tong in service Also inspect all chains master links and turnbuckles again if any damage is noted replace the damaged part s before placing the tong in service 9 Inspect tong for signs of premature wear or moving part
42. oot lewel Loosen mounting bolts shin as required Contamination burs on seal Clean seal proove replace setioan seal Oil leeks at ether end Correct high back pressure of spol L condition Replace seals seal retamers spee Wephercensompspone Spring centered spools Misalignment of operating Cheek linkage for di mat retin neutral linkage mechanecal binding Foreign particles in system Clean valve and system Cylinder leaking or wom Check eylinder repair i a Loud will nor held Port relief valve nor holding Remove and elean or replace Sponl pr housing scored ar Heplaee section wom excessively Lond drops when spool Dirt or foreign particles Disassemble clean moved frum nemiral lodged hetwecn chesk wilve amp resemble poppet ind sem er sticking check Replace poppet valve poppet Wom pump Check flow amp pressure Defective cylinder ur motor Repar or repluce niti Slow or Clogged suction strainer Clean or replace eric system Ine Check lines operation Relief valve nat properiy set heck presare setting Reliel valve poppel or Replace relief lt seul stored amp sucking open valve Valve nor shifted Check spool linee to full siroke travel AACCCOY MOVING GLOBAL ENERGY FORWARD 7 40 Section CONTENTS TECHNICAL MANUAL
43. pins 71 593 71 544 2 8186 2 8167 For shaft types Z and HZ DIN 5480 W70 x 3x 22x 7h AACCOY Base 7 12 Section CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD Motor INFORMATION STAFFA KT20000 20 50K Tone in their application 70 89 69 52 i 2 791 2 737 65 6 2 58 19 0 0 75 gt Motor mounting face SHAFT TYPES Q AND MODEL CODE POSITION Female shaft with 24 splines to BS 3550 Note The 0 and shafts will transmit the maximum torque given on page 4 However customers should ensure that their own mating shaft will transmit the torque required Major diameter Minor diameter Pin diameter 3 658 0 1440 Pin flatted to 3 560 0 1400 Diameter between pins 45 626 45 550 1 7963 1 7933 53 246 52 916 2 0963 2 0833 48 811 48 684 1 9217 1 9167 Shaft type 0 26 2 1 03 dia hole through motor 79 5 77 98 3 13 3 07 2032 8 0 dia 22222222 222224 nominal A 21 68 0 74 7 20 75 0542 2 94 dia Spigot MEE 34 dia 0 301 57 301 50 7222 11 873 11 870 dia 9 8 0 39 Y Spline data To BS 3550 Flat root side fit modified Pressure angle 30 Number of teeth 24 Pitch 12 24 A Use mounting face spigot for motor location Long taper with key Key size 19 05 19 10 0 750 0 752 sq 10 77 10 92 0 424 0 430
44. plumbing to the support assemblies installed in Step 47 51 Install tong hangers i Attach four tong hanger bracket weldments PN 101 3985 to the bottom plate using 3 8 NC x 2 1 2 hex bolts and 3 8 lock washers 2 each per weldment ii Attach four tong hanger bracket bases 101 4006 to the top plate using 3 8 NC x 2 1 2 hex bolts and 3 8 lock wash ers 2 each per base 52 Attach the chain sling to the four chain sling hangers using one shackle and bolt set PN 02 9063 per hanger DO NOT EXCEED THE SPECIFIED LENGTH OF FASTENER BOLTS NUTS CAP SCREWS MACHINE SCREWS ETC REPLACEMENT FASTENER BOLTS NUTS CAP 5 5 MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHERWISE SPECIFIED DRILLING amp AACCCOY MANUAL 3 21 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K MAINTENANCE I DAILY INSPECTION 8 MAINTENANCE CHECKLIST POWER TONG Farr recommends that the following inspection and maintenance procedures be performed before each use and at least once per day when the tong is in steady use in the order in which they are listed 1 Rotate cage plate rotary gear until the opening in the rotary gear faces towards the rear of the tong DO NOT PERFORM ANY FURTHER ACTIONS OR MAINTENANCE WHILE THE TONG IS CON NECTED TO ANY HYDRAULIC POWER SUPPLY FARR RECOMMENDS THAT ALL HYDRAULIC LINES ARE FULLY DIS
45. shifter detent tension 35 Position the top cage plate PN 101 1580 on the top plate of the tong over the previously installed cam followers 36 Position the bottom cage plate PN 1037 D 51 against the bottom plate of the tong over the previously installed cam followers and support until it is attached to the top cage plate Secure the bottom cage plate to the top cage plate using two 1 NC x 8 hex bolts and the rear cage plate bolt PN 1037 36 Do not neglect to install the three cage plate spacers PN 1037 C 38 between the top and bottom cage plates ILLusrRATION 3 H 7 amp Bottom CAGE PLATE INSTALLATION 37 Press the four door pivot shoulder bushings PN 101 0110 into the RH door weldment PN 101 1703 and the LH door weldment PN 101 1697 The bushings are installed so that the shoulders are towards the inside of the weldments 38 Install latch weldment PN 101 1570 onto RH door assembly see 5 28 5 29 Install two latch springs between the latch weldment and the door weldment and secure latch to RH door using the door latch shaft PN 1037 C 200 and two latch cam plates PN 1037 C 151 Secure each latch cam plate to the top and bottom door plates with one 3 8 UNC x 1 1 4 hex bolt and 3 8 lock washer 39 If not already done install the door pivot roller components that fit between the two body plates i e everything except the roller shafts nuts washers and door stop spacers 40 Install the threa
46. term storage These procedures are essential for ensuring proper protection of the equipment from environmental attack and to aid in the quick turnaround when returning the equipment to service Store all o rings seals packings gaskets etc in strong moisture proof airtight containers Ensure that these items are not crushed nicked or otherwise damaged Do not perform any further actions or maintenance while the tong is connected to any hydraulic power supply Farr recommends that all hydraulic lines are fully disconnected and residual hydraulic pressure is bled off Ensure adequate containment is in place to prevent environmental contamination from residual hydraulic fluid DEPRESSURIZATION PROCEDURE IN PREPARATION FoR STORAGE 1 Rotate the tong so that the opening in the rotary gear faces the gear train towards the rear of the tong Ensure tong and backup doors if equipped are closed Fully extend the lift cylinder if equipped If mounted in a frame retract the float cylinders if equipped 2 De energize the power unit 3 Repeatedly actuate the tong motor control valve lever IN BOTH DIRECTIONS to dissipate any residual pressure in the valve and motor 4 Remove the hydraulic SUPPLY line from the equipment 5 Repeatedly actuate the remaining control valve levers INBOTH DIRECTIONS to dissipate any residual pressure in the remain der of the hydraulic control system 7 Disconnect the hydraulic RETURN line from the equi
47. that are damaged or defective shall not be used Slings shall not be shortened with knots or bolts or other makeshift devices Sling legs shall not be kinked Load bearing devices shall not be loaded in excess of their rated capacities Slings shall be securely attached to their load Load bearing devices shall be protected from snagging and shall not be further obstructed by any object Suspended loads shall be kept clear of all obstruction All employees shall be kept clear of loads about to be lifted and of suspended loads Hands or fingers shall not be placed between the sling and its load while the sling is being tightened around the load Shock loading is prohibited Do not stand directly under a load during lifting 3 Storage Of Load Bearing Devices Proper storage of out of service load bearing devices is important to ensure full integrity of the device once it is returned to service Farr recommends observing the following practices Wipe off all excess grease Use a solvent based cleaner on rags to wipe all external surfaces to remove residual grease or hydraulic fluid Once the outside surfaces have been de greased wipe all external surfaces with clean water to remove re sidual solvent Farr amp recommends that an anti corrosive agent such as 9 506 be applied to all external surfaces Refer to manufacturer data sheets for proper application and safety information Allow the anti corrosive coating ample
48. the tong door against the latch post h Ensure tubing is roughly centered within the tong jaws rig personnel are required to stabilize the tong above the connec tion until the jaws have been cammed on to the pipe or casing i Breakout torque is only available when tong is in low gear See Section 2 G 3 for instructions on shifting your tong to low gear Do not shift gears while the tong is rotating SHIFTING TONG WHILE ROTATING THE MOTOR AND CAGE PLATE MAY RESULT IN CATASTROPHIC GEAR TRAIN FAILURE DRILLING amp SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 2 24 SETUP amp OPERATION 20000 20 50K Breaking A Connection Continued j Pull the motor control valve toward the operator to rotate the cage plate in the break out direction TA ILLUSTRATION 2 H 9 ConTROL BREAK OuT 1 When the tong jaws on to the tubing pull the rotation control handle all the way out to break the connection When the connection breaks stop rotation and shift to high gear see Section 2 G 3 to shift to high gear This will enable the tong to completely un thread the connection at high speed n Pull the rotation control handle all the way out to completely un thread the connection Reverse the rotation control handle push toward tong to release the tong jaws from the tubing see Illustration 2 H 10 n m 1
49. time to dry refer to manufac turer data sheets for drying times at room temperature Store in a clean dry location When returning to service note that a full inspection of the device must be performed ENSURE CHAINS DO NOT BECOME ENTANGLED IN ANY EQUIPMENT SUPERSTRUCTURE WHEN USING CHAIN SLINGS TO HOIST EQUIPMENT DRILLING amp AACCCOY TECHNICAL MANUAL 2 3 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K SETUP amp OPERATION B MAJOR COMPONENT IDENTIFICATION ILLUSTRATION 2 1 IDENTIFICATION 01 DRILLING amp 2 4 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION KT20000 20 50K Tonc ILLUSTRATION 2 3 Major IDENTIFICATION 03 DRILLING amp MANUAL 2 5 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K SETUP amp OPERATION E 4 12 13 14 15 16 17 ILLUSTRATION 2 4 Major IDENTIFICATION 04 DRILLING amp 2 6 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION 20000 20 50K Tonc 18 ILLUSTRATION 2 B 5 COMPONENT IDENTIFICATION 05 Item Description Page 1 Chain Sling Hanger 3 1 Control Valve Bank 3 1 3 2 3 M
50. tong motor to rotate in a clockwise direction as seen from the top of the tong This is the desired direction of rotation for making up a joint Pulling the valve handle in the opposite direction results in counter clockwise rotation which is the desired direction of rotation for breaking out a joint E uw E ILLUSTRATION 2 6 1 VALVE LIFT CYLINDER This is a proportional valve Pushing the valve handle forward will cause the lift cylinder to lift the tong vertically Pulling the valve handle in the opposite direction will cause the lift cylinder to lower the tong ILLUSTRATION 2 6 2 CYLINDER CONTROL VALVE DRILLING amp AACCODY TECHNICAL MANUAL 2 17 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Setup amp OPERATION 3 SHIFTING GEARS The shifting shaft has three detent positions identifying the low speed high torque position the neutral or free spinning posi tion and the high speed low torque position The detent strength may be adjusted by releasing the locknut on the detent tube and increasing or relaxing pressure on the detent spring Ensure the locknut is tightened once the desired detent pressure has been set To shift to the high speed gear move the shifting handle downward from neutral position To shift to the low speed gear move the shifting handle up through the neutral detent to its highest position Note that the hig
51. tubular connection equipment for example motors valves etc may specify maintenance tasks and intervals over and above what McCoy Drilling amp Completions recommends as part of their recommended procedures Users of this equipment may choose to perform or ignore these additional tasks at their discretion Premature fouling of particulate filters within your prime mover or ancillary hydraulic power unit requires immediate hydraulic fluid laboratory analysis to prevent premature wear of hydraulic system due to high levels of wear metals in the fluid McCoy Drilling amp Completions recommends tracking all maintenance activity including the lubrication schedule This may be a simple as keeping a paper log or using a software based maintenance tracking utility A maintenance log is a valuable tool that can be used for easily retrieving maintenance history or identifying trends that require correction DRILLING amp AACCCOY TECHNICAL MANUAL 31 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K MAINTENANCE D LUBRICATION Use a quality multipurpose bearing lubricant that will remain within its viscosity range at expected operating temperatures In addi tion Farr recommends the following lubrication procedure at the completion of each job prior to storage 1 Plate Cam Followers The cage plate cam followers are sealed units and do not require lubrication However the cage plate and rotary gear gr
52. with key H S Cylindrical 14 splines to BS 3550 H Z Cylindrical shaft to DIN 5480 W70 x 3 x 22 x 7h H Q Female 24 splines to BS 3550 T Long tapered keyed shaft X Short tapered keyed shaft For installations where shaft is vertically upwards specify V after shaft type letter to ensure that additional high level drain port is provided Features shown in brackets may be left blank according to requirements F HM BO80 H V 3 PL 3 n MAIN PORT CONNECTIONS Models with 21 4 distributor valvea F2e SAE 1 4 bolt UNC flanges FM2e SAE 1 4 bolt metric flanges Models with 3 distributor valve 503 6 bolt UNF flange Staffa original valve housing SAE 11 4 4 bolt UNC flanges FM3 SAE 17 4 4 bolt metric flanges Models with 4 distributor valve m Must be specified when requiring hollow shafts type HP HS HZ or HQ 504 6 bolt UNF flange Staffa original valve housing Gives minimum overall length of 080 motor Max inlet flow 200 l min 53 USgpm reduced max continuous speed and output power see Performance Data page 4 W Obligatory for hollow shafts See increased installation dimensions with 4 valve El rAcHO ENCODER DRIVE T Staffa original tacho drive Suitable for Hohner 3000 series encoders Encoder to be ordered separately Omit if not required and when specifying shaft t
53. 0 5 44 20 0 0 78 __ 6 holes 3 8 24 UNF 2B 16 0 0 625 44 0 1 75 81 0 3 12 2 ports 32 0 1 25 dia L r 22 0 0 875 51 0 2 0 SHAFT TYPES AND HP MODEL CODE POSITION Cylindrical shaft with key SHAFT TYPES S AND HS MODEL CODE POSITION Cylindrical shaft with 14 splines to BS 3550 1963 SHAFT TYPES Z AND HZ MODEL CODE POSITION Ej Cylindrical shaft with splines to DIN 5480 Shaft types HS and HZ Key supplied 18 037 18 019 0 7101 0 7094 77 0 3 03 2 m Ms wide x 11 99 11 94 0 472 0 470 thick ug 18 044 18 001 0 7104 0 7087 a e E Shaft types S and Z 5 1 2 20 UNF 2B 32 0 5 1 25 full thread depth 0 60 013 59 992 2 125 3 2 3627 2 3619 dia 54 00 53 95 131 9 133 1 2 126 2 124 5 19 5 24 5 z Spline data Shaft type 1 2 20 UNF 2B x 32 0 171 2 169 9 ayo 6 74 6 69 1 25 full thread depth For shaft types S and HS to BS 3550 SAE J498c ANSI B92 1 1970 class 5 Shaft type HP 0 26 2 1 03 dia Flat root side fit class 1 hole through motor Pressure angle 30 Number of teeth 14 Pitch 6 12 Major diameter 62 553 62 425 2 4627 2 4577 Form diameter 55 052 2 1674 Minor diameter 54 084 53 525 2 1293 2 1073 Pin diameter 8 128 0 3200 Diameter over
54. 000 4500 500 1000 1500 2000 2500 3000 3500 4000 4500 PRESSURE psid PRESSURE psid Performance of the Rineer 125 Series Motor has been greatly enhanced by internal design changes resulting in a pressure balanced rotating group Benefits of this new design include reduced cross port leakage and increased efficiency as well as greater reliability at higher pressures This patented design has been in effect for over 5 years B1 218 218 BEARING LIFE FOR RADIAL LOAD AT 2 8 FROM MOUNTING FACE TO CENTER OF OUTPUT SHAFT Bearing Data Standard Motor 16000 14000 3000 irs 1500 hrs 12000 4 1000 hrs 10000 8000 Radial Load Ibf 6000 4000 2000 0 150 250 200 Speed rpm B1 218 218 BEARING LIFE 3 000 HRS 110 AT DISTANCE FROM MOUNTING PLATE 14000 BEARING LOADING bearings the 125 Series can accept radial load per the radial capacity charts to the right Thrust loading is not recommended for the standard motor For thrust type applications see the thrust capable motor bearing chart on the opposite page HORSEPOWER LIMITATION Maximum horsepower limitation may vary with differen
55. 0000000 9 90099 09099 09899998099 65616656 3 10 Recommended Periodic Checks 3 10 RR 3 11 Proceduro idiot ierit ist I AM LEER AMI LI LINE LUI ML AAA E 3 12 Daily Tong Inspection amp Maintenance Checklist 3 22 Monthly Tong Inspection amp Maintenance Checklist a 12 24 Daily Power Unit Inspection amp Maintenance Checklist esses ener nnne 3 27 De commissioning amp Storage 3 28 Re commissioning ProGeUr s 1 eu HABE RA e pa ET ehe ua pU LAUR o Rand qp Ye eM Ma ue dap d 3 31 LIGHCnemm Section 4 Tong Will Not Develop Sufficient Torque 4 1 Failure Of Jaws To Grip Pipe 43 Tong Running Too eb E e tb Edere as 4 4 Failure Or Difficulty Of Tong TO Shift cie 4 7 General Comments 1 4 8 Assemblies And Parts Section 5 Gear Train Layout m2 Support Roller Assembly x ui a a A deae ida o re c E DEM 5 4 Door Pivot Roller Assembly e omiies pred HE Rain aa EE OF ERAT 5 6 Rotary lei
56. 04 over the bottom end of the splined clutch shaft PN 1037 D 38 Install two upper clutch bearings PN 02 0103 over the top side of the clutch shaft Press bearings tight to the center gear on the splined clutch shaft 16 Slide the low clutch gear PN 1037 D 40 over the lower bearing so that the larger diameter gear on the low clutch gear is tight to the center gear on the clutch shaft and place end of clutch shaft into bottom clutch bearing installed in Step 7 Mesh the low clutch gear with the low pinion gear as it is installed DRILLING amp 3 14 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 20000 20 50K Assembly Procedures Cont d 17 Place the shifting collar PN 1037 D 34 over the middle section of the clutch shaft 18 Slide the high clutch gear PN 1037 D 41 over the two top clutch bearings 19 If not already done insert the two remaining gear keys in the pinion gear shaft Install the high pinion gear PN 1037 D 12 over the top of the pinion gear shaft meshing with the high clutch gear as it is installed 20 Fasten the lower shifter bushing PN 1037 C 21B to the bottom plate with four 3 8 NC x 1 1 4 hex bolts and 3 8 lock washers 21 Place the shifting fork weldment PN 1037 D 27 up against the shifting collar roughly in its final position 22 Install 25 cam followers PN 1037 0 58 in the top plate 1037 7 02 as shown in the
57. 10 E Part Pinion Bearing 2 02 0106 F Part High Pinion Gear 1 1037 D 12 G Part Gear Key 4 1037 D 15A H Part Pinion Gear 1 1037 D 15 4 Bottom Pinion Bearing 1 1037 C 33 K Part Low Pinion Gear 1 1037 D 32 DRILLING amp AACCODY TECHNICAL MANUAL 5 13 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Tone A Ma lt n B 777 6 CLUTCH ASSEMBLY 5 14 CONTENTS TEcHNICAL MANUAL AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS CLuTCH ASSEMBLY 20000 20 50K Tonc Item Type Description Qty Part Number A Part High Clutch Gear 1 1037 D 41 B Part Top Clutch Bearing 2 02 0103 C Part Splined Clutch Shaft 1 1037 D 38 D Part Shifting Collar 1 1037 D 34 E Part Clutch Bearing 1 02 0104 F Part Low Clutch Gear 1 1037 D 40 G Part Bottom Clutch Bearing 1 02 0105 H Part Clutch Bearing Cap 1 1037 C 17 J Part 5 8 Lock Washers 4 09 5114 K Part 5 8 NC x 1 1 2 Hex Bolts 4 09 1230 L Part 1 8 NPT Grease Fitting 1 02 0005 M Part 1 8 x 909 Grease Fitting 2 02 0093 DRILLING amp AACCODY TECHNICAL MANUAL 5 15 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K SHIFTER ASSEMBLY DRILLING amp 5 16 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD
58. 3 2 3 6 Replaced lubrication point graphics 3 3 8 Added Subsection Door Alignment 3 3 8 Added Subsection Shifter Detent Force Adjustment 3 3 12 3 21 Added Section Assembly Procedures 3 3 22 Added Section Daily Power Tong Inspection amp Maintenance 3 3 24 Added Section Monthly Power Tong Inspection amp Maintenance 3 3 27 Added Section Daily Power Unit Inspection amp Maintenance 3 3 28 Added Section Tubular Connection Equipment De commissioning 3 3 31 Added Section Connection Equipment Re commissioning Continued On Next Page DRILLING amp AACCCOY TECHNICAL MANUAL V MOVING GLOBAL ENERGY FORWARD 20000 20 50 Summary Of Revisions Continued Date Section Page Description Of Revision 4 Renumbered Troubleshooting section as Section 4 Removed old section Storage Recommendations see Maintenance section Equipment de commissioning amp Equipment re commissioning 5 Renumbered Assemblies amp Parts section as Section 5 5 5 2 5 3 Replaced Gear Train Layout images with current versions 5 5 4 5 5 Updated Support Roller graphics amp BOM to reflect current version June 2011 5 5 6 5 7 Updated Door Pivot Roller graphics amp BOM to reflect current version 5 5 18 5 19 Removed Tong Body graphics amp BOM inserted Hydraulic Supports amp Hanger Legs graphics and BOM 5 5 20 5 21 R
59. 5 holes 0 20 0 0 79 dia uo 8 o E 5 E ofdrans For shaft details see i 138 0 167 0 6 6 Shaft type X applicable spotfaced to 0 38 0 1 5 dia Pl 649 77 to dual mount on page 11 Model Tapping size code El F2 3 16 UNC 2B x 22 0 0 87 deep 2 M10 x P1 5 x 22 0 0 87 deep 6015 0 006 AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS TECHNICAL MANUAL SECTION CONTENTS 7 11 20000 20 50 Tone HypRAuLic Motor INFORMATION STAFFA section O ring 0 254 0 10 60 0 2 375 Flow direction for shaft rotation shown on main drawings pages 8 and 9 Reverse flow for opposite 63 2 5 343 0 13 5 10 0 0 375 270 0 10 6259 6 holes 129 0 5 06 3 8 24 UNF 2B N 16 0 0 62 deep 51 0 51 0 Vag E r 19 0 75 Port 1 A 028 1 125 dia with recess for 31 0 1 22 x 4 0 157 dia direction of shaft rotation 3 VALVE HOUSING WITH 6 BOLT FLANGE 503 IN MODEL CODE POSITION El Mounting face 4 VALVE HOUSING WITH 6 BOLT FLANGE 504 IN MODEL CODE POSITION 0 254 0 10 0 dia Mounting face Flow direction for shaft rotation shown on main drawings pages 8 and 9 Reverse flow for opposite direction of shaft rotation 397 0 15 625 278 0 10 94 138
60. 97 D20 125 over the bottom end of each shaft and secure the pads with a 1 1 2 UNF hex nylock nut 11 Slide low pinion gear PN 1037 D 32 over bottom end of pinion gear shaft PN 1037 D 15 and place end of pinion gear shaft into pinion bearing and bearing cap installed Step 6 Ensure the gear keys PN 1037 D 15A are placed into the pinion gear shaft before installing gear two keys per gear 12 Install a retaining ring PN 02 0009 into each of the two pinion idler gears PN 1037 D 1 Press one each of the idler bearings PN 02 0011 into each of the pinion idler gears followed by a second retainer ring in each Slide each pinion idler gear and bearing assembly over an idler shaft PN 1050 D5 117 and centre as well as you are able 13 Slide a bearing seal PN 02 0010 over each end of the pinion idler shafts ensuring that the lip on the seals are towards the centre bearing followed by an idler spacer PN 1050 D5 121 over each end of the shafts 14 Install each pinion idler in their respective locations in the bottom plate ASSEMBLY NOTE when the pinion idler assemblies are placed vertically the bearing seal and idler spacer on the bottom side will have to be held in place by hand as the assembly is lowered through the bottom plate Once the assembly is through the bottom plate place an idler pad PN 997 D20 125 over the bottom end of each shaft and secure the pads with a 1 1 2 UNF hex nut 15 Slide clutch bearing PN 02 01
61. AL MANUAL SECTION CONTENTS 13 20000 20 50K SPECIFICATIONS Use an EP synthetic grease that meets or exceeds the following specifications Thickener Lithium Complex NLGI consistency grade 2 NLGI performance grade GC LB Penetration ASTM D 217 25 77 265 295 minimum 0 1 mm worked 60 strokes Dropping point F C ASTM 02265 550 288 minimum High temperature life hours ASTM D 3527 160 minimum Oxidation stability psi ASTM D 942 100 hr 300 hr 0 3 Water washout percent ASTM D 1264 1 8 max Rust and corrosion ASTM D 1743 pass Oil separation percent loss ASTM D 1742 1 1 max 24 hours 25 77 Leakage g lost ASTM D 4290 1 0 max Four ball wear test mm scar ASTM D 2266 0 40 max Fretting wear mg ASTM D 4170 3 4 max Four ball EP kgf ASTM D 2596 Weld point 400 minimum Load wear index 50 minimum Timken OK load test 16 ASTM D 2509 50 Low temperature torque N m ASTM D 4693 1 3 max 40 C 40 F LT 37 pumpability g min 360 7 60 F 0 F 16 C 18 C Copper corrosion ASTM D 4048 1B Disc brake wheel bearing specifications Ford ESA M1C 198A Yes Chrysler MS 3701 Yes Oil viscosity 40 C 104 F cSt 151 100 C 212 F cSt 19 2 Flash point F C ASTM 92 45012321 Use premium quality hydraulic fluid that meets or exceeds the following specifications Typical Density kg m3 878 Viscosity cSt 40 68 8 cSt 100 8 7 Viscosity Index 97 Pour Point F
62. CE Assembly Procedures Cont d ILLUSTRATION 3 H 2 RorARY GEAR amp Support ROLLER INSTALLATION 6 Press pinion bearing PN 02 0106 into bottom pinion bearing cap PN 1037 C 33 and install bearing cap into bottom plate of tong using four 5 8 SS lock washers and four 5 8 NC x 1 1 2 hex cap screws 7 Press lower clutch bearing PN 02 0105 into bottom clutch bearing cap 1037 C 17 and install bearing cap into bottom plate of tong using four 5 8 lock washers and four 5 8 NC x 1 1 2 hex cap screws 8 Install a retaining ring PN 02 0009 into each of the two rotary idler gears one each of PN 1037 D59 Press one each of the idler bearings PN 02 0011 into each of the rotary idler gears followed by a second retainer ring in each Slide each rotary idler gear and bearing assembly over an idler shaft PN 1050 D5 117 and centre as well as you are able 9 Slide a bearing seal PN 02 0010 over each end of the rotary idler shafts ensuring that the lip on the seals are towards the centre bearing followed by an idler spacer PN 1050 D5 121 over each end of the shafts 10 Install each rotary idler in their respective locations in the bottom plate ASSEMBLY NOTE when the rotary idler assemblies are placed vertically the bearing seal and idler spacer on the bottom side will have to be held in place by hand as the assembly is lowered through the bottom plate Once the assembly is through the bottom plate place an idler pad PN 9
63. COMPONENT IDENTIFICATION 02 222000000 000000000000000500000000 2 5 ILLUSTRATION 2 B 4 MAJOR COMPONENT IDENTIFICATION 04 26 ILLUSTRATION 2 B 5 MAJOR COMPONENT IDENTIFICATION 05 222220 0200 0000000000000500000 2 7 IREUSTRATION 2 C 1 HYDRAULIC SCHEMATIC vie icsisasveses ices sos 200508 88666 5 0081 11060812161 8644016420208 sh 606541160 6 04040 rp SY FL 2 8 ILLUSTRATION 2 C 2 HYDRAULIC COMPONENT IDENTIFICATION 01 29 ILLUSTRATION 2 C 3 HYDRAULIC COMPONENT IDENTIFICATION 02 22222 2 2 22 0225000000000000000000000000000050000000000 2 10 ILLUSTRATION 2 C 4 HYDRAULIC COMPONENT IDENTIFICATION 03 2 221 2220200000000000000000000000000000000000000000 assent ra ass sss sena 2 10 ILLUSTRATION 2 0 1 HyDRAULIC CONNECTIONS 01 2 11 ILLUSTRATION 2 0 2 HYDRAULIC CONNECTIONS 02 2 00000 2 000000000000 ina tuas sans ssa R RR ieie ERR RN RAN EL reied NN A MER r aad aad 2 11 TELUSTRATION Z SEEN PA ro M Em 2 13 ILLUSTRATION 2 1 TONG SUSPENSION RELATIVE To AXIAL CENTRE 2 14 ILLUSTRATION 2 F 2 TONG SUSPENSION RELATIVE VERTICAL 2 22 20 0000000000000000000000000000000000000000 2 14 ILLUSTRATION 2 F 3 LEVELING TONG USING 5 4222 00 0 000000000000000000000000
64. CONNECTED AND RESIDUAL HYDRAULIC PRESSURE IS BLED OFF ENSURE ADEQUATE CONTAINMENT IS IN PLACE TO PREVENT ENVIRONMENTAL CONTAMI NATION FROM RESIDUAL HYDRAULIC FLUID DEPRESSURIZE HYDRAULIC SvsrEM IN PREPARATION For MAINTENANCE 1 Rotate the tong to the open throat position Ensure tong and backup doors if equipped are closed Fully extend the lift cylinder 2 De energize the power unit 3 Repeatedly actuate the tong motor control valve lever IN BOTH DIRECTIONS to dissipate any residual pres 2 sure the valve and motor 4 Remove the hydraulic SUPPLY line from the equipment 5 Repeatedly actuate the remaining control valve levers IN BOTH DIRECTIONS to dissipate any residual pres sure in the remainder of the hydraulic control system 7 Disconnect the hydraulic RETURN line from the equipment 8 Disconnect remaining hoses such as case drains or lines connected to the turns counter HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN SMALL AREAS OF THE EQUIPMENT ENSURE ALL MAINTENANCE IS CARRIED OUT BY A QUALIFIED SERVICE TECHNICIAN AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIP MENT IS USED TO GUARD AGAINST PRESSURE INJURIES 3 Perform an initial wash of the tong in order to remove the majority of dirt and grease build up Ensure adequate contain ment is in place to prevent environmental contamination from residual hydraulic fluid and dirty grease 4 Remove the access panel on the side
65. Double Spline 41 Tapered Thrust 42 Keyed w Opt 43 Splined w Opt 44 Tapered w Opt 52 Smooth Shaft 53 Thread 120 120 in3 1967cc rev 136 136 in 2229cc rev 150 150 in 2459cc rev 164 164 in 2688cc rev 180 180 in 2950cc rev SINGLE STACK 196 196 in3 82120 060 60 in3 983cc rev 068 68 in 1115cc rev 082 82 in3 1344cc rev 098 98 in3 1606cc rev 113 113 in3 1852cc rev 125 125 in3 2049cc rev Rotary Group Designation 1S Code 61 Standard 1L Code 61 Low Speed 211 211 in 3458cc rev 226 226 in 3704cc rev 238 238 in3 3901cc rev 250 250 in3 4098cc rev Applications r ma For durable hydraulic motors that meet your demands specify Rineer For over 35 years we have specialized in only one thing engineering the right motor for your needs Rineer delivers the performance you can count on Visit our website at www rineer com Limited Warranty Policy 331 Breesport San Antonio Texas 78216 210 341 6333 Fax 210 341 1231 e mail sales rineer com DRILLING amp AACCODY TECHNICAL MANUAL 7 17 MOVING GLOBAL ENERGY FORWARD This page intentionally left blank HyprauL ic Motor REPAIR RINEER 20000 20 50K Repair Manual 125 Series HYDRAULIGSANG Key Spline 125 Double Stack Key Spline 4 Port Key Spline Series
66. E EQUIPMENT UNLESS SUPPLIED BY MCCOY DRILLING amp COMPLETIONS WHEN RE ASSEMBLING LOAD BEARING DEVICES CHAIN SLINGS RIGID SLINGS BACKUP LEGS ETC NOTE THAT THE ASSOCIATED FASTENERS MUST BE TIGHTENED TO THE CORRECT TORQUE SPECIFIED FOR THAT SIZE OF FASTENER SEE SECTION 3 OVERHAUL ANY THREADED FASTENER A LOAD BEARING DEVICE MUST BE SECURED WITH RED OR BLUE LOCTITE ANY REPLACEMENT FASTENER BOLTS NUTS CAP SCREWS MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHERWISE SPECIFIED DRILLING amp AACCCOY TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD 20000 20 50K Tone TABLE Or CONTENTS Introduction amp Specifications mcm Section 1 Introduction amp Company 1 1 Tong DIMCNSIONS coro a e ra pa ete ES 1 2 Equipment Specifications 1 3 Lubrication Specifications 1 4 Setup 8 Operation Section 2 Sling amp Load Bearing Device Safety im 22 Major Component Identification 2 2 ripeto initi eno aen pese 2 4 Hydraulic Schematic Hydraulic Component Identification sess eee 2 8 Hydraulic Connections us d Tong Jaw Availability amp Installation cessisse sesenta ntes ht
67. EER Information Standard 125 series seal kit BoltTorque KT SE1250948 single Stack Main Bolts 5 8 11 200 ft Ibs Standard 125 thru key seal kit Double Stack Main Bolts 5 8 11 220 ft Ibs KT SE1250947 4 Port Main Bolts 5 8 11 200 ft Ibs Standard 125 drill motor seal kit Seal Plate 3 8 16 45 ft 16 KT SE1250947 Grease used for bolt threads Standard 125 double stack seal kit and o ring retention KT SE1250948DS Pennzoil 707L RED Standard 125 4 Port seal kit Shaft seal assembly lube KT SE1250948FP Mobilgrease special with Moly Note The above seal kits are applicable to the motors shown in this repair manual Any special motor may have 1 25 Series seals amp O rings unique to that motor Cross Section ZZ TN WV 74 A NS CK Lela VY 7 26 DRILLING amp SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD HvbRAuLIC VALVE INFORMATION 20000 20 50K Inlets 2500 psi End Inlet Mum OSS niat aaron Acting 4 Posilgn in Minio Spaal 47 SAB Outlets Tank Return Type End Pon mere woes rurwer TASS asma sam 54 5 NOTE Spe Secton G Page 3 Pan Plugs Adjustable Relief Valve Cartridges For Inlets and Mid section in
68. IONS MOVING GLOBAL ENERGY FORWARD 20000 20 50K Door ASSEMBLY Description Qty Part Number A Part 1 1 8 Flat Washer 2 09 5041 B Weldment LH Door Weldment 1 1037 D43 142 RHA C Part Door Bushing 4 101 0110 D Part 1 Flat Washer 2 09 5026 E Part 1 UNS Thin Nylock Nut Support Roller 4 09 9167 F Part 5 8 x 3 4 UNC Shoulder Bolt 4 09 0049 G Assembly Door Cylinder Assembly 2 1037 A4 144 H Part Door Cylinder Mounting Lug 2 101 0446 J Part Door Pivot Roller Shaft Support Roller 2 101 3940 K Part 1 2 UNC Hex Jam Nut 4 09 5810 L Part Unbrako Flat Point 1 2 x 1 1 2 Set Screw 4 M Part 3 8 NC x 3 4 Hex Bolt 2 09 2048 N Part 3 8 Regular Carbon Steel Lock Washer 2 09 5106 P Part Door Latch Cam 2 1037 C 151 Q Part Door Latch Shaft 1 1037 C 200 R Weldment RH Door Weldment 1 1037 D43 142 LHA S Part Door Latch Spring 2 997 16 T Weldment Latch Weldment 1 101 1570 See next page for safety door components DRILLING amp AACCODY TECHNICAL MANUAL 5 31 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Door OPTION DRILLING amp 5 32 TECHNICAL MANUAL NAO Y MOVING GLOBAL ENERGY FORWARD Door OPTION Description Qty Part Number A Part 3 8 NC x 3 4
69. LIGNMENT ADJUSTMENT SET SCREWS 3 9 ILLUSTRATION 3 E 5 SHIFTER DETENT FORCE ADJUSTMENT 3 10 ILLUSTRATION 1 CAM FOLLOWER INSTALLATION BOTTOM 3 13 ILLUSTRATION 3 H 2 RoTARY GEAR amp SUPPORT ROLLER INSTALLATION 2 3 14 ILLUSTRATION TOP PLATE CAM FOLLOWER 5 1222 222 100 000000000000005000000200000000000200000 assis ses nara 3 15 ILLUSTRATION 4 TOP PLATE FASTENER EXCLUSIONS ccccccccccscessssccecseceesusssneeeceeceeeaseeeesesssesaceeeceseseasseeeeeesececisseeesecsenentaeseeeess 3 16 ILLUSTRATION 3 H 5 INSTALLATION OF HORIZONTAL CAM FOLLOWERS AND GUIDES 3 16 ILLUSTRATION 3 H 6 SUPPORT ROLLER BRAKE BAND WELDMENT 3 17 ILLUSTRATION 3 H 7 TOP amp BOTTOM CAGE PLATE 5 2 2000000000000000000000000000082000000000000000 nennen neen 3 18 ILLUSTRATION 3 H 8 DooR SPRING CYLINDER POST INSTALLATION 3 19 ILLUSTRATION 9 SAFETY DOOR VALVE LOAD PLUNGER INSTALLATION 3 20 ILLUSTRATION 10 DELTROL SAFETY DOOR VALVE INSTALLATION 3 20 ILLUSTRATION 6 1 TORQUE GAUGE Fon ILLUSTRATION PURPOSES ONLY 6 1 EEUSTRATION 6 A 2 TENSION OAD ELE ede a poer a Fas dra cuc
70. MAINTENANCE 2 Door Latch Adjustment Normal operation of the tong may cause wear of the door latch which will cause the door to develop a loose fit at the latch Two latch cam plates are located on the right hand door assembly one on the top of the weldment and one on the bottom see Illustration 3 E 2 next page The cam plates have eight positioning holes located on a 360 degree bolt circle The latch cam shaft extends down through the door and is secured at the top by a 3 8 hex head bolt To make adjustments in door alignment remove the 3 8 bolt and turn the cams with a wrench When the door has been adequately aligned replace the 3 8 bolt ADJUST BOTH DOOR LATCH CAMS SIMULTANEOUSLY ROTATE BOTH LATCH CAMS THE SAME AMOUNT IN THE SAME DIRECTION IMPERATIVE TO KEEP A SECURE FIT AT THE DOOR IN ORDER TO MAINTAIN PROPER GEAR ALIGNMENT AND TO MINIMIZE THE POSSIBILITY OF DAMAGE TO THE GEAR TRAIN WHEN OPERATING THE TONG AT SPECIFIED TORQUE A CLOSED DOOR ALSO ENSURES SAFETY OF OPERATING PERSONNEL THE DOOR IS IMPORTANT PART OF THE STRUCTURAL INTEGRITY OF THE TONG IT IS Identical adjustment cam is located on bottom of door weldment ILLUSTRATION 3 E 2 Door Larcu ADJUSTMENT CAMS 3 Door Alignment Each door weldment is equipped with two set screws along with jam nuts to lock position to align the door when it is in the closed position Initial Alignment Ensure tong doors are closed and inspect how one door alig
71. OBAL ENERGY FORWARD 20000 20 50K MEASUREMENT N a Y N Description Qty Part Number Assembly Standard Turn Counter Encoder Mount 1 60 0001 A Part 6 32 x 3 8 Hex Socket Head Set Screw 4 B Part Helical Flexible Encoder Shaft Coupling 1 60 0130N C Part Internal Retainer Ring 2 1376 13 D Part Bearing 2 1376 05 E Part Encoder Housing 1 1392 104A Part Internal Retainer Ring 1 02 0436 L G Part Encoder Shaft 1 1392 103A 01 H Part Encoder Gear 1 01 0320 J Part 10 24 x 1 1 4 Hex Socket Head Set Screw 1 ILLUSTRATION 6 4 6 TURN Counter Mount EXPLODED 6 4 CONTENTS TECHNICAL MANUAL AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS Torque MEASUREMENT KT20000 20 50K B TROUBLESHOOTING Under normal operating conditions and with proper maintenance the torque gauge and load cell system are designed to give lasting trouble free performance Faulty indication on the gauge will very often define a fault within the gauge IF TROUBLESHOOTING REVEALS THAT THERE IS INSUFFICIENT FLUID IN THE SYSTEM BEFORE RECHARGING CHECK THAT ALL SYSTEM COMPONENTS ARE FREE FROM DAMAGE THIS WILL ENSURE THAT FLUID LOSS WILL NOT CONTINUE AFTER RELOADING Symptom Possible Problem Solutions Possible Problem Solution Po
72. OCKED OUT Visually inspect main electrical line between main power source and power unit Perform a visual inspection of all parts Check to ensure there are no loose or missing fasteners Check hydraulic fluid level ensure cold level is approximately half way up the sight glass on the hydraulic fluid res ervoir Perform a visual inspection to ensure there are no hydraulic fluid leaks correct if necessary Check that the main supply and return lines on the hydraulic fluid reservoir are both fully open Apply grease to any grease fittings that your power unit may have Apply grease to each fitting until grease is visibly displaced from bearing or as recommended by your power unit manual Ensure supply and return connections at the power unit and at the equipment in use are fully made up FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES ARE FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE Check hyaraulic fluid filter back pressure must be done while fluid is circulating If needle on indicator gauge is in the red zone the filter should be changed the next time the unit is shut down DRILLING amp AACCCOY TECHNICAL MANUAL 3 27 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Tonc MAINTENANCE L TUBULAR CONNECTION EQUIPMENT DE COMMISSIONING PROCEDURE Perform the following decommissioning procedures when removing tubular connection equipment from service with the intent of short to long
73. RANKCASE DRAIN 20000 20 50K Motor axis horizontal The crankcase drain must be taken from a position above the horizontal centre line of the motor Axis vertical shaft up Additional drain port 01 4 BSPF Standard drain port 3 4 16 UNF 0 35 bar 5 psi An additional 61 4 BSPF drain port is provided when the V shaft vertically upwards designator is given after the shaft type letter in position Ell of the model code This additional drain should be connected into the main motor off load 2000 cSt 9270 sus GENERAL casing drain line downstream of Max on load 150 cSt 695 SUS 9 Spigot 0 39 bar psi check Valve To Optimum 50cSt 232 SUS motor should be located by the ensure lubrication of the upper Minimum 25 cSt 119 SUS PETROLEUM OIL RECOMMENDATIONS The fluid should be a good hydraulic grade non detergent petroleum oil It should contain anti oxidant anti foam and demulsifying additives It must contain antiwear or EP additives Automatic transmission fluids and motor oils are not recommended 7 TEMPERATURE LIMITS 30 C 22 F 70 158 F Ambient min Ambient max Max operating temperature range mounting spigot on a flat robust surface using correctly sized bolts The diametral clearance between the motor spigot and the mounting must not exceed 0 15 mm 0 006 in If the appli
74. TENTS 7 13 20000 20 50K Tone Motor INFORMATION RINEER OF HYD RINEER HYDRAULICGSING Features of the 125 Series Standard Motor Standard Motor 3000 PSI Code 61 A variety of fixed displacement motors ranging from 60 in to 250 ins 4 Port double motors providing 2 Speed operation with external valving Starting and stall torques equal to 90 9496 of theoretical torque Speed to 350 RPM continuous Up to 300 HP continuous Compact envelope sizes Weighs 225 lbs to 280 lbs ENVELOPE 4 72 9 94 10 06 5 8 11UNC 2B 1 25 7 00 D FLAGES EQ SP POWER to be the Best MOTOR SELECTION GUIDE REAR FACE STD SAE 1 5 4 BOLT FLANGE OPTIONAL 1 1 2 20 RING BOSS PORT EXTERNAL CASE DRAIN 1 2 O RING BOSS 2 PLACES 2 Made USA _ OPTIONAL SHAFT 21 32 DIA THRU PLACES EQ SP A 11 75 B C SAE FLAT nd SIDE FIT 20 T 6 12 DI INVOLUTE SPLINE PUBLICATION DS1251005 3 04 TECHNICAL MANUAL 7 14 SECTION CONTENTS DRILLING amp COMPLETIONS AACCOY MOVING GLOBAL ENERGY FORWARD HvbRAuLIC Motor INFORMATION RINEER 20000 20 50K Tonc Performance Data VANE CROSSING VANE With it s vane crossing vane design the Rineer motor produces much higher volumetric and Charts shown are for 123 GID Seo website at mech
75. TION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Torque Gauce Mounts 20000 20 50K Item Type Description Qty Part Number A Weldment Torque Gauge Mount 1 1500 09 03A B Weldment Torque Gauge Mount Holder Rineer Motor 1 101 0480 C Weldment Torque Gauge Mount Holder Staffa Motor 1 101 4465 D Part HITCH PIN 148 X 2 938 1 E Part 3 8 UNC x 1 1 4 Hex Bolt 2 09 1048 F Part 3 8 Lock Washer 2 09 5106 DRILLING amp AACCCOY MANUAL 5 23 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Brake BAND ASSEMBLY DRILLING amp 5 24 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Brake BAND ASSEMBLY 20000 20 50K Tonc Item Type Description Qty Part Number A Part Support Roller Shaft Shown For Illustration Purposes Only 4 101 3939 B Weldment Brake band Lug Weldment RH Top LH Bottom 2 101 1636 C Weldment Brake band Weldment Lined 2 1037 D 63 D Weldment Brake band Lug Weldment LH Top RH Bottom 2 101 1637 E Part 3 8 NC Hex Nylock Nut 4 09 5607 F Part Brake band Spring 4 9588K340 G Part 3 8 NC x 4 1 2 Hex Bolt 4 09 1064 H Part Brake band Retainer 4 101 1631 J Part 3 8 Regular Carbon Steel Lock Washer 8 09 5106 K Part 3 8 NC x 1 Hex Bolt 8 09 1170 DRILLING amp AACCODY
76. a Screws 2 381 1433 015 391 14334122 a 3241 14112 115 10 Chech Valve 1 381 0881 044 381 0881 044 391405 5 008 Lir wane Gap Fl hi 1 301 2251 015 301 221 015 1 Ring 1 38T 2887 204 917 2881 214 91 2881 24477 12 Check Spring 1 301 358 f 7 1 1 381 3 amp 8281 713 3581 3581 77 5 1 Chock 1 30 244 1 0423 init nA RH DELI 391 2383 081 Paral Sealing Face Includes mats and ref eri hind in neutral Sections AACCOY DRILLING amp COMPLETIONS MOVING GLOBAL ENERGY FORWARD TEcHNICAL MANUAL SECTION CONTENTS 7 31 HvoRAULIC VALVE INFORMATION KT20000 20 50K Tone Spring Centered and Detent Spool Operators See Figure 2 14 Stripper 1 381 1432 022 291 1432 021 381 1402 452 15 Cantering Spring 1 391 3581 808 381 3581 833 391 3581 330 18 Spring Guides 2 391 1642445 391 1642 013 391 1842 161 17 Detent Siegve 1 301 3283 015 301 3283 008 391 3384 310 18 Detent 2 391 0282 010 391 0282 009 391 0282 011 19 Detent Spring 391 3881 130 391 3591 015 391 3581 316 20 Detent Poppat Retainer 381 2583 008 391 2583 006 301 3384 311 21 Detent Spacer 1 Sm CERE 391 3782 208 AACCCOY 7 32 CONTENTS TEcHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD HvbRAuLIC VALVE INFORMATION 20000 20 50K Tonc 5 Valve Disassembly Instructions Reference exploded view an
77. ace in the correct position The cage plate opening must be aligned with the door opening when setting the backing pin position NALCO Y MOVING GLOBAL ENERGY FORWARD TECHNICAL ManuaL 2 2 19 KT20000 20 50K Setup amp OPERATION Making A Connection Continued ILLUSTRATION 2 H 2 SETTING BAckiNG Pin To Make up Position c Ensure the load cell and snub line s are properly configured for making up connections A snub line is a length of wire rope that connects the rear of the tong body to a sturdy anchor on the drill floor see Section 2 F 1 The snub line pre vents the tong body from spinning in the opposite direction of the cage plate when torque begins to build in the joint Farr Canada Corp recommends using two snub lines when running the equipment to eliminate uncontrolled movement in either rotational direction The snub line s must be rated for the applied torque plus whatever safety margins stated by your own operating policies The snub line connection point on the drill floor must be sturdy enough to absorb all applied forces when making up the joints When making up joints the load cell must be connected to the driller s side of the tong which is the left side of the tong as seen from the rear For accurate torque measurement the snub line between the tong body and the anchor must be perpendicular to the vertical and perpendicular to the centre line of the tong d Actuate the lift cyli
78. ainTong Assembly 3 1 4 Manual Shift Assembly 3 2 5 Access Panel 3 2 6 Torque Gauge Mounting Plate 3 2 7 Staffa HMB 80 or Rineer GA125 Hydraulic Motor 8 Motor Mount 9 Backing Pin Assembly Cage Plate Assembly Tong Jaw Chain Sling Hanger Brake band Tong Door Cylinder RH Door Assembly Door Latch LH Door Assembly 18 Safety Door Hardware Where equipped 3 4 DRILLING amp TECHNICAL MANUAL 2 7 MOVING GLOBAL ENERGY FORWARD 20000 20 50K Tone Setup amp OPERATION HYDRAULIC SCHEMATIC 8 COMPONENT IDENTIFICATION TONG MOTOR O OPTIONAL ILLUSTRATION 2 C 1 SCHEMATIC 9 ITEM QTY DESCRIPTION PART NUMBER 1 1 DVA35 A880 Inlet Valve 10 9016 2 1 DVA35 MRV 2 Relief Valve 10 0062 3 1 DVA35 MA8 Motor Section Valve 10 9014 5 1 DVA35 SA8 Lift Section Valve 10 9015 6 1 DVAS5 TR99 Outlet Valve 10 0086 7 1 1 2 Needle Valve 08 0066 Continued on next page 2 8 Section CONTENTS TECHNICAL MANUAL AACCCOY MOVING GLOBAL ENERGY FORWARD Setup amp OPERATION KT20000 20 50K Hydraulic Component List Continued ITEM QTY DESCRIPTION PART NUMBER 8 1 Staffa HMB 080 Hydraulic Motor 87 0210B 1 Optional Rineer GA125 Hydraulic Motor 87 0150 9 1 Motor Speed Valve Optional 10 9024 10 1 Safe
79. ance the equipment should be removed from storage and exercised on a regular basis depending on the storage environment Farr recommends that for equipment stored in a salt water maritime or exposed dusty environment repeat steps 9 through 24 monthly For equipment stored in isolated storage in a non maritime environment repeat steps 9 through 24 quarterly Replace desic cant packs at this time depleted desiccant packs may be treated as regular dunnage DRILLING amp 3 30 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 20000 20 50K Tonc M TUBULAR CONNECTION EQUIPMENT RE COMMISSIONING PROCEDURE Perform the following recommissioning procedures when removing tubular connection equipment from short or long term storage back into regular service These procedures are essential for ensuring proper equipment preparation and operation The following procedures also assume that the decommissioning and storage procedures recommended by Farr have been strictly observed 1 2 Remove all protective plastic wrapping If there are desiccant packs with the assembly they may be disposed of with the regular garbage Remove the access panel on the side of the tong directly adjacent to the shifter mechanism Wipe excess grease or heavy oil from exposed cylinder rods If applicable re connect chain sling to lifting lugs Perform a visual inspection of all lifting points if visible
80. anical efficiencies than is possible with a standard vane obtained at 140 F with ISO 46 25 Code 61 and 62 data type design This design provides a sealing vane between stator shown Code 62 extended data applies only to Code 62 High cavities to improve mechanical and volumetric efficiencies Pressure Series motor Actual Torque and Power 98 CID Actual Torque and Power 125 CID 5500 300 RPMI is 300 RPM 50 RPM 50 RPM um 4000 5 3500 E 350 3000 400 8 300 350 2500 2 300 E 250 300 _ 2000 250 RPM 200 RPM 80g 250 1500 150 2 200 150 150 5 1000 100 RPM 100 100 500 s 1 50 RPM 50 50 0 0 0 500 1000 1500 2000 2500 3000 2500 4000 4500 500 1000 1500 2000 2500 3000 3500 4000 4500 L CODE 61 1 CODE 61 L CODE 62 L CODE 62 PRESSURE psid PRESSURE psid Actual Flow 98 CID Actual Flow 125 CID 150 190 140 300 RPM 180 300 RPM 130 170 160 120 250 RPM 250 RPM 110 140 100 200 200 RPM 120 90 110 2 10 150 RI 5 70 150 RPM 2 60 5 80 100 RPM i 70 59 60 100 RPM 40 50 40 s 50 RPM 30 50 RPM 20 p 10 16 0 0 500 1000 1500 2000 2500 3000 3500 4
81. ase in the vanes o ring grooves Line up the housings and rotating group with the paint line made on the motor in step 6 Y DRILLING amp 7 24 Section CONTENTS TECHNICAL MANUAL MCCO COMPLETIONS MOVING GLOBAL ENERGY FORWARD Hyprautic Motor Repair RINEER KT20000 20 50K Motor Assembly Tips WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION Note On double stack motors rotor vane slots must line up 1 Place both rotors on the spline of the shaft rotating one rotor until vane slots line up 2 Mark the end of one spline tooth inside each rotor where they meet with white out This will allow visual realignment after motor is assembled 3 When motor is assembled make sure marks line up before installing shaft Be careful not to rotate one rotor independently of the other while installing the shaft Grease the first inch of threads and UNDER the head of the 5 8 11 bolts and insert into motor Set torque wrench as specified for type of motor to be assembled see back cover of this manual and tighten in a star pattern Install shaft bearings and seal plate in reverse order of previous procedures Rotate shaft to insure no binding is present AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS TEcHNICAL MANUAL Section CONTENTS 7 25 KT20000 20 50K Hyprautic Motor REPAIR RIN
82. asten the ends of the brake bands to the brake band lug weldments using two 3 8 NC x 4 1 2 adjustment bolts and 3 8 NC hex nylock nuts per brake band one per side Ensure that the adjustment spring PN 08 9264 is installed between the head of the adjustment bolt and the tab on the brake band weldment four locations see Pp 5 22 5 23 Install the backing pin assembly i Drop the backing pin PN 1037 C 39A into one of the two backing pin receiver holes in the top cage plate i Place the backing pin retainer PN 1037 B 54 over the rear cage plate bolt and the backing pin ASSEMBLY NOTE Ensure the larger diameter hole in the retainer slides over the backing pin iii Secure the backing pin retainer to the rear cage plate bolt using a 3 8 UNC x 3 4 hex bolt and regular 3 8 flat washer iv Thread the backing pin knob PN 02 0017 on to the backing Install the safety door components if equipped i Attach RH safety door latch plate PN 101 0479 to the RH door weldment using two 3 8 UNC x 1 1 2 hex bolts and lock washers and two 3 8 UNC x 1 1 2 flat head countersunk cap screws i Attach RH safety door latch block PN AE13 302M to the RH safety door latch plate iii Attach LH safety door latch plate PN 101 0915 to the LH door weldment using three 3 8 UNC x 1 1 2 flat head counter sunk cap screws iv Attach LH safety door latch block PN AE13 301S to door latch plate 2 PN AE13 311 using three
83. ations B CLEANING Clean tong thoroughly cleaned with a good petroleum based cleaning agent after each job prior to storage Farr recommends that the motor and valve assembly be periodically removed along with the top tong plate so that guides rollers and gears can be prop erly cleaned Ensure that cleaning solvents and chemicals are captured to prevent environmental contamination and dispose of all materials according to your company s proscribed environmental protection regulations C PREVENTIVE MAINTENANCE PRACTICES Regular maintenance programs are necessary and must be established to assure safe dependable operation of your Hydraulic Tubular Connection System and to avoid costly breakdown maintenance The following maintenance procedures provides informa tion required to properly maintain your equipment Your equipment may require more or less maintenance depending upon the frequency of use and the field conditions under which your equipment operates These maintenance procedures are designed for equipment operating at 10 C to 35 C ambient temperature for 10 hours per day McCoy Drilling amp Completions recommends that the inspection and maintenance procedures in this section be performed as recommended in the maintenance checklists see Appendices or in conjunction with your maintenance foreman s experience and best estimate of when your equipment is due for this maintenance Purchased components included with your hydraulic
84. aulic line or gauge Refer to torque measurement trouble shooting in Section 6 of this manual SOLUTION Load cell has been damaged Replace load cell or return to McCoy for repair and re calibration DRILLING amp AACCCOY MANUAL 41 MOVING GLOBAL ENERGY FORWARD 20000 20 50 Tone TONG WILL NOT DEVELOP SUFFICIENT TORQUE Cont d TROUBLESHOOTING 11 POSSIBLE PROBLEM Incorrect motor speed selected SOLUTION Maximum torque can only be developed when motor is in the lowest speed Ensure motor is in low speed 12 POSSIBLE PROBLEM Incorrect tong gear selected SOLUTION Maximum torque can only be developed when tong is in low gear Ensure tong is in low gear MCCOY DRILLING amp COMPLETIONS GUARANTEES CALIBRATION OF A LOAD CELL TORQUE GAUGE ASSEMBLY FOR A PERIOD OF ONE YEAR MCCOY SUGGESTS THAT THE LOAD CELL TORQUE GAUGE ASSEMBLY BE RETURNED TO THE FACTORY FOR RE CALIBRATION ON A YEARLY BASIS DRILLING amp 4 2 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD TROUBLESHOOTING 20000 20 50K Tonc B FAILURE OF JAWS TO GRIP PIPE 1 POSSIBLE PROBLEM Dies have become too dull to provide adequate grip SOLUTION Replace dies 2 POSSIBLE PROBLEM Incorrect jaws are being used SOLUTION Double check jaw size to ensure they are rated for the diameter of pipe or casing being run 3 POSSIBLE PROBLEM Incorrect dies are bein
85. cation incurs shock loading frequent reversing or high speed running then high tensile bolts should be used including one fitted bolt Bolt torque The recommended torque wrench settings for the mounting bolts are M20 bolts 4072 14 Nm 300 10 Ibf ft 3 4 bolts 393 14 Nm 290 10 Ibf ft Shaft coupling bearing see above diagram Axis vertical shaft down Use any drain position The drain line should be run above the level of the uppermost bearing if there is risk of siphoning then a siphon breaker should be fitted START UP Petroleum Water Where the motor is solidly coupled to a Fill the crankcase with system fluid oil containing shaft having independent bearings the Where practical a short period 30 shafts must be aligned to within minutes of running in should be Min 20 C 4 F 10 50 F 0 13 mm 0 005 in TIR carried out 80 C 175 F 54 130 F To obtain optimum service life from both fluid and hydraulic system components 65 C 150 F normally is the maximum temperature except 7 for water containing fluids AACCCN DRILLING amp vilia sons TECHNICAL MANUAL SECTION CONTENTS 7 9 KT20000 20 50K HypRautic MOTOR INFORMATION STAFFA 13 INSTALLATION DIMENSIONS IN MM INCHES FRONT MOUNTING MODELS 080 MOTORS WITH TYPE 11 4 SAE PORT CONNECTION ard angle QUI See separate drawing for dua
86. d cross port leakage of the 125 Series single stacked motor is approximately 1 to 1 1 2 GPM per 1 000 PSI while the double stack motor is approximately 2 GPM per 1 000 PSI This will vary with the oil viscosity and internal clearance selection HOUSING OPTIONS The standard 125 Series motors have one six bolt front housing and one rear housing Special 125 Series motors are available with two six bolt front housings or two rear housings The rear housing is provided with six each 5 8 11 mounting threads on a 8 750 bolt circle The mounting position is unrestricted The shafts pilots and mounting faces should be within 002 TIR 7 SHAFT DIMENSIONS ARE TYPICAL BOTH ENDS 4 BOLT FLANGE EXTERNAL CASE DRAIN 1 2 O RING BOSS STD 7 8 KEYWAY 2 PLACES SAE FLAT ROOT SIDE FIT 20T 6 12 DP 30 FLUID We suggest premium grade fluids containing high quality rust oxidation and foam inhibitors along with anti wear additives For best performance minimum viscosity should be maintained at 100 SSU or higher Fluid temperature should not exceed 180 F Elevated fluid temperature will adversely affect seal life while accelerating oxidation and fluid breakdown Fire resistant fluids may be used with certain limitations Contact Rineer for additional information FILTRATION 25 micron minimum Bearing Data Thrust Capable BEARING LOADING THRUST CAPABLE The bearings in the 125 Series Thrust capable m
87. d or bending or for material build up around the hole Repair or replace components that appear distorted Ensure all hardware is tight and in good condition Replace missing hardware if necessary All hardware must be free of rust and corrosion Additional inspections shall be performed during sling use where service conditions warrant Periodic inspection intervals shall not exceed one year The frequency of periodic inspections should be based on Frequency of use of the load bearing device Severity of service conditions Nature of lifts being made Experience gained on the service life of load bearing devices used in similar cirrumstances Guidelines for the interval are Normal Service yearly Severe Service monthly to quarterly Special Service as recommended by a qualified person DRILLING amp 2 2 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION 20000 20 50K Units designed and manufactured in accordance with EN 12079 and DNV 2 7 1 should be tested and examined in accordance with the following schedule of examination and test The user of the load bearing device shall place a permanent placard or plate upon which the type and date of the last test shall be recorded To avoid confusion the plate shall not carry the date of the next test or examination only the most recent Test Examination Non DESTRUCTIVE THOROUGH Surri
88. d parts list F pape 2 and 3 for w rk section idetall MNT ae Step 1 Valve Bank rbe mosi im the disossembly Th abel el inr enum ibd ibe sabre bank properiy reassembled alter repasrs hara heap made Webs vwgeerpeoonf quick reingt marker mark enc with amp cduegilial t m rking he inler with the finish by manking the wenden wilh thee degeret mmis port bes chest bo back eap on caeli werk soria wiih a H ior back cap end Tim dhie quond baaa jai cach wok wills 0 for clesie endi ltr ered fr e thet adve b nk They met Ise marked wiihithe porresqeniting sumber et ihe coating pert kann E or 1 from s hich they were remendd ans Atl ibe afe with a casing number anie Slop 2 Tie Bolis ike iie badis ihal hatl hee tink pelhe Bid the NOTE V valve cle belis dheewdl ihe rastinp valve bolts pass trong entire bank respuiring washers amil bes mwm va Ire fastened at bed li ends of the Step 3 Section Seals The inlet zu parallel wok secho have seals Fi pairs 1 amp Z andbe d s
89. d sling must be used to suspend the tong Do not suspend the tong from any other point See Illustration 2 H 1 b Set the backing for breakout operation Lift on the backing pin and rotate it to the breakout position which is 2 o clock as seen from the front of the tong The opening in the rotary gear must be aligned with the tong door opening in order to properly set the backing pin see Illustration 2 H 8 ILLUSTRATION 2 H 8 SETTING Pin To BnEAk Our Position c Ensure the load cell and snub line are configured for break out operation The load cell must be transferred to the off driller s side the right hand side as seen from the rear of the tong and the snub line must be transferred to the driller s side to perform break out operations d Open the tong doors see Illustration 2 H 4 e Actuate the lift cylinder control valve to lift the assembly from the drill floor if necessary Pushing the valve toward the center of the tong will retract the lift cylinder to lift the assembly see illustration 2 H 3 Note that rig personnel are required to Stabilize the tong and backup as it is being lifted so it does not swing and collide with other rig equipment RIG PERSONNEL MUST STABILIZE THE TONG AS IT IS LIFTED FROM THE DRILL FLOOR f Move the tong on to the tubing joint Use the lift cylinder to ensure the tong jaws are at the correct location above the con nection joint 9 Firmly close
90. damage is seen including cracks broken lugs distorted metal etc replace damaged part s before placing tong in service Also inspect all chains master links and turnbuckles again if any damage is noted replace the damaged part s before placing the tong in service If your company requires yearly certification of lifting equipment ensure that the most recent test date falls within the past year Perform recertification if necessary Perform a liberal lubrication of the equipment refer to Maintenance section of manual to determine lubrication points Generously fill the gear train housing with grease through the access panel and also through the opening in the rotary gear o m 111 oO OO Connect the equipment to a hydraulic power unit Ensure all lines are fully made up to prevent equipment damage from excessive back pressure Do not neglect to connect the motor drain FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES ARE FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE Energize power unit Ensure that supply pressure is at or above the tong s specified operating pressure and that the return pressure is less than 350 psi Perform a thorough inspection of pressurized hydraulic lines and fittings Any leaking hydraulic fluid lines or fittings must be replaced before the equipment is returned to service 7 8 9 0 L LI LI Perform a thorough inspecti
91. ded door spring cylinder posts 101 0446 one on each side of the top plate adjacent to the brake band lug weldments on the top plate see illustration 3 H 8 next page DRILLING amp 3 18 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 20000 20 50K Tonc Assembly Procedures Cont d 41 42 43 44 45 46 ILLUSTRATION 3 H 8 DooR SPRING CYLINDER Post INSTALLATION Thread two 1 2 UNC x 1 1 4 hex socket head set screws into each door assembly Thread far enough through the door weld ments that a 1 2 jam nut can be threaded on to each set screw from the inside of the door assemblies Slide a 1 1 8 wide flat washer on to each door pivot roller shaft PN 101 3940 Position the RH door assembly in its proper location and insert a door pivot shaft from the top through the door assembly and the support roller components Secure the door pivot shaft on the bottom using a 1 wide flat washer and 1 UNS thin nylock nut Repeat the installation procedure for the LH door assembly Install the door spring cylinders PN 1037 A4 144 using 5 8 x 3 4 UNC hex socket head shoulder bolts Install top and bottom lined brake band weldments PN 1037 D 63 Fasten each brake band weldment to the top and bottom body plates with two brake band retainers PN 101 1631 securing each retainer with two 3 8 NC x 1 hex bolts and 3 8 lock washers F
92. e Periodic inspections of the load cell hydraulic lines and fittings are recommended in order to keep the system in top operating condition A thorough inspection should be made at each rig up Fluid Recharge Recharge hydraulic system with W15 16 fluid through the check valve on the torque indicating gauge Recharging must only be performed when there is no load on the load cell Refer to the illustrations on pages 6 3 amp 6 4 for guidance if required a Place the torque indicating gauge higher than the load cell Remove the brass 1 4 cap from the fitting on the check valve on the top of the gauge Connect the hand pump to the check valve fitting Elevate the load cell so it is higher than the torque gauge and hand pump UN CONTAINED SPILLAGE OF THE HYDRAULIC FLUID IN THIS SYSTEM MAY CONTRAVENE GOVERNMENTAL ENVIRONMENTAL REGULATIONS OR THE ENVIRONMENTAL REGULATIONS AND POLICIES OF YOUR COMPANY FARR CANADA CORP HIGHLY RECOMMENDS PLACING YOUR LOAD CELL IN A CONTAINMENT BASIN BEFORE PROCEEDING WITH THE BLEEDING amp REFILLING PROCESS Fill hand pump bowl with W15 16 hydraulic fluid MAINTAIN GREATER THAN HALF FULL FLUID LEVEL IN THE HAND PUMP BOWL TO AVOID PUMPING AIR INTO THE SYSTEM DO NOT ALLOW THE LEVEL TO FALL BELOW ONE HALF FULL e Remove the vent plug screw and Stat O Seal Items C and D on Illustration 6 A 4 or item on Illustration 6 A 5 to allow trapped air to escape f Pump fluid into the system until n
93. e Description Qty Part Number Assembly 52 Arm 60K Torque Gauge Compression Load Cell Assembly 1 10 0023T 1 Part 52 Arm 60 000 Ft Lbs Torque Gauge 1 10 0023G 2 Part Tension Load Cell 1 10 0008T 3 Part Hydraulic Hose 1 02 0069 4 Part Torque Gauge Flange 1 997 D7 5 5 Part Tension Load Cell Shackle 1 02 0078 6 2 DRILLING amp SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD ToRQUE MEASUREMENT 20000 20 50K Tonc Item Type Description Qty Part Number This is the standard tension load Assembly Tension Load Cell 4 08 ir 1 10 0008T cell supplied by McCoy Drilling amp A Part O Ring 1 02 0800 Completions Farr Contact our sales B Part Load Cell Body 1 LC99 104 department for information about C Part 1 4 NC x 1 2 Binding Head Machine Screw 1 09 0045A 2 plication sp ecific tension D Part Stat O Seal 1 02 0307 O Ring 1 02 0350 F Part O Ring 1 08 0596 G Part Load Cell Piston 1 LC99 101 H Part Load Cell End 1 LC99 003 J Part Flange Gasket 1 02 0073 K Part Load Cell Rod 1 LC99 002 L Part Wiper 1 08 1558 N K M Part 3 8 NC x 3 8 Cup Point Hex Set Screw 2 09 0106 Seal Kit Replacement Seal Kit 4 08 in Tension Load Cell 02 4578 ILLUSTRATION 6 4 TENSION Loan CELL ExPLODED DRILLING amp TECHNICAL MANUAL 6 3 MOVING GL
94. e damage is seen including cracks broken lugs distorted metal etc replace damaged part s before placing tong in service Also inspect all chains master links and turnbuckles 1 2 again if any damage is noted replace the damaged part s before placing the tong in service Refer to Section 2A of the technical manual Sling Load Bearing Device Safety for information on recommended testing and recertification Please note that turnbuckles with part number 101 3086 short turnbuckles use a high strength pin which must be supplied by Farr SHORT TURNBUCKLES HAVING PART NUMBER 101 3086 EMPLOY HIGH STRENGTH PINS WHICH MUST BE SUPPLIED BY FARR Rotate the gear train by hand and use a flashlight to perform a visual inspection of the gear train through the access 1 3 C panel and the opening of the rotary gear while the gear train is being rotated If gear damage or chips of metal are seen the tong should be removed from service and overhauled to avoid further damage Replace access panel when inspection is complete Inspect all jaws and dies in use for the maintenance interval Inspect the jaw roller pins for signs of damage replace 14 pins if necessary If the pins are welded place remove and quarantine the jaw until the weld is repaired Ensure dies are secure in the jaw replace worn dies if necessary Ensure that the jaw rollers rotate freely 15 Inspect backing pin s If cracked broken or bent it they mus
95. e design allows the vane to lean slightly in the slot providing the required mechanical seal DRILLING amp AACCODY comprenons TECHNICAL MANUAL 7 23 MOVING GLOBAL ENERGY FORWARD 20000 20 50K Tone WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION Hyprautic Motor Repair RINEER Assembly of Motor 21 PLATES Normal wear results in marking or polishing of the timing plate surface which does not impair motor performance Replacement of the timing plate is required if any smearing galling or heat cracks are present ROTOR Normal wear results in polishing of rotor faces which does not impair motor performance Examine the rotor vane Slots closely Polishing down in the slots is normal but if there is any indication of a pocket forming in the wall of the Slot the rotor should be replaced STATOR Normal wear results in polishing of cam form which does not impair motor performance Noticeable wear may be the corner of one side of the stator vane slot This does not necessarily replacement of the stator but may slightly affect volumetric efficiency Measure the rotor and stator length to the fourth decimal point and supply 1 Reverse the in steps 13 12 11 and 10 Before installing timin onto completed sides of rotating group pour a small a
96. e listed Rigorous inspection and maintenance especially lubrication is essential in order to ensure that your equipment always meets specifications and to prevent catastrophic failures that can severely damage your equipment and cause worker injury If using a stand alone power unit perform the following inspection and maintenance procedures before each use and at least once per day when the power unit is in steady use Do not perform any maintenance while the power unit is energized electric or if the engine is running diesel Ensure the electri cal supply is locked out or if using a diesel power supply ensure that the engine is locked out or the starting mechanism otherwise disabled DiEsEL ONLY 1 1 2 11 3 L 4 ELECTRIC ONLY LL 2 1 ALL Units 5 6 1 7 8 9 L 10 11 2 Check engine oil levels add if necessary Check diesel fuel tank fill if necessary Visually inspect all fan belts Activate mechanical shut off device ensure that shut off switch on engine is engaging when manual shut off switch is actuated Visually inspect all electrical lines and visible connections If your unit is NOT explosion proof open the electrical en closure and VISUALLY inspect contacts and connections for signs of corrosion or arcing Do not open explosion proof enclosures NEVER PLACE HANDS INSIDE AN ELECTRICAL ENCLOSURE UNLESS YOU HAVE CON FIRMED THAT THE POWER HAS BEEN DISCONNECTED AND L
97. e placing into service The following guidelines will assist you when leveling your tong i Support the tong by the chain sling Preset the positions of all four chains by rotating the turnbuckles on each chain hanger until the eye bolts are about half way engaged in the turnbuckle The turnbuckles can often be turned by if this is not the case use an adjustable wrench across the flats on the turnbuckle to turn it Rotating the turnbuckles in one direction will cause the two eye bolts to extend away from the centre of the turnbuckle while rotating them in the other direction will cause the eye bolts to retract toward the centre of the turnbuckle ii Place a level axially side to side across the tong ensuring that it is parallel with the surface of the tong Equally rotate the two turnbuckles on one or the other side of the tong until the level indicates the tong is parallel for instance if you decide to adjust the left side hangers to adjust the axial leveling adjust the left side front and rear chains the same amount If there seems to be a large adjustment to make split the adjustment between the two sides make half the adjustment using the two chains on one side and the remaining adjustment using the two chains on the other side If all four chains were pre set there should not be a large adjustment to make iii Place a level lengthwise front to back along the tong ensuring that it is parallel with the surface of the tong I
98. e to the tong When lowering the tong onto the beams ensure that the beams come into flat contact with the bottom of the tong away from bearing caps brake bands or other protrusions on the bottom of the tong Ensure that the tong hanger chains are loose but not dangling into contact with the hangers or top plate of the tong DEPRESSURIZATION PROCEDURE FoR STORAGE 1 Rotate the tong to the open throat position 2 Exercise each hydraulic cylinder several times open the tong and backup doors if equipped retract and extend the remote backing pin ramp if equipped retract and extend the float cylinders Leave all cylinders except for the door cylinders in their fully retracted position The general idea is to have as little of the chrome cylinder rods exposed as possible 3 De energize the power unit 4 Repeatedly actuate the tong motor control valve lever IN BOTH DIRECTIONS to dissipate any residual pressure in the valve and motor 5 Remove the hydraulic SUPPLY line from the equipment 6 Repeatedly actuate the remaining control valve levers IN BOTH DIRECTIONS to dissipate any residual pressure in the remainder of the hydraulic control system 7 Connecta low pressure air supply line 10 PSI or less to the hydraulic supply line and force a small amount of the remaining hydraulic fluid from the valve assembly this will allow for thermal expansion of the hydraulic fluid if the equipment is stored or transported in high ambient te
99. emoved existing graphics inserted Motor Options graphics amp 5 5 22 5 23 Updated Brake Band graphics amp BOM to reflect current version 5 5 28 5 29 Updated Door Assembly graphics amp BOM to reflect current version 6 All Complete revision of torque measurement section All All Updated manual to conform to current branding standards Jan 2092 1 1 3 Corrected specifications 2 2 12 Added jaw die kits to list of available kits 5 22 Inserted diagrams amp BOM torque gauge mounts VI DRILLING amp SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Tone WARNINGS A LOAD BEARING DEVICE IS A CHAIN SLING RIGID SLING SPREADER BAR ASSEMBLY FRAME OR ANY OTHER DEVICE THAT BEARS THE PARTIAL OR TOTAL WEIGHT OF THE EQUIPMENT FOR WHICH THIS MANUAL HAS BEEN PRODUCED THE LOAD BEARING DEVICE SUPPLIED BY MCCOY DRILLING amp COMPLETIONS IS DESIGNED TO SUP PORT THE EQUIPMENT DESCRIBED IN THIS MANUAL MCCOY DRILLING amp COMPLETIONS WILL NOT GUARANTEE THE ABILITY OF THE LOAD BEARING DEVICE TO SUPPORT ANY OTHER PART ASSEM BLY OR COMBINATION OF PARTS AND ASSEMBLIES MCCOY DRILLING amp COMPLETIONS WILL NOT GUARANTEE THE ABILITY OF THE LOAD BEARING DEVICE TO LIFT OR SUPPORT THE EQUIPMENT DESCRIBED IN THIS MANUAL IF THERE ARE ANY MODIFICATIONS TO THE LOAD BEARING DEVICE OR ANY ADDITIONS TO THE EQUIPMENT DESCRIBED IN THIS MANUAL THAT ADD WEIGHT TO TH
100. engine and allow it to idle until warm Allow hydraulic fluid to circulate for approxi mately 10 minutes then slowly close the Bypass Valve to allow hydraulic fluid to circulate through the hoses and to the tong circulating pressure should not exceed 200 psi Place the tong gear shifter in low gear and rotate the tong slowly forward and then reverse with the throttle valve control lever Once this has been done and the proper size jaws have been installed the tong is then ready to run pipe 2 VALVE OPERATION 4 way proportional valves control operation of hydraulic devices on the tong assembly such as hydraulic motors and cylinders When any one valve is centered or in the detent position there is no hydraulic output from the valve When the valve is pushed forward there is an effect and when the valve is pulled back there is an opposite effect These valves feature proportional con trol which means that further extension of the valve handle thereby further opening the valve orifice results in proportionally higher hydraulic output to the controlled device The following illustrations demonstrate the type and effect of the hydraulic valves with which this tong is may be equipped DRILLING amp 2 16 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION KT20000 20 50K Tonc MOTOR This is a proportional valve Pushing the valve handle forward will cause the
101. er to the power unit technical manual for startup procedures Listen to power unit for a moment to see if there are any unusual mechanical sounds rubbing grinding excessive pump noise If using a diesel unit allow sufficient time for the engine to reach operating temperature before increasing engine RPM Once engine is warm gradually increase engine RPM until operating speed is reached 1 6 Ensure that supply pressure is at or above the tong s specified operating pressure and that the return pressure is less 2 than 350 psi 1 f Perform a visual inspection of pressurized hydraulic lines Document and correct any hydraulic fluid leaks 1 8 Perform a full functional test of the tong Report and correct any hydraulic leaks from the hydraulic valve bank or from z any hydraulic cylinders that are used Perform a visual inspection of the load cell If using a tension load cell replace any cracked broken or distorted com 19 ponents including links and chains If using a compression load cell replace component that has been crushed otherwise distorted through compression 2 0 If applicable inspect the load cell anchor pins tension load cell only Replace the anchor pins if cracking or metal 5 distortion is seen If applicable the weld securing the single load cell anchor to the bridge bar main plate must be inspected compression 21 load cell only If the integrity of the weld has been compromised the ton
102. evention or environ mental protection DRILLING amp X SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD INTRODUCTION 20000 20 50K Congratulations on the purchase of your FARR 20000 20 tong This unit will provide you with years of outstanding performance Simple maintenance and care will extend its life and ensure years of excellent performance and reliability The setup operating and main tenance instructions in this manual will assist you in giving your equipment the care it requires Please carefully read the manual before installing and using your equipment Replacement parts are readily available from McCoy Drilling amp Completions Farr in Edmonton Alberta Note that many parts are transferable between FARR tongs and backups Should you need replacement parts or should you experience any difficulty not covered in this manual please contact McCoy Drilling amp Completions Farr 14755 121A Avenue Edmonton Alberta Canada T5L 2 2 Phone 780 453 3277 Fax 780 455 2432 Sales Fax 780 481 9246 Email Engineering engFarr mccoyglobal com Email Sales salesFarr mccoyglobal com Website http www mccoyglobal com index php arilling completions ILLUSTRATION 1 4 1 20000 DRILLING amp TECHNICAL MANUAL 1 1 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K SPECIFICATIONS 80 25
103. f the tong needs to be leveled front to rear adjust both chains equally either both rear chains or both front chains The leveling process may have to be repeated in order to optimize the adjustment of the hanger chains and ensure the tong is level ILLUSTRATION 2 F 3 LEVELING TONG UsinG TURNBUCKLES DRILLING amp AACCCOY MANUAL 2 15 MOVING GLOBAL ENERGY FORWARD 20000 20 50K SETUP amp OPERATION G TONG OPERATION 1 Initial Start up and Break in Procedure YOUR EQUIPMENT HAS BEEN THOROUGHLY TESTED AND INSPECTED AT THE FACTORY HOWEVER WE ADVISE INSPECTION AND TESTING OF YOUR NEW TONG AFTER TAKING POSSESSION IN ORDER TO ELIMINATE THE POSSIBILITY OF SHIPPING DAMAGE McCoy Completions amp Drilling recommends that the following pre operating tests be performed after receipt from the factory or after extended storage prior to releasing the tong to operations Perform a complete inspection of all fasteners to ensure none have loosened during transport Connect the tong to the power unit and apply full hydraulic pressure Inspect and correct any leaks Operate the tong at full speed and in high gear for a duration of one half hour Hot bearing caps may indicate impending bear ing failure Switch to low gear and operate for an additional one half hour at full speed Run the backup through several clamp un clamp sequences to ensure functionality Inspect all c
104. fied maintenance personnel Wear approved eye wear and footwear and follow all of your company s safety guidelines Do not begin a maintenance task without the proper tools or materials on hand or the proper drawings and documentation necessary Schedule planned maintenance with operators to avoid conflicts unnecessary downtime and the danger of accidental equipment activation Notify operations when maintenance procedures are complete and equipment functionality is restored Isolate the location of the maintenance under way to prevent unaware personnel from inadvertently exposing themselves to a hazard Use tape rope or signage to clearly indicate off limits area Replacement of large heavy individual parts and or heavy structural components must be performed using an approved lifting device of sufficient lifting capacity Use care when attaching the lifting device and safeguard area to avoid endangering personnel or equipment All spare parts must meet or exceed OEM specifications in order to maintain equipment integrity especially protective equipment McCoy Drilling amp Completions recommends that disconnection of hydraulic connectors be performed with the power unit off and the hydraulic circuit depressurized Your equipment uses materials that may be harmful to the environment if improperly disposed of hydraulic fluid grease etc Dispose of all materials according to your company s proscribed environmental protection regul
105. fmm 3 Wah atl pans thoroughly in cleaning and section nr dees seraiches peuges arewcessive wear how 4 before pesssembiy Pre special xo bre e eit He cio Minor aient number and betters marked un ifie purs rm the poi armed check poppe cam be in 1 Lamy marks are removal duning re paid away witha very ne ene iat ik 1 Examine machined surfaces ef ihe valve bonang far 4 adhesive from threads of spool prius bolt and birre that could leakage berwarn screws mat Chime Lighily sborie these surfaces iv remove uny Gaber Remover CAUTION shallew millied aren extends across the O ring ol the valva housing This should rat be stoned or ground off DRILLING amp AACCODY TECHNICAL MANUAL 7 35 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K VALVE INFORMATION Valve Assembly Instructions T Preparation of Parts CAUTION Failure to follow the Spray te of he ne Fig 2 bem 41 recommended assembly instructions urpped diresdind apod end all screws and screw baies on can result poor performance or bod ends of tbe ating wb LOCQUIC Prater Dirade product malfunctian Pr
106. fted off providing access to the inside of the gear case Use this opportunity to inspect the cam follower array mounted on the top plate replace damaged cam followers Assembly of Farr Hydraulic Power Tongs is simple and can be accomplished without the use of special tools The instructions on this page are presented as a guide only and are similar to the assembly sequence our technician would use while assembling TIGHTENING TORQUE GUIDE SAE GRADE 8 FINE THREAD SIZE CLAMP LOAD PLAIN PLATED 1 4 28 250 3 263 14 ft Ibs 10 ft Ibs 5 16 24 3125 5 113 27 ft Ibs 20 ft Ibs 3 8 24 375 7 875 49 ft 16 37 ft 16 7 16 20 4375 10 650 78 ft Ibs 58 ft Ibs 1 2 20 500 14 400 120 ft Ibs 90 ft Ibs 9 16 18 5625 18 300 172 ft Ibs 129 ft Ibs 5 8 18 625 23 025 240 ft Ibs 180 ft Ibs 3 4 16 750 33 600 420 ft Ibs 315 ft Ibs 7 8 14 875 45 825 668 ft Ibs 501 ft Ibs 1 12 1 000 59 700 995 ft 16 746 ft 158 1 14 1 000 61 125 1019 ft Ibs 764 ft Ibs 1 1 8 12 1 125 77 025 1444 ft 16 1083 ft Ibs 1 1 4 12 1 125 96 600 2012 ft Ibs 1509 ft Ibs 1 3 8 12 1 375 118 350 2712 ft 16 2034 ft Ibs 1 1 2 12 1 500 142 275 3557 ft Ibs 2668 ft Ibs SAE GRADE 8 COARSE THREAD SIZE CLAMP LOAD PLAIN PLATED 1 4 20 250 2 850 12 ft Ibs 9 f
107. g must be removed from service until the weld is repaired The load cell beam will need to be disconnected and removed so the weld is visible Before re installing the beam liberally grease the anchor pin before reinserting into the load cell beam Test safety door feature if equipped Open the tong door s and attempt to rotate the cage plate at low speed low 2 2 gear in both directions makeup breakout If cage plate begins rotating the safety door mechanism is not func tional and the tong must be removed from service until the safety door mechanism can be repaired If the safety door is operating correctly cage plate rotation will not be inhibited once the door is closed and latched NEVER OPERATE YOUR EQUIPMENT WITH A BYPASSED OR MALFUNCTIONING SAFETY DOOR While rotating the cage plate ensure that the jaws properly cam If the jaws do not cam properly the brake bands 23 need to be tightened Incrementally adjust both the top and bottom brake bands EQUALLY until proper cam action is achieved see section 3 E 1 DRILLING amp AACCCOY TECHNICAL MANUAL 3 23 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Tonc MAINTENANCE J MONTHLY MAINTENANCE CHECKLIST POWER TONG The following maintenance checklist is intended as a guideline rather than a definitive maintenance schedule Your equipment may require more or less maintenance depending upon the frequency of use the percentage of maximum
108. g used SOLUTION Ensure dies loaded in the jaws are appropriate for the type of pipe or casing being run 4 POSSIBLE PROBLEM Brake band s is are insufficiently adjusted not allowing jaws to cam properly SOLUTION Adjust brake bands to give proper resistance to cage plates 5 POSSIBLE PROBLEM Jaw roller broken or worn SOLUTION Remove jaw assembly and inspect Replace rollers that are visibly flat spotted or otherwise damaged DRILLING amp AACCCOY MANUAL 43 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Tonc TROUBLESHOOTING C TONG RUNNING TOO SLOWLY POSSIBLE PROBLEM Obstruction in tong hydraulic circuit preventing adequate flow SOLUTION Inspect self sealing couplings to ensure they are properly engaged SOLUTION The main hydraulic lines supply and discharge to the tong are obstructed Remove and clean if required POSSIBLE PROBLEM Power unit is not producing adequate flow or pressure SOLUTION Troubleshoot power unit see user s manual for your particular unit POSSIBLE PROBLEM Tong motor is excessively worn and is leaking hydraulic fluid past the vanes SOLUTION Replace motor or rebuild as per Section 7 of this manual POSSIBLE PROBLEM Bearings in gear train and rotary section are excessively worn SOLUTION Overhaul tong See Section 3 of this manual for tong overhaul procedures POSSIBLE PROBLEM Shifter has malfunctioned and the tong is not shifting to high gear
109. group on a clean surface for disassembly and inspection 2 Remove dowel pins and o rings from the housing NOTE DOUBLE STACK When disassembling a double stack the rotating group next to the rear housing has the center plate attached Remove this rotating group first then carefully remove front group 1 Place cartridge on any object which will hold it off the table 2 Remove two each 10 32 plate screws 3 Remove timing plate Using a small screwdriver or pick remove o ring and all rotor and stator springs Note Some series rotating groups may contain additional wave RR in the stator vane slot see inset 1 Replace plate on rotor stator cartridge 2 Turn rotor stator cartridge over 3 Repeat steps 11 amp 12 1 Remove the rotor 2 Remove both the rotor and the stator vanes NOTE On motors manufactured prior to 1987 rotor vane slots and rotor vanes should be numbered 50 that vanes can be reassembled in the same vane slot 3 Separate parts and rinse in solvent tank Inspect all parts and replace any parts which obviously show excessive wear or damage We recommend changing all springs and seals whenever the motor has been disassembled VANES Normal wear results in slight flattening of vane tips which does not impair motor performance Replace vane if radius is reduced by 50 Clearance between the rotor vane and rotor vane slot varies with the vane selection Th
110. h clutch gear or the low clutch gear may not be exactly aligned when shifting so the operator may need to bump the motor control handle slightly to turn the main clutch gear shaft and shifting collar into alignment This is most effective when applying a small amount of pressure on the gear shift lever in the direction you want to shift the tong ensuring the shifting collar will catch when the main clutch gear aligns with either the high or low clutch gear see Illustration 2 G 3 SHIFTING TONG WHILE ROTATING THE MOTOR AND CAGE PLATE MAY RESULT IN CATASTROPHIC GEAR TRAIN FAILURE ILLUSTRATION 2 G 3 SHIFTING GEARS GENERAL COMMENTS a Position rotary gear in contact with both idler gears when breaking out joints or collars where high torques are required b When making up integral shouldered joints it is essential to make up the last turn of the threads in low gear This reduces the tendency of an instant stop or a sudden increase in torque which induces extremely high stresses on the gear train DO employ the snap break method of breaking out joints when pulling a string By definition the snap break method is a procedure used by some operators to break out connections accomplished by leaving slack in the jaw pipe engagement and then quickly pulling the throttle valve control lever allowing the tong to snap into its loaded or high torque condition Although this method is very effective in breaking out joints the
111. inion Idler Bearings Apply grease to these bearings through the grease fittings in the ends of the idler half shafts located on the bottom face of the tong 2 locations total ILLUSTRATION 3 0 5 Pinion IDLER LUBRICATION 5 Pinion Bearings Apply grease to these bearings through the grease fittings in the pinion bearing caps which are located on the top face of the tong under the hydraulics and on the bottom face of the tong between the pinion idlers four locations total ILLUSTRATION 3 D 6 Pinion LUBRICATION 34 MANUAL COY MOVING GLOBAL ENERGY FORWARD MAINTENANCE 20000 20 50K Tonc 6 Clutch Shaft Apply grease to these bearings through the grease fittings in the clutch bearing cap which is located at the bottom face of the tong Do not neglect to apply grease to the middle fitting which is inset in the bearing cap ILLUSTRATION 3 0 7 CLUTCH SHAFT LUBRICATION 7 Shifting Shaft Apply grease to the shifting shaft and shifting shaft bushings which may be accessed through the cover plate on the side of the tong Access shifter shaft and bushings through this panel ILLUSTRATION 3 0 8 SHIFTER COMPONENT LUBRICATION ACCESS COY TECHNICAL MANUAL 3 5 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K MAINTENANCE 8 Jaw Rollers Apply grease to the jaw rollers through the grease fitting at the end of the jaw roller pin ILLUSTRATION 3 0 9
112. ion n Push the rotation control handle all the way in to complete the connection at low speed high torque Observe the torque gauge when the specified make up torque is reached stop rotation Reverse the rotation control valve to release the tong jaws from the tubing see Illustration 2 H 6 fS L J 1 ILLUSTRATION 2 6 Motor RELEASING JAWS 2 22 Section CONTENTS TECHNICAL MANUAL vibe eee SETUP amp OPERATION KT20000 20 50K Tonc Making A Connection Continued When tong jaws are free align the opening in the rotary gear with the mouth of the tong and open the tong doors to free the tong from the drill string Note that rig personnel may be required to stabilize the tong as it completely releases from the drill string Guide the tong away from the string and use the lift cylinder control to lower it to the drill floor if desired ILLUSTRATION 2 7 CYLINDER CONTROL LOWER Repeat steps through o until the desired number of connections are made up DRILLING amp AACCODY TECHNICAL MANUAL 2 23 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Tonc SETUP amp OPERATION 2 Breaking A Connection YOUR TONG SHOULD BE PROPERLY SUSPENDED CONNECTED TO A HYDRAULIC POWER SOURCE AND READY TO BREAK CONNECTIONS a Ensure hydraulic power supply to the tong and backup is energized The master link on the rigi
113. is guide should be referred to our engineering department for their evaluation and recommendations A TONG WILL NOT DEVELOP SUFFICIENT TORQUE 10 Malfunctioning relief valve on tong hydraulic circuit a POSSIBLE PROBLEM Relief pressure set too low SOLUTION Increase setting To check block the oil line beyond the relief valve and determine pressure with a gauge b POSSIBLE PROBLEM Relief valve is stuck SOLUTION Check for contamination of oil that may inhibit the way the valve actuates Remove valve and clean ensuring that the valve spring operates smoothly c POSSIBLE PROBLEM Relief valve is leaking SOLUTION Check valve seat for scouring Check oil seals Check for particles stuck under the valve system POSSIBLE PROBLEM Directional valve is leaking SOLUTION Check directional valve Neutral position should return fluid directly to the reservoir Replace or repair valve to ensure correct operation POSSIBLE PROBLEM Power unit is not producing adequate pressure SOLUTION Troubleshoot power unit see user s manual for your particular unit POSSIBLE PROBLEM Poor hyaraulic pressure at the tong despite adequate pressure at the power unit or excessive back pressure in the return line SOLUTION Restrictions exist in line between power unit and tong Inspect integrity of self sealing couplings to ensure they are allowing full fluid flow Check to ensure no other restrictions exist contaminated catch screens or filter
114. isplacement Hydraulic Motor CCOY DRILLING amp COMPLETIONS TECHNICAL MANUAL 73 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Tone CONTENTS Page 1 General 2 2 Functional Symbols 2 3 Model Code 3 4 Performance Data Motor data 211 4 Rating definitions 4 Output torques Bearing life 5 HvoRAuLIC Motor INFORMATION STAFFA 1 GENERAL DESCRIPTION The 080 fixed displacement motor is one of 12 frame sizes in the Kawasaki Staffa range of high torque low speed radial piston motors which extends from 94 to 6800 cm r 5 76 to 415 in3 r capacity The rugged well proven design incorporates hydrostatic balancing techniques to achieve high efficiency combined with good breakout Volumetric efficiency 6 torque and smooth running capability 5 Circuit and Application Notes Starting torques 6 Various features and options are Low speed operation available including on request High back pressure mountings to match competitor Boost pressure interfaces Cooling flow Motor casing pressure 7 The 080 is capable of torque 6 Hydraulic Fluids 2 7 Ou
115. l mount model projection See additional views for shaft types and for types S03 and S04 port connection See drawing of dual mount model for details of types F2 and FM2 port connection 253 0 590 9 96 2 35 43 0 87 0 Tu i a 3 43 3 drain ports 3 4 16 UNF 2B 46 5 174 0 6 84 He 21 0 0 82 two normally plugged 1 83 Pipe fitting must not enter port more than 12 0 5 8 holes see table 2 below for thread sizes i 4 Spigot 0 301 57 301 50 11 873 0 254 0 11 870 dia 10 0 4 i 10 181 0 370 777 7 125 dia 1 46 0 368 0 14 5 11 4 code 61 LE OP SAE ports 0 497 0 19 56 dia Flow directions for shaft Mounting rotation shown face Pressure gauge Reverse flow directions for S 1 100 0 connection opposite rotation 3 94 7 5 holes 20 0 0 79 dia into each main port of ras equi spaced as shown on supplied plugged see 327 03 12 875 table 343 0 13 5 See Shaft types spotfaced to 0 38 0 1 5 dia on pages 10 and 11 Port flange bolt tappings Model Tapping size Gauge connections code F3 7 16 14 UNC 2B x 27 0 1 06 full thread depth 9 16 18 UNF 2B SAE J475 FM3 M12 x P1 75 x 27 0 1 06 full thread depth 61 4 BSPF 90 5 0 006 DRILLING amp 7 10 SECTION
116. lets 5 RUN nane 900 2000 pei 1500 pie 08 53 geen 2 Main pressure mme 20012500 pet Fairy se pal 50 gom vani DRILLING amp AACCODY TECHNICAL MANUAL 7 7 MOVING GLOBAL ENERGY FORWARD HvoRAULIC VALVE INFORMATION KT20000 20 50 Lo Boy Work Sections Parallel Circuits Tr MOVING GLOBAL ENERGY FORWARD SECTION CONTENTS TEcHNICAL MANUAL 7 28 HypRAULIC VALVE INFORMATION KT20000 20 50K m Brief Circuit Descriptions Series DA AU only menna eror i mph unguem deri ns ooetaton Win pim Fran ue wp doe nue Pagi Pr ppn Gente wien apo Gre ini Tru bs Vi sacle Dicas leui Ircem ihe garin oe Cc unione nnt Pu Burg Wes Ps Te m i fires bom ie bak api canas Dianin senor ran be arijas
117. lines on the motor shaft are properly aligned with the grooves in the clutch shaft Secure with five 3 4 NC x 2 1 2 hex bolts and 3 4 lock washers Guide the shifting shaft PN 1037 C 20A through the top shifter bushing and secure to shifting fork weldment using two 7 8 UNF hex jam nuts Once the shifting fork has been secured place the bottom of the shifting shaft into the lower shifting bushing Attach the toe of the shifting handle weldment PN 1037 D 20B to the shift pivot lug weldment using a 5 16 x 1 1 2 clevis pin and secure the clevis pin with a small hitch pin Bolt the shifter lug weldment PN 101 0016 to the top plate next to the top shifter bushing using four 3 8 UNC x 1 hex bolts and 3 8 DRILLING amp AACCODY TECHNICAL MANUAL 3 17 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K MAINTENANCE Assembly Procedures Cont d 33 Connect the shifting handle weldment to the shifting shaft using two shifting links PN 02 0120 and two 5 16 x 1 1 2 clevis pins Secure the clevis pins with small hitch pins 34 Insert the shifter detent ball PN 02 0018 into the detent tube on the top shifter bushing Insert the shifter detent spring PN 997 0 64 into the detent tube Thread a 7 16 UNF jam nut on to the 7 16 UNF x 1 1 4 hex bolt and then thread the bolt into the end of the detent tube Lock the bolt to the detent tube with the hex nut See Section 3 E 4 for information about adjusting the
118. lity of the customer DRILLING amp AACCCOY TECHNICAL MANUAL 2 13 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K SETUP amp OPERATION Suspension amp Restraint Cont d Snub lines must be securely connected to the rear of the tong and tied off to a suitable anchor One snub line must be secured to the load cell which is then secured to the rear of the tong The side of the tong the load cell connects to is dependant upon whether make up or break out activities are underway To ensure accurate torque measurement the torque measurement line must be connected perpendicular to the lengthwise axis of the tong and perpendicular to the hang line see illustrations 2 F 1 and 2 F 2 Connect the second snub line on the opposite side of the load cell perpendicular to the lengthwise axis of the tong and perpendicular to the vertical MCCOY DRILLING amp COMPLETIONS ACCEPTS NO RESPONSIBILITY FOR DESIGNING AND SELECTING AN ADEQUATE SUSPENSION AND RESTRAINT SYSTEM FOR YOUR DRILLING EQUIPMENT ALL SELECTED FASTENERS SHACKLES CLAMPS ETC USED FOR CONSTRUCTING THE SUS PENSION AND SNUB LINES MUST BE RATED FOR THE CALCULATED FORCES ILLUSTRATION 2 F 2 SUSPENSION RELATIVE To VERTICAL CENTRE NALCO Y 2 14 Section CONTENTS TECHNICAL MANUAL eei SETUP amp OPERATION KT20000 20 50K Tonc 2 Tong Leveling The tong must be leveled side to side and front to rear befor
119. m plate as shown in the illustration Secure each with 7 8 lockwasher and 7 8 UNF jam nut ILLUSTRATION 3 H 1 Cam FOLLOWER INSTALLATION Bottom PLATE 3 Insert support roller inner spacer PN 1037 C 134 into each support dumbbell roller Press two support roller bearings PN 02 0094 into each end of each support roller 16 assemblies total Once the assembly of the support rollers is complete tem porarily slide the support roller shafts into each assembly for assistance in correctly positioning each support roller NOTE do not include the two door pivot rollers in this step only perform this action with the fourteen body rollers 4 Place rotary gear on bottom plate over the cam followers installed in Step 2 Note that the backing pin grooves are in the top side of the rotary gear 5 Rotate the rotary gear so that the opening in the gear faces the first three support roller positions closest to the mouth of the tong do not include door pivot rollers at this point Install three support roller assemblies including shafts but not including fasteners in the locations exposed in the rotary gear opening Continue to rotate rotary gear around the tong installing the support roller assemblies as the gear is rotated Finish with the rotary gear aligned with the opening in the bottom plate DRILLING amp AACCODY comprenons TECHNICAL MANUAL 3 13 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K MAINTENAN
120. mage or defects are found at either inspection the damaged or defective component shall be quarantined from service until it can be properly repaired or replaced Removal Criteria A load bearing device shall be removed from service if conditions such as the following are present Missing or illegible sling identification Cracks or breaks Evidence of tampering is seen sling tag has been modified or obscured or tamper proof nuts are missing Signs of impact on load bearing components including spreader bars lifting lugs rigid slings amp rigid sling weldments and legs amp leg mounts Broken or damaged welds Excessive wear nicks or gouges Refer to the chart below to ensure minimum thickness on chain links supplied is not be below the values listed Minimum Allowable Chain Link Thickness at Any Point Nominal Chain Size Minimum Thickness Inches 0 189 0 239 0 273 Refer ASME B30 9 4 80 6 07 6 93 8 69 11 26 13 87 17 45 19 05 22 53 27 71 Stretched bent twisted or deformed chain links or components Evidence of heat damage Excessive pitting or corrosion Lack of ability of chain or components to hinge articulate freely Weld splatter For hooks removal criteria as stated in ASME B30 10 Other conditions including visible damage that cause doubt as to the continued use of the sling Inspect all lugs and fixing points for signs of elongation an
121. manufaeturer s turing Full Lightly enar the cengerins wiih highs emperane t t grex preven rusting Sei spool asdi 2 parts opera Let d cure Fon ac tem enum ns 1 affer cuni beat ihe atop per bo m ke cum 12 in Wa al hreakaway torque DRILLING amp 7 36 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD HvoRAULIC VALVE INFORMATION KT20000 20 50K Valve Assembly Instructions Detent Spool Assembly Step 1 Spocl 4ssembly Detant App Parker Super 2 1 so the spool sgal Fig 1 B asd lile d endis Slike fing Fio 1 iem T and ame plane Fig d iem Cm E LLLI pa odii de pana that they irserfere mih the cperatur Dici iei aliave im contest wall the sharp edpe of the neh Apaly 2 2 inopes Lemie 262 or an equivalent near the mio ddl of he female thrends on che CADTIOS Fallow the adhesive manufsecturer s instructions fur proper cleaning and erring Failure ta clean prepare parts pruperiv im assembly Failure Step 2 Spool Assembly Detent he hail netemer Pay 2
122. meatr m lec work seerorns and the VA GSS sr Fiere mid altis hare seciion ils an the d i pitam Saee Pig be 1 Those calis berernosed acd discal REMINDER ALL WORK MUST BE PERFORMED IN CLEAN AREA DRILLING amp AACCODY TECHNICAL MANUAL 7 33 MOVING GLOBAL ENERGY FORWARD 20000 20 50K VALVE INFORMATION Valve Disassembly Instructions 9 Step 4 Valve Back Cap lhirgr a large Phallips bead perewiriver remire sacer Prs 1 eri 41 ieh fastem tis los eap ihe work inp ine end of the handle wth a 5armmmer t Arak adhesive Remove Te back 1 55 Step 5 Control Spool and Seals mie spem gcn of tie pool ath a Hart fre elei amid pall the inel of te Roaring using d vu iin Generally ie remar plai Fi 1 abe Bakap 1 TI Fig 1 wall anne woth spend CAUTION For detented pool models be careful nol to remove he detent pappet sleeve Fig 2 hem 17 it is ta be serviced Using lane Phillspeshead remave the teg apewe Pg 7 serm 9h fro deny eril af the wes secun Lighily mp the ene al ihe screw iriver vols mumamer 10 break the Idhesi
123. mount of hydraulic oil onto rotor surface 2 NOTE Make sure that the radiused edge of each stator vane points to the rotor and the radiused A e of each rotor vane points to the stator 3 NOTE Make sure springs are seated in the bottom of the spring ocket in both the rotor and stator STE Do not allow the coil SEA spring catch on the edge ofthe rotor or stator vanes Wave springs in the 125 series do not need to be replaced Certain model codes do not contain wave springs while other model codes may contain two per vane Place the stator vane and wave spring in the stator vane slot simultaneously Note orientation as shown Do not let the coil spring loop catch between the wave spring and vane Using a medium India honing stone lightly dress all machine surfaces to remove any raised metal or burrs RS particular attention to the front and rear housing machined faces Rough handling can cause raised surfaces near the O D of the housings which will prevent proper seating of the timing plates to the machined surfaces of the housing NOTE The pedestal surface center ofthe front and rearhousing containing two or three o rings is 002 003 belowthe outer machined surface Dress these surfaces independently Assemble the motor by reversing the previous procedures Insure that the main body and pedestal o measurement when rings are held in place by using an ordering rotor stator or adequate amount of gre
124. mperatures Failure to do this may result in damaged or destroyed seals in the equipment 8 Disconnect the hydraulic RETURN line from the equipment 9 Disconnect remaining hoses such as case drains or lines connected to the turns counter 1 8 If any hydraulic fittings or hoses leaking they must be repaired or replaced before proceeding Wipe all excess grease from outside of equipment Replace the access door panel Use a solvent based cleaner on 19 rags to wipe all external surfaces to remove residual grease or hydraulic fluid Once the outside surfaces have been de greased wipe all external surfaces with clean water to remove residual solvent 2 0 Farr recommends that chain slings be removed and stored separately Rigid slings and other rigid suspension devices 2 1 Apply grease or heavy oil to all exposed cylinder rods 2 2 C Farr recommends that an anti corrosive agent such as Tectyl 506 be applied to all external surfaces EXCEPT cylinder rods including chain slings Refer to manufacturer data sheets for proper application and safety information DO NOT ALLOW ANTI CORROSIVE AGENTS TO CONTACT CYLINDER RODS CYLINDER ROD DAMAGE WILL OCCUR 2 3 Allow the anti corrosive coating ample time to dry refer to manufacturer data sheets for drying times at room tempera 5 ture 2 4 Wrap entire assembly in 100 gauge 1 mil corrosion inhibiting wrap at least 3 layers
125. nder control valve to lift the assembly from the drill floor Pushing the valve toward the center of the tong will retract the lift cylinder to lift the assembly see Illustration 2 H 3 below Note that rig personnel are required to stabilize the tong and backup as it is being lifted so it does not swing and collide with other rig equipment RIG PERSONNEL MUST STABILIZE THE TONG AS IT IS LIFTED FROM THE DRILL FLOOR pm IN ILLUSTRATION 2 3 Lirr CYLINDER CONTROL RAISE DRILLING amp 2 20 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION KT20000 20 50K Tonc Making A Connection Continued Grasp the tong door latch and pull to open the door on the left side as seen from the front of the tong After the latch side door is open grasp the handle on the second door and swing open Since your equipment is equipped with safety doors opening the door will inhibit rotation of the cage plate OPEN THIS SIDE SECOND OPEN THIS SIDE FIRST ILLUSTRATION 2 H 4 OPENING Doors f Manually engage the threads of the tubing connection being made up Ensure threads are not cross threaded g Move the tong on to the tubing joint Use the lift cylinder to ensure the tong jaws are at the correct location above the con nection joint h Firmly close the tong door on the right side as seen from the front of the tong followed by the latched d
126. ne duty 2 Side load and no axial thrust cycle To determine 110 life predictions per ISO SHAFT STRESS LIMIT 281 1 1977 multiply the median figure by 0 2 The shaft stress limit in the nomograph is based on the fatigue rating of shaft 080 types 5 and H P Infrequent Example 1 follow chain dotted line bei limits d be Side load W a 0 permitted consult Kawasaki System pressure P b 207 bar 3000 psi Speed N 300 r min Median bearing life d 23 000 hrs 110 bearing rating median x 0 2 4600 hrs Example 2 follow chain dotted line Side load W Load offset A from motor mounting face System pressure P e 40 kN 9000 Ibf f 50 mm 2 0 in 0 207 bar 3000 psi Speed N h 25 r min Median bearing life i 62 000 hrs 110 bearing rating median 0 2 12 400 hrs DRILLING amp COMPLETIONS MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL SECTION CONTENTS 7 7 20000 20 50K Tone VOLUMETRIC EFFICIENCY HypRAuLic MOTOR INFORMATION STAFFA Shaft speed r min 100 10 25 50 300 Viscosity cSt SUS The shaft creep speed occurs when the load attempts to rotate the motor against closed ports as may occur for example in winch applications 5 CIRCUIT AND APPLICATION NOTES STARTING TORQUES The starting torques shown on the graph on page 4 are average and will va
127. ne or the other will render the calibration inaccurate even if the actual model numbers appear to be identical The serial numbers of matching load cell and torque gauges are clearly identified on the calibration certificate Should you suspect the accuracy of your torque measurements or wish to replace either component the pair should be returned to the factory for re calibration before placing into service TORQUE GAUGES AND LOAD CELLS ARE FACTORY SUPPLIED SUPPLIED AS MATCHED CALI BRATED PAIRS IF REPLACING EITHER COMPONENT THE LOAD CELL AND TORQUE GAUGE MUST BE RETURNED TO THE FACTORY FOR RE CALIBRATION BEFORE PLACED INTO SERVICE DRILLING amp AACCCOY MANUAL 6 1 MOVING GLOBAL ENERGY FORWARD 20000 20 50K MEASUREMENT BASIC TORQUE MEASUREMENT Continued The images on the preceding page are for illustration purposes only and may not accurately represent the torque gauge and load cell that have been supplied with your equipment Please note that the parts listed in the following table are correct for accurate torque measurement while using the equipment for which this manual is supplied THE TORQUE GAUGE USED IS FULLY DEPENDANT UPON THE ARM LENGTH AND TORQUE RANGE OF THE EQUIPMENT IN USE THE PART NUMBERS LISTED IN THE FOLLOWING TABLE ARE CORRECT FOR ACCURATELY MEASURING TORQUE USING THE EQUIPMENT FOR WHICH THIS MANUAL IS SUPPLIED Item Typ
128. ng Ensure the weight of the lift cylinder is known if it has not been included in the total weight of the tong All forces upon the suspension line must be considered when calculating necessary strength of the suspension line The weight of the tong the weight of the lift cylinder the weight of the spring hanger and the force imparted on the suspension line by the spring hanger must all be added together in order to arrive at the total force supported by the suspension line Select your suspension line based upon the total force and the margins of safety dictated by the policies of your company and by estab lished engineering practices Ultimately calculating the force on the suspension line and selection of the suspension line is the complete responsibility of the customer Farr Canada Corp recommends using dual backup snub lines of sufficient strength to withstand the force imparted by the maximum rated torque of the tong in use Calculate the force on the snub lines by dividing the maximum torque of the tong by the tong s torque arm expressed in feet For example an 50 000 Ibs ft tong with 52 inch 4 333 ft torque arm will generate 11 540 Ibs of force against the snub line Select your snub lines based upon the total force and the margins of safety dictated by the policies of your company and by established engineering practices Ultimately calculating the force on the snub line and selection of the snub line is the complete responsibi
129. ning hoses such as case drains or lines connected to the turns counter HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN SMALL AREAS OF THE EQUIPMENT ENSURE ALL MAINTENANCE IS CARRIED OUT BY QUALIFIED SERVICE TECHNICIAN AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIP MENT IS USED TO GUARD AGAINST PRESSURE INJURIES Clean the exterior of the tool thoroughly using either water if using a pressure washer ensure a low pressure wash wand 3 is used or an appropriate solvent based grease cutting cleaner such as Varsol Ensure adequate containment is in place to prevent environmental contamination from residual hydraulic fluid dirty grease and cleaning agents 4 Remove the access panel on the side of the tong directly adjacent to the shifter mechanism Clean the interior of the tong thoroughly using either water do not use a pressure washer or an appropriate solvent based grease cutting cleaner such as Varsol Ensure adequate containment is in place to prevent environmental con 5 tamination from residual hydraulic fluid dirty grease and cleaning agents Make a note if any metal shavings or metal pieces are flushed out of the gear train cavity if shavings or metal pieces are seen the tong must be overhauled before it is returned to service 6 C Inspect all fasteners and fastener safety wires if equipped Replace any missing fasteners use Grade 8 bolts only un less otherwise specified Re torque all ex
130. nit and perform another generous lubrication of the gear train including the gear housing 2 6 C Energize power unit Rotate tong for one minute stop and reverse the direction of rotation for another minute ending with the opening of the rotary gear facing the gear train 2 f De energize the power unit and perform a third generous lubrication of the gear train including the gear housing DRILLING amp AACCCOY TECHNICAL MANUAL 3 25 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K MAINTENANCE 2 8 C Re energize power unit and extend all hydraulic cylinders Inspect cylinder rods for signs of mechanical damage flak ing or rust Farr recommends that damaged cylinders be replaced 2 9 C Rotate tong in low gear for 5 minutes while monitoring pressurized seals and hydraulic lines If a seal line or fitting begins to leak while tong is rotating it must be replaced before the equipment is returned to service Rotate tong in high gear for 5 minutes while monitoring temperature of top and bottom bearing caps If the bearing caps 30 are hot to the touch higher than approximately 50 replace the applicable bearings Likewise if the tong is making unusual noises check for damaged bearings see Maintenance Manual for all bearing locations Install load cell If using a tension load cell perform a visual inspection and replace any cracked broken or distorted 3 1 components including
131. ns with the other at the point at which they meet If misalignment is seen choose one or the other door to adjust Use a box end wrench to loosen the lock nuts on the insides of the door weldment the nuts may be accessed from the side of the door weldment Use a hex key to turn the hex head set screws either clockwise or counter clockwise to adjust the door Note that the top and bottom of the door weldment may not need to be adjusted equally each set screw should be adjusted independently until the doors are aligned Final Alignment Rotate the cage plate and stop it when the inside circumference of the door is completely covered Perform three measurements see illustration below 1 From the insides of the outer edge of each door weldment to the cage plate 2 measurements total 2 From the exact centre point where the two doors meet to the cage plate DRILLING amp 3 8 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 20000 20 50K Measurement 2 ILLUSTRATION 3 E 3 Door ALIGNMENT MEASUREMENT PoiNTS The three measurements should be equal If the centre measurement is less than the two outside measurements loosen all four locking nuts on the set screws and turn all four set screws EQUALLY clockwise until the centre measurement is equal to the two outer measurements If the centre measurement is more than the two outside measurements loosen all fou
132. o more air is seen escaping from the vent port g Replace the vent plug screw and Stat O Seal and tighten securely h Remove load cell from containment vessel and wipe clean Reclaim the hyaraulic fluid if it is clean or dispose of all waste materials according to governmental or your company s proscribed environmental protection regulations Disconnect the hand pump from the torque gauge j Replace the brass cap on the torque gauge check valve fitting 3 Repair And Calibration Load cell and indicator gauge should be returned to authorized repair facility for any repairs or calibration required AACCOY 6 6 Section CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD 20000 20 50K AACCQDY MOVING GLOBAL ENERGY FORWARD FARR Section 7 Hydraulic Component Information The manufacturer information contained in this section has been obtained from publicly available web sites and has been provided for information purposes only Farr Canada Corp does not guarantee the accuracy of the infor mation contained in this section original copyrights claimed by the manufacturer s apply DRILLING amp TECHNICAL MANUAL 7 1 MOVING GLOBAL ENERGY FORWARD This page intentionally left blank Motor INFORMATION STAFFA KT20000 20 50K D 54 Kawasaki Motors Corp U S A Precision Machinery Division Staffa Fixed D
133. oduct should Se iniri be thoroughly tested to ensure proper operation before the valve is placed back into service Spring Center Spool Assembly Step 1 Spool Assambly Spring Centered Clamp the clevis ul Uwe amil apesid im eal jawed ve Apply Pauker Super iL jo the seil Fie 4 Siem amp alate b one the of sanal oway Teom Slide am ibe back up ning 1 Wem 7 end netamer plar amp ihes ibere Phe fcd ifo nod merine the spre anem duri Ds allow the C ning pama f cerner full Pe warp od the quae Step 2 Attach Spring Guides and Spring 2 3 deae of MIW iu mura adhesive neni mulie of ihe tere ihe sposa sermo Hir spring guldes i Fig 2 spring Fig 2 ivem 15 and 4 Fig 2 14 cabo spon of Siep Tl peque bo 175 im sex Un CAUTION Care mast taken easure the sprime reraimer is mot plniched smder the aboulder during This cam ruli in beurre Ibat cause binding Check lir binding ln r mpresxinz the spring guidis ar by the spring guide nearest the hutang LAULTIO Fellow the
134. om hyaraulic cylinders that are used Test safety door feature if equipped Begin rotating the tong at low speed and open the tong door s If rotation does 3 7 not immediately stop this is an indication that the safety door mechanism is not operating correctly and the tong must f be removed from service until the mechanism is repaired Repeat the test while operating the tong in the opposite direc tion If the safety door is operating correctly cage plate rotation will not be inhibited once the door is closed and latched NEVER OPERATE YOUR EQUIPMENT WITH A BYPASSED OR MALFUNCTIONING SAFETY DOOR Farr recommends that an anti corrosive agent such as Tectyl amp 506 be applied to all external unpainted surfaces 3 8 and chain slings EXCEPT cylinder rods jaw rollers and rotary gear camming surfaces Refer to manufacturer data sheets for proper application and safety information Once all of the above maintenance checklist items have been satisfactorily completed the tool may be returned to service DRILLING amp 3 26 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 20000 20 50K K DAILY INSPECTION amp MAINTENANCE CHECKLIST POWER UNIT Farr recommends that the following inspections and maintenance procedures be performed before each use and at least once per day when the equipment is in steady use in the sequence in which they ar
135. om l high back pressures reduce the the crankcase leakage figure see To obtain effective torque output of the motor Volumetric Efficiency graph above 4 Volumetric efficiency 91 8 Allowance should be made for other 5 Crankcase leakage 1 9 l min BOOST PRESSURE system losses and also for wear 115 0 in min When operating as a motor the outlet and tear during the life of the motor 6 Shaft creep speed 1 9 r min pressure should equal or exceed the pump and other system components COOLING FLOW Operation within the continuous ratings does not require any additional cooling For operating conditions above continuous up to the intermittent ratings additional cooling oil may be required This can be introduced through the spare crankcase drain hole or in special cases through the valve spool end cap Consult Kawasaki about such applications 7 8 SECTION CONTENTS TECHNICAL MANUAL AACCOY DRILLING amp MOVING GLOBAL ENERGY FORWARD COMPLETIONS HvoRaAuLIc Motor INFORMATION STAFFA MOTOR CASING PRESSURE With the standard shaft seal fitted the motor casing pressure should not exceed 3 5 bar 50 psi On installations with long drain lines a relief valve is recommended to prevent over pressurizing the seal Notes 1 The casing pressure at all times must not exceed either the motor inlet or outlet pressure
136. omponents and hydraulic fittings for possible defects following completion of the tests All FARR Tongs have been thoroughly tested at the factory prior to shipping but shipping damage must be identified before running the tong in an operational environment Carefully inspect the safety door components and test to ensure that the safety device on each door is operating correctly before releasing the tong to the operating environment TONG DOOR MUST BE CLOSED AND SECURELY LATCHED BEFORE THE POWER UNIT IS STARTED IN ORDER TO ASSURE THE SAFETY OF OPERATING PERSONNEL Ensure adequate lube oil and hydraulic oil levels before starting engine Use start up procedures as recommended by the power unit engine operator s manual Open the Bypass Valve on the hydraulic system and inspect all pressure and return line hose connections to ensure correct and secure installation IMPROPERLY SECURED HYDRAULIC CONNECTIONS WILL INTERRUPT HYDRAULIC FLUID FLOW AND COULD RESULT IN THE FOLLOWING FAILURES Arestriction in the pressure supply hose will result in high pressure within the power unit hydraulic system which will activate the hydraulic governor and increase the engine speed to as high as maximum RPM Arestriction in the return line will result in high pressure within the power unit and the tong hydraulic system causing engine speeds as high as maximum RPM and possible failure of the motor seal Following inspection of the hoses start the
137. on of all seals Any seal that is leaking or weeping must be replaced before the equipment is returned to service Rotate low gear for 5 minutes while monitoring pressurized seals hydraulic lines If a seal line or fitting begins to leak while tong is rotating it must be replaced before the equipment is returned to service Finish this step with the rotary gear opening facing the gear train De energize the power unit Inspect all flexible hydraulic lines for signs of wear blistering or any other signs of potential failure replace if signs of potential failure are identified a a N Inspect the gear train housing If the amount of grease is inadequate liberally grease the gear train through the access panel and through the opening in the rotary gear Inspect top and bottom brake band linings replace if necessary Unequal wear of the brake bands indicates that the brake band tension is not evenly adjusted Refer to the maintenance section of the manual for instructions on properly adjusting brake bands Ensure that all grease is wiped from brake band linings and the parts of the cage plates that come into contact with the brake band linings A Re install access panel Install set of pre inspected jaws that are the correct size for the pipe or casing being run Install load cell If using a tension load cell perform a visual inspection and replace any cracked broken or disto
138. ontal plane The Working Load Limit is identified on the sling The Working Load Limit or Design factor may be affected by wear misuse overloading corrosion deformation intentional al terations sharp corner cutting action and other use conditions Shock loading and extraordinary conditions must be taken into account when selecting alloy chain slings See OSHA Regulation for Slings 1910 184 ANSI ASME B30 9 SLINGS ANSI ASME B30 10 HOOKS ANSI AMSE B30 26 RIGGING HARDWARE for additional information THE MINIMUM SLING ANGLE THE ANGLE OF THE LEG OF THE SLING MEASURED FROM THE HORIZONTAL MUST NEVER FALL LOWER THAN THE ANGLE SPECIFIED FOR THE SLING IN USE ILLUSTRATION 2 1 SLING ANGLE DRILLING amp AACCCOY TECHNICAL MANUAL 2 1 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K SETUP amp OPERATION 1 Inspection Of Slings McCoy Completions amp Drilling strongly recommends the following practices A complete inspection of new load bearing devices and attachments shall be performed by a qualified designated person prior to initial use Each link and component shall be examined individually taking care to expose and examine all surfaces including the inner link surface The sling shall be examined for conditions such as those listed in the removal criteria below In addition daily inspection of slings fastenings and attachments shall be performed by a designated person If da
139. oor on the left side as seen from the front Tug firmly on the door handle on the right side as seen from the front to ensure the latch is firmly engaged i Ensure tubing is roughly centered within the tong jaws rig personnel are required to stabilize the tong above the connec tion until the jaws have been cammed on to the pipe or casing j Begin rotation with the tong in high gear high speed low torque See Section to properly set the tong to high gear Do not shift gears while the tong is rotating SHIFTING TONG WHILE ROTATING THE MOTOR AND CAGE PLATE MAY RESULT IN CATASTROPHIC GEAR TRAIN FAILURE DRILLING amp AACCODY TECHNICAL MANUAL 221 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K SETUP amp OPERATION Making A Connection Continued k Push the motor control valve toward the tong to rotate the cage plate in the make up direction 9 E ILLUSTRATION 2 5 MAKE UP 1 When the tong jaws on to the tubing push the rotation control handle all the way in thread the connection together at high speed As the joint becomes fully made up the increasing torque demand will stall the motor and displayed torque will increase m Stop rotation and shift to low gear low speed high torque See Section 2 G 3 for instructions for shifting to low gear This will enable the tong to produce adequate torque for making up the joint to specificat
140. ooves in which the cam followers ride should be lightly greased When the cage plate is rotated as a unit the cam follow ers are exposed and can be greased Continue rotating the cage plate assembly until all cam followers top and bottom are greased see first illustration below otate cage plate assembly until all cam followers are greased ILLUSTRATION 3 0 1 CAGE PLATE CAM FoLLOWER LUBRICATION Rotate the rotary gear into the mouth opening as illustrated below Apply grease to the top and bottom cage plate grooves Continue to rotate the rotary gear and lubricate the grooves until the gear is well lubricated Apply grease to top amp bottom rotary gear grooves tmn LLUSTRATION 3 D 2 RorARY GEAR LUBRICATION DRILLING amp 3 2 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 20000 20 50K 2 Support Roller Bearings Lubricate support roller bearings through the grease fittings in the top ends of the support roller shafts 16 locations total ILLUSTRATION 3 0 3 SUPPORT ROLLER LUBRICATION 3 Rotary Idler Bearings Apply grease to these bearings through the grease fittings in the ends of the rotary idler shafts 2 locations total located on the top face of the tong ILLUSTRATION 3 0 4 Rotary IDLER LUBRICATION COY TECHNICAL MANUAL 33 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Tonc MAINTENANCE 4 P
141. op side of the top plate and secure with 1 4 NC x 1 1 4 hex socket head cap screws and 1 4 high collar lock washers Install ten horizontal cam followers PN 02 0108 in the horizontal cam follower guides and secure each with a 7 16 UNF jam nut and 7 16 lock washer ILLUSTRATION 3 H 5 INSTALLATION OF HorizonTAL CAM FOLLOWERS AND GUIDES 3 16 SECTION CONTENTS TECHNICAL MANUAL COY MOVING GLOBAL ENERGY FORWARD MAINTENANCE 20000 20 50K Tonc Assembly Procedures Cont d 27 28 29 30 31 32 33 Re install the support roller shafts Note that the two top and bottom brake band lug weldments top RH and bottom LH weldments are PN 101 1636 and the top LH and bottom RH weldments are PN 101 1637 are retained by four support roller shafts as shown in illustration below Secure the support roller shafts with 1 UNF thin nylock nuts and 1 narrow flat washers except where noted ASSEMBLY NOTE 1 narrow flat washers are not used where the support roller shafts are coincidental with the brake band lug weldments ILLUSTRATION 3 H 6 SuPPORT RoLLER BRAKE BAND WELDMENT INSTALLATION Install the remaining 1 1 2 UNF nylock nuts and idler pads over the tops of the four idler assemblies Press the remaining bearing in the pinion assembly into the top pinion bearing cap PN 1037 C 10 and install the bearing cap in the top plate of the tong using four 5 8 lock washers and four
142. oss Obstruction in hydraulic hose Check hyaraulic hose for kinks Replace hyaraulic hose Snub line not at right angle to tong handle Check angle of snub line and correct if necessary Internal mechanism of gauge is damaged Replace gauge Incorrect torque gauge in use not part of the original torque gauge load cell pair Replace gauge with gauge properly calibrated for the load cell in service Gauge indication is erratic or sluggish Insufficient hydraulic fluid in torque measurement section Recharge hyaraulic fluid see Section 6 C NOTE Ensure any breaches in the hydraulic system between the load cell and torque gauge are repaired to prevent further fluid loss Loss of damping fluid in torque gauge Top up or refill damping fluid NOTE Ensure leakage points in gauge are identified and repaired to prevent further loss of damping fluid Air bubbles in hydraulic fluid in the torque measurement system Bleed air from load cell and torque gauge and top up fluid if necessary as per Section 6 C Internal mechanism of gauge is damaged Replace gauge AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS TECHNICAL MANUAL Section CONTENTS 6 5 KT20000 20 50K MEASUREMENT 1 C PERIODIC INSPECTION AND MAINTENANCE Inspection The torque measurement system supplied with your equipment is designed and built to provide years of trouble free service with minimum maintenanc
143. otary Idler Shaft 1 1050 D5 117 H Part Cylindrical Roller Bearing 1 02 0011 J Part Rotary Idler Gear 1 1037 D59 DRILLING amp TECHNICAL MANUAL 5 9 MOVING GLOBAL ENERGY FORWARD 20000 20 50 Pinion IDLER ASSEMBLY DRILLING amp 5 10 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD IDLER ASSEMBLY 20000 20 50K Tonc Item Type Description Qty Part Number A Part 1 1 2 UNF Nylock Nut 2 09 5740 B Part Idler Pad 2 997 D20 125 Idler Spacer 2 1050 D5 121 D Part Pinion Idler Shaft 1 1050 D5 117 E Part Retainer Clip 2 02 0009 F Part Bearing Seal 2 02 0010 G Part Cylindrical Roller Bearing 1 02 0011 H Part Grease Fitting 1 02 0005 4 Part Pinion Idler Gear 1 1037 D 1 DRILLING amp AACCODY comprenons TECHNICAL MANUAL 5 11 MOVING GLOBAL ENERGY FORWARD 20000 20 50 A Pinion ASSEMBLY 5 12 CONTENTS TECHNICAL MANUAL NALCO Y MOVING GLOBAL ENERGY FORWARD PiNION ASSEMBLY 20000 20 50K Tonc Item Type Description Qty Part Number A Part 1 8 NPT x 90 Grease Fitting 4 02 0093 B Part 5 8 NC x 1 1 4 Hex Bolts 8 09 1228 C Part 5 8 Lock Washers 8 09 5114 D Part Top Pinion Bearing Cap 1 1037 C
144. otor can accept thrust and radial load per the push pull capacity charts to the right Thrust loading is allowed up to the parameters indicated on the charts with shaft configurations including standard keyed and splined as well as a light duty API drill motor For applications not requiring thrust see the standard motor bearing charts on the opposite page HORSEPOWER LIMITATION Maximum horsepower limitation may vary with different applications When using the 125 Series standard motor above 300HP consult a Rineer Application Engineer S T1 32021X 30218X T1 32021X 30218X 18 000 21 32 DIA THRU 6 PLACES EQ SP ONA 11 75 B C ROTATION The 125 Series motor rotates equally well in either direction and smoothly throughout its entire pressure and speed range Looking into the end of the shaft rotation is clockwise when oil is supplied to the port nearest the shaft CASE DRAIN The 125 Series motor requires an external case drain Two case drain ports are supplied use the port at the highest elevation We recommend case pressure of less than 35 PSI CASE DRAIN CIRCULATION Fluid should be circulated through the two case drain ports when a temperature differential exists between the motor and the system in excess of 50 F Should this occur contact a Rineer Application Engineer
145. pment 8 Disconnect remaining hoses such as case drains or lines connected to the turns counter HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN SMALL AREAS OF THE EQUIPMENT ENSURE ALL MAINTENANCE IS CARRIED OUT BY A QUALIFIED SERVICE TECHNICIAN AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIP MENT IS USED TO GUARD AGAINST PRESSURE INJURIES 1 Perform an initial wash of the tool in order to remove the majority of dirt and grease build up Ensure adequate contain ment is in place to prevent environmental contamination from residual hydraulic fluid and dirty grease 2 Remove the access panel on the side of the tong directly adjacent to the shifter mechanism Clean the interior of the tong thoroughly using either water do not use a pressure washer or an appropriate solvent based grease cutting cleaner such as Varsol Ensure adequate containment is in place to prevent environmental con 3 tamination from residual hydraulic fluid dirty grease and cleaning agents Make a note if any metal shavings or metal pieces are flushed out of the gear train cavity if shavings or metal pieces are seen the tong must be overhauled before it is returned to service Clean the exterior of the tool thoroughly using either water do not use a pressure washer or an appropriate solvent 4 based grease cutting cleaner such as Varsol Ensure adequate containment is place to prevent environmental contami nation from resid
146. pper ball 1 nem 14 with wrench Lightly top Hals wilh a Farmer a punh help break ther adbesive application of heat may Ve requin ie fre die sanc am ihres adhesive was uad dering iis CAUTION Too much heal may distort spool fhe threads dingge he prg i Fig Lim F and smag gusdes Fig 2 item bon wil rile The epeal Dalent Spool The denen acsermbly choald pat he ibe spo ales these penis naal Wrap ibe abere Pig 2 iem 771 wnth a clean lii rec Crip the zlanh cevered skceve and pull firmis rhe deca moves hackwanda the delent balla Fig 2 iiem 18 dieieni Fig 2 ahrupily The cloth belit lese pana prevent Ibeir 1045 Pact Ging hinc ipiri ged Seer and roe the detent popped retainer 2 201 Place ui har ibe doen bull hene girly tap the deteni poppa rebimer with a hammer and a help bezak Ibe elective Csubicuc application af head ary be required sare ene adhesive des alen ixl ii ia rriganzr vermis CAUTION Too much heal may distort the spool CLEANING INSPECTION AND REPAIR 1 che eperal heme tramsibim check sent aml seno
147. que for given pressure differential 207 b 4000 3000 psi 172 b ELLE 2500 psi 8 3000 5 138 b ES 2000 2000 psi 4 103 b 1500 2000 500 psi 10004 69 1000 1000 500 3C 3 Upper limit of continuous rating 0 0 envelope see Rating definitions above 0 50 150 200 250 300 Shaft speed r min AACCCON DRILLING amp 7 6 Section CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD Motor INFORMATION STAFFA KT20000 20 50K BEARING LIFE S 9 e 2 2 2 2 E 9 D s S M GT Dol WS N 012 9 2 h 2 2 92 jJ oet 34 0 k yo yo Lmedian 250 150 75 000 40 20 15 10000 5000 4 3000 200000 100000 50000 30000 7500 kN ed 2000 10 lt Cy 4000 A W A 150 mm 67 Side load din 30 1 o Distance from mounting e face to load centre 8000 e 5 Max pressure 40 port 1 or port 2 10 000 f Shaft speed r min 2 Nb 7 12 000 4 lt 60 nomograph allows the median a For more precise life prediction or bearing life to be determined for where axial thrusts are incurred a conditions of computer analysis can be provided by 1 No side load and no axial thrust Kawasaki on receipt of machi
148. r 1 09 5026 4 1 UNS Thin Nylock Nut 1 09 5627 DRILLING amp TECHNICAL MANUAL 5 5 MOVING GLOBAL ENERGY FORWARD 20000 20 50K Tone Door Pivot RoLLER A 5 6 SECTION CONTENTS TECHNICAL MANUAL AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS Pivor RoLLER 20000 20 50K Item Type Description Qty Part Number A Part 1 4 UNF Straight Grease Fitting 1 02 0097 B Part Support Roller Shaft 1 101 3940 C Part 1 1 8 Flat Washer 1 09 5041 D Part Bearing Spacer 2 101 3871 E Part Support Roller Bearing 2 02 0094 F Part Support Roller Spacer 1 1037 C 134 G Part Support Roller 1 1037 135 H Part 1 Wide Flat Washer 1 09 4 1 UNS Thin Nylock Nut 1 09 5627 DRILLING amp TECHNICAL MANUAL 5 7 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Rotary IpLER ASSEMBLY AACCCOY 5 8 SECTION CONTENTS ManuaL 7 7 ee Rotary IpLER ASSEMBLY 20000 20 50K Tonc Item Type Description Qty Part Number A Part 1 8 NPT Grease Fitting 1 02 0005 B Part 1 1 2 UNF Nylock Nut 2 09 5740 C Part Idler Pad 2 997 D20 125 D Part Idler Spacer 2 1050 D5 121 E Part Retainer Clip 2 02 0009 F Part Bearing Seal 2 02 0010 G Part R
149. r for the pinion drive gear by removing the four 5 8 bolts which secure the bearing cap Thread two of the removed bolts into the extra holes on top of the bearing cap and use them as lifting lugs to lift the bearing cap out of place IF THE BEARING REMAINS ATTACHED TO THE GEAR SHAFT AFTER THE BEARING CAP IS PULLED MCCOY SERVICE PERSONNEL RECOMMENDS LEAVING IT IN PLACE UNTIL THE TOP TONG PLATE IS REMOVED MOVING GLOBAL ENERGY FORWARD DRILLING amp AACCCOY TECHNICAL MANUAL 3 11 20000 20 50 Tone 19 Remove the top 1 1 2 nylock nuts and pads for the rotary and pinion idler gears H ASSEMBLY PROCEDURES the tong in our plant MAINTENANCE 20 Remove the thin nylock nuts and washers from all support roller shafts One at a time use a soft alloy material e g brass rod etc to lightly tap the shafts up through the support roller assemblies until the shafts and flat washers come free at the top Use caution that the threads on the ends of the support roller shafts are not damaged Note that the brake band lug weldments will come free when the support roller shafts are removed 21 Remove the top plate fasteners hex head bolts amp socket head cap screws around the perimeter of the tong which secure the top plate to the gear case housing Note that the rear door cylinder mounting lugs must also be removed to release the top plate 22 With all the above steps taken the top tong plate can be li
150. r generous lubrication of the gear train including the gear housing DRILLING amp 3 28 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 20000 20 50K 1 3 Energize power unit Rotate tong for one minute stop and reverse the direction of rotation for another minute ending with g the opening of the rotary gear facing the gear train 14 De energize the power unit and perform a third generous lubrication of the gear train including the gear housing 1 5 Energize power unit and rotate the tong for a final time one minute in one direction stop and reverse the direction of rotation for another minute this time ending with the rotary gear in the open throat position 1 6 Extend all hydraulic cylinders and inspect cylinder rods for signs of mechanical damage flaking or rust Farr recom mends that damaged cylinders be replaced prior to storage If you are using a frame mounted tool the tong must be lowered onto the backup in order to remove the risk of sudden and catastrophic movement when pressure is removed from the float cylinders Cover the top of the backup with protec tive cloth to protect the paint on the backup Place two wooden beams across the top of the tong ensuring that the beams 1 f have minimum size of 4 x 4 x the width of the tong Cover the tops of the wooden beams with more protective cloth to prevent paint damag
151. r is found or if either pin is bent SHIFTING SHAFT The shifting yoke is secured to the shifting shaft by one hex jam nut above the shifting yoke and one locknut on the bottom of the yoke Check these nuts after each job Do this by removing the clutch inspection plate and ensuring a snug fit prior to lubrication TORQUE GAUGE ASSEMBLY Periodic calibration of the torque gauge is recommended to assure accurate torque readings When having the torque gauge serviced and calibrated it is critical to note the arm length of the tong as indicated in the Specifications section Farr recom mends that the torque gauge assembly be calibrated yearly Periodically check to ensure the load cell is filled with oil see Section 6 3 10 SECTION CONTENTS TECHNICAL MANUAL COY MOVING GLOBAL ENERGY FORWARD MAINTENANCE 20000 20 50K Tonc G OVERHAUL PROCEDURES The tong may be overhauled following the disassembly instructions in the following procedure Access to the gear train is possible by removing the top plate of the tong ALL MAINTENANCE AND OVERHAUL SHOULD BE PERFORMED FROM THE TOP THE BOTTOM PLATE OF THE TONG IS TYPICALLY WELDED TO THE SIDE BODY AND CANNOT BE REMOVED REPLACEMENT FASTENERS BOLTS NUTS CAP SCHEWS MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHER WISE SPECIFIED TOP PLATE REMOVAL 1 Remove load cell assembly and load cell pins while tong
152. r locking nuts on the set screws and turn all four set screws EQUALLY counter clockwise until the centre measurement is equal to the two outer measurements Ensure that the locking nuts are tightened when this procedure is complete ILLUSTRATION 3 E 4 DooR ALIGNMENT ADJUSTMENT SET SCREWS COY TECHNICAL MANUAL 3 9 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Tonc MAINTENANCE 4 1 Shifter Detent Force Adjustment Over time wear to the shifting shaft wear to the detent ball and loss of spring tension in the detent spring may result in a loose or sloppy fit within the top shifter bushing The detent pressure may be increased or otherwise adjusted by loosening the 7 16 UNF locking jam nut and turning the 7 16 UNF detent bolt Should adequate detent action not be achieved the shifting shaft detent ball or detent spring or possibly all three may need to be replaced ILLUSTRATION 3 E 5 SHIFTER DETENT FORCE ADJUSTMENT F RECOMMENDED PERIODIC CHECKS DOOR STOP SPRING The spring inside the actuator cylinder must be of sufficient strength to enable the door latch mechanism to snap closed prop erly and to hold the door in the open position when opened Door stop spring fatigue will result in sluggish latch operation Replace the latch spring inside the cylinder when this occurs BACKING PIN Perform a visual inspection of the backing pin after each job Replace the pin if stress cracks or excessive wea
153. reads on the ends of the support roller shafts are not damaged 12 Disconnect the shifting handle from the shifting shaft and shifting lug 13 Remove the motor from the motor mount Staffa motors are secured with five 3 4 bolts while Rineer motors are secured with six 5 8 bolts Inspect the splined motor shaft for clashing or spline damage 14 Remove the motor mount by removing the five socket head cap screws The motor mount can be lifted out of place Take care not to lose the two position dowels one or both may come off with the mount 15 Remove the access panel on the body side adjacent to shifter assembly Back off the detent adjustment bolt on the top shifter bushing Remove the 7 8 jam nut from the shifting shaft to loosen the shifting fork The shifting shaft may now be carefully rotated and pulled out of the top shifter bushing THE CAGE PLATE BOLTS ARE THE ONLY ITEMS FASTENING THE BOTTOM CAGE PLATE TO THE TONG SUPPORT THE BOTTOM CAGE PLATE FROM BELOW PRIOR TO REMOVING CAGE PLATE BOLTS IN ORDER TO PREVENT DAMAGE TO THE BOTTOM CAGE PLATE OR PERSONAL INJURY TO THE MECHANIC 16 Remove the 3 8 hex bolt connecting the backing pin to the rear cage plate bolt Remove the backing pin 17 Remove the two front cage plate bolts and the rear cage plate bolt and the cage plate spacers The cage plates may now be removed Use caution not to damage the cam followers while removing the cage plates 18 Pull the top bearing cap and space
154. rear of the backup between the backup and a stationary frame The load cell must be located in the centre of the compression force vector generated between the backup and the frame Hydraulic force generated by a load cell is transmitted to the torque gauge via a reinforced flexible hydraulic line The hydraulic force is displayed as torque in units of Ft Lbs The torque gauge has a red peak torque indicator that tracks with the torque gauge needle to the point of highest torque and remains at the point of highest torque until manually reset Note that every model of tong and tong and backup assembly has a unique arm length and the torque gauge must be calibrated for that arm length Torque gauges that are not calibrated for the arm length of the tool in service will not display correct torque To ensure correct torque measurement ensure the arm length or handle as displayed on your torque gauge matches the arm length of the tool in service as listed on the specifications page of the technical manual The images on this page are for illustration purposes only and may not accurately represent the torque gauge and load cell that have been supplied with your equipment THE IMAGES DISPLAYED ARE SUPPLIED FOR ILLUSTRATION PURPOSES ONLY ILLUSTRATION 6 1 GAUGE Fon ILLUSTRATION Purposes ONLY ILLUSTRATION 6 A 3 CouPRESSION Loan CELL Torque gauges and load cells are supplied as a matched calibrated pair Substituting o
155. rity or agency which may affect the operation safety or equipment integrity that may overrule the content of this documentation The user will acknowledge and obey any general legal or other mandatory regulation in force relating to accident prevention safety and equipment integrity Summary Of Revisions Date Section Page Description Of Revision June 2007 N A N A Initial Release Intro Added list of tong models covered by this manual Oct 2007 Intro v Added Warnings 4 4 9 Added torque table for load bearing components Dec 2007 7 7 15 Corrected part numbers for items B J amp L All All Re branded manual Intro ix Added Table of Illustrations All All Improved warnings throughout manual 2 Moved Assembly Instructions to Maintenance section Section 2 becomes Setup amp Operation 2 2 1 Section Sling amp Load Bearing Device Safety 2 2 8 Replaced hydraulic schematic amp hydraulic B O M 2 2 9 Added hydraulic component identification graphics 2 2 13 Added Section Tong Rig up amp Leveling 2 2 17 Replaced valve operation graphics 2 2 18 Added Subsection Shifting Gears 2 2 19 Added Section Making amp Breaking Connections 2011 3 Renumbered Maintenance Section as Section 3 3 3 1 Added Section General Maintenance Safety Practices 3 3 1 Added Section Preventive Maintenance Practices 3
156. rt Shackle Assembly 4 02 9063 ALL FASTENERS USED DURING REASSEMBLY OF LOAD BEARING COMPONENTS CHAIN SLINGS RIGID SLINGS BACKUP LEGS MUST BE TIGHTENED TO THE CORRECT TORQUE THREADED FASTENERS USED IN LOAD BEARING DEVICES MUST BE SECURED WITH RED LOC CHECK ALL CHAINS FOR DAMAGE BEFORE PLACING UNDER LOAD DO NOT ALLOW CHAINS TO KINK BEFORE PLACING UNDER LOAD DRILLING amp AACCCOY MANUAL 5 35 MOVING GLOBAL ENERGY FORWARD This page intentionally left blank ToRQUE MEASUREMENT 20000 20 50K Tonc A BASIC TORQUE MEASUREMENT Basic torque measurements are performed using a simple hydraulic measurement system A hydraulic load cell connects to a cali brated torque gauge through a reinforced flexible hydraulic hose The torque gauge is factory calibrated to display accurate torque measurements for a tong or tong and backup assembly with a particular arm length The arm length is a measurement from the centre of the pipe or casing to the centre of the force being applied to the load cell Two load cell options are available A tension load cell is typically used with a suspended stand alone tong This application requires that the load cell be attached to the rear of the tong as part of the restraint line that opposes the force generated when the tong makes up or breaks out a joint A compression load cell is used in a tong and backup assembly and is typically located on the
157. rted components including links and chains If using a compression load cell replace any component that has been crushed or otherwise distorted through compression If applicable inspect the load cell anchor pins tension load cell only Replace the anchor pins if cracking or metal distor tion is seen e If applicable the weld securing the single load cell anchor to the bridge bar main plate must be inspected compression load cell only If the integrity of the weld has been compromised the tong must be removed from service until the weld is repaired The load cell beam will need to be disconnected and removed so the weld is visible Before re installing the beam liberally grease the anchor pin before reinserting into the load cell beam 19 Re energize power unit DRILLING amp AACCCOY TECHNICAL MANUAL 3 31 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K MAINTENANCE 2 0 Perform a full functional test of the equipment including if applicable backup components and float frame components 5 Report and correct hydraulic leaks from the hydraulic valve bank or from any hydraulic cylinders that are used If using a frame mounted tong and backup system raise the tong off the beams that it is resting upon Remove the beams 2 1 and protective cloths inspect the paint on top of the backup the bottom of the tong to ensure it has not been dam aged
158. ry with system parameters LOW SPEED OPERATION Minimum operating speeds are determined by load conditions load crankcase pressure If pumping occurs i e overrunning loads then a positive pressure P is required at the motor inlet ports Calculate P according to port connection type being used from 1 Cbar Dpar psi 14 5 C psi Dpsi Where speed r min C crankcase pressure D see table 4000 gt 3000 gt 2000 1000 0 4 0 50 10 150 200 in min 0 10 20 3 0 l min Crankcase leakage drain flow rate 70 80 90 100 Y EAS ese 05 0 05 1015 25 2055 Shaft creep winch slip speed r min This nomograph enables the average inertia drive elasticity etc For Port D value volumetric efficiency crankcase drain operation at speeds below 3 r min connection type leakage and winch slip shaft creep consult Kawasaki speed to be estimated F2 amp FM2 Dbar 1500 HIGH BACK PRESSURE Dpsi 103 Example follow chain dotted line When both inlet and outlet ports are S03 S04 Dpar 10 000 Given pressurized continuously the lower F3 FM3 Dpsi 690 1 Pressure 207 bar 3000 psi pressure in one port must not exceed 2 Speed 70 bar 1000 psi Consult Kawasaki on The flow rate of oil needed for the 3 Viscosity 50 cSt 232 SUS applications beyond this limit Note that make up system can be estimated fr
159. s for example POSSIBLE PROBLEM Fluid viscosity is not appropriate too high or too low SOLUTION Ensure hydraulic fluid being used is the viscosity recommended by McCoy Drilling amp Completions Power unit pump may not prime if fluid is too heavy and the hydraulic system will overheat if fluid is too light Replace with proper viscosity fluid SOLUTION Hydraulic fluid viscosity is affected by environmental conditions Ensure the fluid being used is suitable for high or low temperatures Replace with proper viscosity fluid for the operating conditions if necessary POSSIBLE PROBLEM Worn or damaged tong motor causing slippage SOLUTION Replace or repair worn or damaged motor POSSIBLE PROBLEM Damaged bearings or gears causing excessive drag SOLUTION Replace or repair worn or damaged gears or bearings POSSIBLE PROBLEM Jaws slipping on pipe SOLUTION Ensure jaw dies are not worn to the point that they cannot grip Ensure the correct sized jaws are in use POSSIBLE PROBLEM Torque gauge is indicating incorrectly SOLUTION Incorrect gauge is being used Ensure gauge is the proper range and has been properly calibrated for the arm length of the equipment in use SOLUTION Gauge has been damaged Check gauge operation and calibration on independent system POSSIBLE PROBLEM Load cell is measuring incorrectly SOLUTION Incorrect load cell is being used SOLUTION Air is trapped in torque measuring circuit load cell hydr
160. s the property of McCoy and is supplied as reference information for users of our products This document and the contents within are considered confidential information not to be disclosed copied transmitted transcribed in any form or stored on any type of data stor age media without the express written consent of McCoy McCoy has made every effort to ensure the information contained in this document is accurate and current This manual is intended to provide equipment operation and safety instructions for your equipment However McCoy does not warrant or guarantee that the information is either complete or accurate in every respect and the user of the manual should consult with its McCoy sales representa tive for any clarifications and updates The user of the manual shall protect indemnify and hold harmless McCoy and its directors officers employees and agents from and against all liability for personal injury death or property damage resulting directly or indirectly from the use of the information contained in this manual Observance of all descriptions information and instructions set out in this manual is the full responsibility of the user This manual is intended for guidance and informational purposes and must be used in association with adequate training and on the job supervision to provide safe and effective equipment use It is the responsibility of the user to conform to all regulations and requirements issued by an autho
161. s that are rubbing bare metal where there used to be paint is a 5 good indication of wear 10 Inspect backing pin s If cracked broken or bent it they must be replaced Inspect top and bottom brake band linings replace if necessary Unequal wear of the brake bands indicates that the 1 1 brake band tension is not evenly adjusted Refer to the maintenance section of the manual for instructions on properly adjusting brake bands 1 2 Perform a visual inspection of all hydraulic lines Replace flexible lines if they appear to be cracked fatigued or have 5 visible signs of wear from contact with a rigid object DRILLING amp 3 22 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 20000 20 50K 1 3 Perform a visual inspection of all hydraulic lines Replace flexible lines if they appear to be cracked fatigued or have visible signs of wear from contact with a rigid object 14 Perform a complete greasing of the tong refer to Maintenance section of the technical manual 1 5 Ensure main supply and return connections to the tong are fully made Re connect the remainder of the hydraulic lines and if applicable the electrical line to the turns counter FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE If using a stand alone power unit start it now ref
162. sary and replace the keeper screws F TONG RIG UP amp LEVELING 1 Suspension amp Restraint Suspend the tong from a location as near to the centre of the drill rotary as possible and from a location high enough on the mast to ensure easy handling The lower the point from which the tong is suspended the more effort will be required to move the tong to and from the connection point The suspension line may be extended over a pulley and balanced by a counterweight equal to the weight of the tong or simply tied off in the derrick to form a dead line When using dead line arrangement it is necessary to use a FARR spring hanger assembly see specification page for recommended spring hanger This spring hanger compensates for the downward move ment of the casing as the thread is made up and imparts additional force to the suspension cable a single spring hanger typically applies 420 Ibs 191 kg to the suspension line for every inch of thread made up a double spring hanger typically applies 840 Ibs 382 kg to the suspension line for every inch of thread made If you do not know which specific spring hanger is in use check the specification page in this manual for information on the recommended spring hanger for this application Farr Canada Corp will not guarantee or specify spring hangers other than what has been supplied by Farr Canada Corp Many applications use a lift cylinder for adjusting the height of the to
163. sing with grease through the access panel and also through the opening in the rotary gear Perform full lubrication refer to Maintenance section of manual to determine lubrication points 2 2 C Ensure main supply and return connections to the tong are fully made up Re connect the remainder of the hydraulic lines and if applicable the electrical line to the turns counter FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE If using a stand alone power unit start it now refer to the power unit technical manual for startup procedures Listen to power unit for a moment to see if there are any unusual mechanical sounds rubbing grinding excessive pump noise If using a diesel unit allow sufficient time for the engine to reach operating temperature before increasing engine RPM Once engine is warm gradually increase engine RPM until operating speed is reached 2 3 Ensure that supply pressure is at or above the tong s specified operating pressure and that the return pressure is less 5 than 350 psi 2 4 Perform a visual inspection of pressurized hydraulic lines If any hydraulic fittings or hoses are leaking they must be z repaired or replaced before proceeding Rotate tong for one minute stop and reverse the direction of rotation for another minute ending with the opening of 2 5 the rotary gear facing the gear train De energize the power u
164. ssible Problem Solution Symptom Possible Problem Solutions Possible Problem Solution Possible Problem Solution Symptom Possible Problem Solution Possible Problem Solutions Possible Problem Solution Possible Problem Solution Possible Problem Solution Symptom Possible Problem Solution Possible Problem Solution Possible Problem Solution Possible Problem Solution No indication on gauge Obstruction in hydraulic hose Check hyaraulic hose for kinks Replace hyaraulic hose Loss of hydraulic fluid Recharge hyaraulic fluid see Section 6 C NOTE Ensure any breaches in the hydraulic system between the load cell and torque gauge are repaired to prevent further fluid loss Internal mechanism of torque gauge is damaged Replace gauge Gauge indication unexpectedly high Excessive hydraulic fluid Completely drain hydraulic fluid from torque gauge load cell system Recharge following the pro cedure in Section 6 C Internal mechanism of gauge is damaged Replace gauge Incorrect torque gauge in use not part of the original torque gauge load cell pair Replace gauge with gauge properly calibrated for the load cell in service Gauge indication unexpectedly low Insufficient hydraulic fluid Recharge hyaraulic fluid see Section 6 C NOTE Ensure any breaches in the hydraulic system between the load cell and torque gauge are repaired to prevent further fluid l
165. t Ibs 5 16 18 3125 4 725 25 ft Ibs 78 ft Ibs 3 8 16 375 6 975 44 ft Ibs 33 ft Ibs 7 16 14 4375 9 600 70 ft 16 52 ft Ibs 1 2 13 500 12 750 106 ft 16 80 ft Ibs 9 16 12 5625 16 350 153 ft Ibs 115 ft 108 5 8 11 625 20 325 212 ft Ibs 159 ft Ibs 3 4 10 750 30 075 376 ft Ibs 282 ft Ibs 7 8 9 875 41 550 606 ft Ibs 454 ft Ibs 1 8 1 000 54 525 909 ft Ibs 682 ft Ibs 1 1 8 7 1 125 68 700 1288 ft Ibs 966 ft Ibs 1 1 4 7 1 125 87 225 1817 ft Ibs 1363 ft Ibs 1 3 8 6 1 375 103 950 2382 ft Ibs 1787 ft Ibs 1 1 2 6 1 500 126 450 3161 ft Ibs 2371 ft Ibs 3 12 SECTION CONTENTS TEcHNICAL MANUAL AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS MAINTENANCE 20000 20 50K Tonc ALL FASTENERS USED DURING REASSEMBLY OF LOAD BEARING COMPONENTS CHAIN SLINGS RIGID SLINGS BACKUP LEGS MUST BE TIGHTENED TO THE CORRECT TORQUE THREADED FASTENERS USED IN LOAD BEARING DEVICES MUST BE SECURED WITH RED LOC TITE CHECK ALL CHAINS FOR DAMAGE BEFORE PLACING UNDER LOAD DO NOT ALLOW CHAINS TO KINK BEFORE PLACING UNDER LOAD APPLY A THIN LAYER OF GREASE TO THE SURFACE OF EACH MOVING PART DURING ASSEMBLY TO AID IN THE ASSEMBLY PROCESS 1 Position the tong body gear case on a Suitable stationary support such that the bottom body plate is accessible 2 Install 25 cam followers 1037 0 58 into the botto
166. t applications When using the 125 Series standard motor above 300HP consult a Rineer Application Engineer Radial Load Ibf SINGLE STACKED DOUBLE STACKED Single stacked motors have displacements ranging from 60 in3 to 125 in3 and are comprised of a single rotor stator package located between two housings Double stacked motors have displacements ranging from 150 in3 to 250 in3 and are comprised of two rotor stator packages located between two housings Any of the single stacked rotor stator packages may be placed together to form a double stacked motor 0 25 3 Distance in DRILLING amp AACCODY 1 15 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Tone Motor INFORMATION RINEER Envelope Double Key STARTING AND STALL TORQUE The Rineer motor produces torque curves which are virtually flat with starting and stall torque equal to approximately 90 94 of theoretical torque MORE POWER STROKES PER REVOLUTION The 125 Series has six stator cavities and 16 rotor vanes Each rotor vane works in each stator cavity once per revolution which results in 96 power strokes per revolution This helps produce higher mechanical efficiency and flatter torque curves SEALS Buna N seals are supplied standard Viton seals may be ordered as an option STD SAE 1 5 CASE DRAIN AND CROSS PORT LEAKAGE The combined case drain an
167. t be replaced Inspect top and bottom brake band linings replace if necessary Unequal wear of the brake bands indicates that the 1 6 brake band tension is not evenly adjusted Refer to the maintenance section of the manual for instructions on properly adjusting brake bands 1 7 Inspect door springs Ensure the springs retain sufficient strength to be able to assist the opening of the door and to keep the door open The springs should also help to snap the door shut Inspect backup springs if applicable The rear extension springs should be equally extended and the front leg springs 1 8 C should be equally compressed Ensure that neither of the rear backup springs have been over extended and lack s sufficient tension to adequately support the backup Ensure that neither of the front leg springs have been over com pressed and still retain enough spring strength to support the front of the backup 1 9 Extend all hydraulic cylinders and inspect cylinder rods for signs of mechanical damage flaking or rust recom 5 mends that damaged cylinders be replaced prior to storage Perform a visual inspection of all hydraulic lines Replace flexible lines if they appear to be cracked fatigued or have 2 0 visible signs of wear from contact with a rigid object If your tong is equipped with rigid hydraulic lines replace any line that is dented or appears to be stressed or cracked 21 C Generously fill the gear train hou
168. tandem and series Circuitry im single bank internal conng of each valve section determines circuitry the number of gasket seals required Al secrians with optional features such as port relief valves crossover relief valves and anti eavitation checks are dimensionally langer when measured from the top of the port to the bottom of the housing These are referred to as hi boy Those without work por options use the low profile castings which are called lo boy sections REPLACEMENT PARTS The illustrations and instructions this manual apply only ta the series assemblies subassemblies and components All valve cumpodents except for spools and housings nne available as replacement parts or subassemblies Spools are honc fitied their individual housings damage to ether of these components means the entire section he replaced We recommend that you usc only genuine V A VG series replacement parts in your service program Manufactured to the same l lersnces and quailty contrals as the original equipment genuine replacement parts may help prevent premature component failure and costly downtime Service parts and asseniblies are avaiable through yor eguipanent dealer or any authorized distributor MAINTENANCE Valves ane ofben used im hazardous environments Inspect them frequently for damage due to improper use
169. ternal fasteners to SAE specifications 7 Repair or replace damaged missing external body parts such as torque gauge mounts hydraulic supports safety door protectors etc Perform a visual inspection of all fasteners and protruding body pieces example hydraulic valve mounts inlet amp outlet 8 line supports tong legs shifter handle pivot lugs Tighten or replace loose or missing fasteners Farr recommends that damaged or missing body parts be repaired or replaced as soon as possible 9 C Inspect tong for signs of premature wear or moving parts that are rubbing bare metal where there used to be paint is a good indication of wear Inspect all paint locations in which the paint has been damaged must be repaired prior to the tong being returned to 1 0 service Prepare areas to be painted to ensure they free of grease dirt or solvent Touch up using a solvent based acrylic paint Farr Blue is paint number RAL5005 contact Farr sales for paint number for custom paint applications Allow sufficient time for paint to dry before proceeding 1 1 Inspect all external welds Any weld that is cracked or separating must be repaired and repainted before returning the 2 tong to service DRILLING amp 3 24 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 20000 20 50K Tonc Perform a visual inspection of all lifting points if visibl
170. that the nut female side is completely made up onto the male connector there is a line on the male fitting that indicates complete make up Snug the female fitting right up to the line lt y amp Hydraulic Return A w L A Hydraulic Supply 1 ILLusrRATION 2 0 1 HyDRAULIC CONNECTIONS 01 Make up female fitting to Marked point on male fitting ILLUSTRATION 2 0 2 CONNECTIONS 02 DRILLING amp AACCODY eT 211 MOVING GLOBAL ENERGY FORWARD 20000 20 50K Tone E TONG JAWS 1 Available Jaws Setup amp OPERATION The following table lists all jaw die kits that are available as standard sizes for this model of tong If your desired size is not listed Farr can engineer custom jaw sizes contact sales for further information Description Part Number 7 Jaw Die Kit 1037 JDK 543 7 5 8 Jaw Die Kit 1037 JDK 539 8 Jaw Die Kit 1037 JDK 541 8 1 4 Jaw Die Kit 1037 JDK 542 8 5 8 Jaw Die Kit 1037 JDK 540 9 5 8 Jaw Die Kit 1037 JDK 545 9 7 8 Jaw Die Kit 1037 JDK 547 10 Jaw Die Kit 1037 JDK 546 10 3 4 Jaw Die Kit 1037 JDK 550 11 3 4 Jaw Die Kit 1037 JDK 555 11 7 8 Jaw Die Kit 1037 JDK 557 12 3 4 Jaw Die Kit 1037 JDK 556 13 3 8 Jaw Die Kit 1037 JDK 558 13 5 8 Jaw Die Kit 1037 JDK 560 14
171. the spral asscemhioy imp thee Wee Do darsi Dimma He careful nel er he dea lake sume thal oriens aee Shep 1 page b disassembly i Step 2 Spool Seal and Back up Apply Parker Super D Lube V iile suas Fig L 8 anil lise 11 niu spon lide em iue buck Fig 1 tem 73 Posh both n ma into bre painter kar hey bottom out Assets past frat plied pluies Fie ising Ihe 4840 Erg 1 planes For peper aia final tongue af 34 In lba 2 in Pha Step 3 Back back rwm bene leno rns 1 iem mo a orgue 01 34 mc Sf in hs Canine Escessbve inripue will damage ihe beck cap cars COY MOVING GLOBAL ENERGY FORWARD 7 38 Section CONTENTS TECHNICAL MANUAL HvoRAULIC VALVE INFORMATION KT20000 20 50K 10 Valve Assembly Instructions Step 4 Install Transition Check check emciponenis lor Insta check popper Fog iem 131 inito iie transition check cai Am fire Fig 2 square the poppet ien place the check Fig 1 poppe and semg Tammy
172. thick Attempt to ensure that the tool is well sealed within the wrapping including the bottom DRILLING amp AACCCOY TECHNICAL MANUAL 3 29 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K MAINTENANCE If possible store in a sealed climate controlled environment If isolated storage is not available Farr recommends storing your wrapped equipment in a secure out of the way location using silica gel desiccant to reduce the humidity within the wrapping As a guideline use 125 g of desiccant for each cubic metre of space or 3 5 g per cubic foot CALCULATION Or REQuiRED DESICCANT 1 Calculate the trapped air volume by measuring the outside dimensions of the tool to be stored and treat that as the volume to be stored For example the external dimensions of a KT20000 20 power tong are 80 25 x 50 5 x 28 which calculates to an approximate volume of 113500 or 66 ft 1 87 m 2 Multiply the calculated air volume in cubic feet by the recommended amount of desiccant per cubic foot Carrying forth the example used in the previous step the required desiccant charge would be 3 5 9 x 66 f equaling 231 g Several manufactur ers offer silica gel desiccant in packaged quantities of 125 grams per bag so two packages of desiccant would be required Please keep in mind that this is a guideline only more or less desiccant may be required in extreme environmental conditions For best corrosion resist
173. this page LIMITS FOR FIRE RESISTANT FLUIDS Fluid type Pressure bar psi Max speed Continuous Intermittent r min HFA 5 95 oil in water 103 1 500 138 2000 50 of limits RATING DEFINITIONS CONTINUOUS RATING For continuous duty the motor must be operating within each of the maximum values for speed pressure and power INTERMITTENT RATING Operation within the intermittent power rating up to the maximum continuous speed is permitted on a 1596 duty basis for periods up to 5 minutes maximum INTERMITTENT MAX PRESSURE Up to 293 bar 4250 psi is allowable on the following basis Up to 50 r min 15 duty for periods up to 5 minutes maximum b Over 50 r min 296 duty for periods up to 30 seconds maximum emulsion for petroleum oil HFB 60 40 water in oil 438 2000 172 2500 As for petroleum oil emulsion m HFC water glycol 103 1500 138 2000 HFD phosphate ester 250 3625 293 4250 As for petroleum oil OUTPUT TORQUES The torque curves indicate the 4 ages Ap maximum output torque and power Ibf ft Nm 25 50 75 100 125 of a fully run in motor for a range 45007 6000 ab of pressures and speeds when 4250 psi operating with zero outlet pressure 4000 276 bar on petroleum oil of 50 cSt 232 SUS 5000 4000 psi viscosity High return line pressures 3500 250 bar 5 3625 psi will reduce tor
174. ting the bypass valve to allow fluid to circulate to tong If the power unit is equipped with an oil temperature gauge ensure that the fluid has reached operating temperature as specified by hydraulic fluid data sheet 5 Allow for adequate drying of moisture prior to lubricating when cleaning tong parts in cold weather AACCCOY 2 26 Section CONTENTS TECHNICAL MANUAL vibe eei MAINTENANCE 20000 20 50K McCoy Drilling amp Completions recognizes that minor on site repairs and modifications are required to maintain peak operating condition of your equipment or to match your equipment with the operating environment Examples of minor repairs are replacement of damaged hydraulic hoses and fittings replacement of malfunctioning pressure gauges and valves replacement of door cylinders replacement of fasteners Any replaced component must be an identical component supplied by McCoy Drilling amp Completions Replaced fasteners must be Grade 8 or equivalent or whatever fastener is specified by McCoy Drilling amp Completions A GENERAL MAINTENANCE SAFETY PRACTICES The practices identified here are intended as a guideline All personnel are responsible for performing their tasks in a manner that ensures worker equipment and environmental safety and may require taking additional steps that are not identified in this section Equipment maintenance shall be performed only by designated quali
175. tong ii Attach L shaped support weldment for the 1 hydraulic inlet line 101 1138 to the top plate just behind the RH pinion idler using two 3 8 UNC x 1 hex bolts and 3 8 lock washers iii Attach the L shaped support weldment for the 1 1 4 hydraulic discharge line PN 101 1138 to the top plate using two 3 8 UNC x 1 hex bolts two 3 8 narrow washers and two 3 8 UNC thin nylock nuts DRILLING amp 3 20 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 20000 20 50K Tonc Assembly Procedures Cont d 47 Attach the hydraulic supports to the top plate continued i Attach the adjustable support plate PN 101 0022 to the hydraulic inlet support base using two 3 8 UNC x 1 hex bolts two 3 8 narrow washers and two 3 8 UNC thin nylock nuts 48 Attach four leg weldments PN 997 08 160 to the bottom plate of the tong using 7 8 UNC 1 1 2 hex bolts and 7 8 plain narrow flat washers 49 Attach torque gauge holder weldment PN 101 4465 to the rear of the top plate behind the motor mount using two 3 8 NC x 1 hex bolts and lock washers Insert the torque gauge mount weldment PN 1500 09 03 into the holder weldment and secure with a 0 148 x 3 hitch pin 50 Boltthe hydraulic valve assembly to the hydraulic valve support posts installed in step 47 i using two 1 2 NC x 4 1 2 hex bolts and 1 2 lock washers Secure the inlet and outlet
176. torque that your equipment is routinely subjected to and the field conditions under which your equipment operates Farr recommends that the following inspection and maintenance procedures be performed monthly or in conjunction with your maintenance foreman s experience and best estimate of when your equipment is due for this maintenance 1 Rotate cage plate rotary gear until the opening in the rotary gear faces towards the rear of the tong DO NOT PERFORM ANY FURTHER ACTIONS OR MAINTENANCE WHILE THE TONG IS CON NECTED TO ANY HYDRAULIC POWER SUPPLY FARR RECOMMENDS THAT ALL HYDRAULIC LINES ARE FULLY DISCONNECTED AND RESIDUAL HYDRAULIC PRESSURE IS BLED OFF ENSURE ADEQUATE CONTAINMENT IS IN PLACE TO PREVENT ENVIRONMENTAL CONTAMI NATION FROM RESIDUAL HYDRAULIC FLUID DEPRESSURIZE HYDRAULIC SYSTEM IN PREPARATION For MAINTENANCE 1 Rotate the tong to the open throat position Ensure tong and backup doors if equipped are closed Fully extend the lift cylinder 2 De energize the power unit 3 Repeatedly actuate the tong motor control valve lever IN BOTH DIRECTIONS to dissipate any residual pres 2 sure the valve and motor 4 Remove the hydraulic SUPPLY line from the equipment 5 Repeatedly actuate the remaining control valve levers IN BOTH DIRECTIONS to dissipate any residual pres sure in the remainder of the hydraulic control system 7 Disconnect the hydraulic RETURN line from the equipment 8 Disconnect remai
177. tputs up to 5950 Nm 4390 Ibf ft and M speeds to 300 r min with a continuous T Tompersnum Limits 7 output of up to 100 KW 134 hp 8 Filtration s 7 9 Noise Levels 7 The Kawasaki Staffa range also 10 Polar Moment of Inertia 7 includes dual and continuously variable T1 M SS ebat 7 displacement motors plus matching brakes and gearboxes to extend the 12 Installation Data available torque range General een 7 Crankcase drain 2 7 Start Up s 7 2 FUNCTIONAL SYMBOLS 13 Installation Dimensions 8 to 11 All model types with variants in model code position n F M 2 F M 3 S03 S04 Y DRILLING amp 7 4 Section CONTENTS TEcHNICAL MANUAL AACCCO COMPLETIONS MOVING GLOBAL ENERGY FORWARD Motor INFORMATION STAFFA KT20000 20 50K 3 MODEL CODE All other features must be specified Blank Petroleum oil F3 Phosphate ester HFD fluid F11 Water based fluids HFA HFB and HFC Blank Standard UK specification 463 1981 Dual mount front or rear El SHAFT Use H prefix code as noted to specify hollow shafts with through hole 26 2 1 03 dia Hollow shafts are available only with type 504 main port connection H P Cylindrical shaft
178. ty Door Switch 08 0337M 11 2 Safety Door Valve 08 1625 12 1 Safety Door Valve Block 101 0727 13 1 0 3000 Pressure Gauge not shown 02 0245 14 1 Check Valve Optional Varies With Application ILLUSTRATION 2 2 HyDRAULIC COMPONENT IDENTIFICATION 01 DRILLING amp AACCCOY MANUAL 2 9 MOVING GLOBAL ENERGY FORWARD KT20000 20 50K Setup amp OPERATION ILLUSTRATION 2 C 3 HYDRAULIC COMPONENT IDENTIFICATION 02 ILLUSTRATION 2 C 4 HyDRAULIC COMPONENT IDENTIFICATION 03 DRILLING amp 2 10 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION KT20000 20 50K Tonc D HYDRAULIC CONNECTIONS A pair of hydraulic lines a 1 supply line and a 1 1 4 return line connect the tong to the power unit see illustration below Ancillary devices hydraulic motors hydraulic cylinders etc are connected through the valve block Perform any hydraulic connection when the power unit is not running or when the hydraulic pump is disengaged The possibility of error in inter changing the high pressure supply hose and the low pressure return hose has been eliminated because the supply side coupling is smaller than the return side These hose couplings are self sealing and care should be taken to ensure complete engagement to prevent partial closure of the check valve in the coupling Ensure
179. ual hydraulic fluid dirty grease and cleaning agents 5 C Inspect all fasteners and fastener safety wires Replace any missing fasteners use Grade 8 bolts only Re torque all external fasteners to SAE specifications 6 Inspect backing pin s If cracked broken or bent it they must be replaced 7 Repair or replace any damaged or missing external body parts such as torque gauge mounts hydraulic supports safety x door protectors etc Inspect all paint locations in which the paint has been damaged must be repaired prior to storage Prepare areas to be 8 painted to ensure they are free of grease dirt or solvent Touch up using a solvent based acrylic paint Farr Blue is paint number RAL 5005 Allow sufficient time for paint to dry before proceeding Perform a liberal lubrication of the equipment refer to Maintenance section of manual to determine lubrication points 9 Generously fill the gear train housing with grease through the access panel and also through the opening in the rotary gear 1 0 Connect the equipment to a hydraulic power unit Ensure all lines are fully made up to prevent equipment damage from excessive back pressure Do not neglect to connect the motor drain 1 1 Energize power unit Rotate tong for one minute stop and reverse the direction of rotation for another minute ending with the opening of the 1 2 rotary gear facing the gear train De energize the power unit and perform anothe
180. ve Remove uec iinet pl les 1 eng Lg 1 7 and Aig V thom or mari the anpreapnerie werk sectim See Step 1 1 5pool scili Puy bucka mias Fig 1 7 dal Step 6 Transition Check ination check ci in tke bono center id the work section botsing C arefiiby he wok enh eiu w hili paris hawn chanig iam adhue Henove the cap Fig 1 ilem 101 55 seal Pup 1 111 Dicari sal Remove ile check sprimi Pig 1 ipn 12 and the poppet re d 134 Only werk sections ports in hava check have anle 7 34 SECTION CONTENTS TECHNICAL MANUAL COY MOVING GLOBAL ENERGY FORWARD VALVE INFORMATION 20000 20 50K 5 Valve Disassembly Instructions Spool Disassembly Spring Centered Spool The be frin the unless esee parts need to be Gnoe rhe the work seche bownng il be handled cvefully 10 damage Mace the sual cdaimpahia on Ue Tad a pon Gere and penne the sto
181. x To BE MARKED Examination NDE VISUAL ON PLATE ATTACHED TiME INTERVAL LIFTING TESTS LIFTING POINTS EXAMINATION To UNIT Initial Certification By bal Interval Not Exceeding At the discretion of At the discretion of 12 inspection body inspection body Interval Not Exceeding At the discretion of 60 Months inspection body Following Substantial Repair or Alteration 1 Lifting test as per S 7 3 BS EN 12079 or DNV 2 7 1 May 1995 T Proof Test non destructive examination VN non destructive examination and visual examination V visual examination Dependant upon whether non destructive examination has been carried out For the purposes of this standard a substantial repair or modification is defined as any repair and or modification that has been carried out which may in the opinion of the inspection body affect the load bearing elements of the container or lifting device or elements that contribute directly to its structural integrity IF MECHANICAL DAMAGE IS SEEN OR SUSPECTED ON A LOAD BEARING DEVICE OR IF THE LOAD BEARING DEVICE HAS BEEN OVERLOADED IT MUST BE REMOVED FROM SERVICE AND QUARANTINED UNTIL RECERTIFIED Written records of the most recent periodic inspection shall be maintained and shall include the condition of the sling 2 Proper Use Of Load Bearing Devices Whenever any load bearing device is used the following practices shall be observed Load bearing devices
182. ypes H NUMBER 3 SERIES Subject to change Installation and performance details remain unaltered for design numbers 30 to 39 inclusive SPECIAL FEATURES PL non catalogued features e g Stainless steel shaft sleeves Alternative encoder and tacho drives Alternative port connections Shaft variants Alternative reduced capacities Special mountings Special paint Number assigned as required to specific customer build DRILLING amp COMPLETIONS AACCOY MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL SECTION CONTENTS 7 5 20000 20 50 Tone HyprRAuLic MOTOR INFORMATION STAFFA 4 PERFORMANCE DATA Performance data is valid for Staffa 080 motors fully run in and operating with petroleum oil See separate table for pressure and speed limits when using fire resistant fluids Leakage values are at fluid viscosity of 50 cSt 232 SUS MOTOR DATA Port connection type see model code 503 F3 FM3 504 F2 FM2 Geometric displacement A cm3 r in r 1344 82 1344 82 Average actual running Nm bar 19 9 19 9 torque Ibf ft psi 1 01 1 01 Max continuous e speed r min 300 150 Max continuous e output kW hp 100 134 77 103 Max continuous e pressure bar psi 250 3625 250 3625 Max intermittente pressure bar psi 293 4250 293 4250 A Other lower displacements are made available to special order See Rating Definitions

Technical Manual - Revision January 2012

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