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Manual HD22000 - Texas International Oilfield Tools LTD

1. 3 29 Tubular Connection Equipment De commissioning 000 0000000000000000000 3 30 Tubular Connection Equipment Re commissioning 3 33 Troubleshooting ii at i n Section Four Tong Will Not Develop Sufficient Torque 1 061 00000000000000000 4 1 Falate O Jaws To GIP FIDE E 4 3 TONG RUNNING TOO SIOW sees set pe ba e ela tul bt i a AENEAN 4 4 Fallure OrDilficuliy OF Tong SRM a a tii ma ae al a anal ata a 4 5 Gereral aq ee TTE 4 6 Assemblies Section Five PRECARI a be at Dd SDPO FOL 5 4 Suppor Roller Brake Band erit ati a ve EEEE ERR beds 5 6 SLIDDOIL Roller Door PIVO ETE 5 8 Rotary Idler Assembly With Gear 5 10 Rotary Idler Assembly Standard Liuius ttai ae at ra a aa Da n anale ia 5 12 9 TASSID oee E E EE E 5 14 POTAS S atit o am i i NU 5 16 E tat die 5 18 Manual AS SOTII pe Dai al a ata ot el atu at 5 20 Cage Pale ASSET AE 9 42 TOG
2. Full Open Pressure Drop External Material Seal Material N Buna N V Viton TECHNICAL MANUAL SECTION CONTENTS 7 29
3. 5 24 mic 5 26 MOUN SNPRA 5 28 DI FSS SIMO ata ot ba ani cc 5 30 DOO _________ _______4__ __ 9 32 coan SJ ASSEDI IRE 5 34 E E Section Six Hydraulic Component Informa lol aici aaa uta bata aur ai i ta Dn il a aia il al a Section Seven DRILLING amp viii SECTION CONTENTS TECHNICAL MANUAL y COMPLETIONS MOVING GLOBAL ENERGY FORWARD TABLE OF ILLUSTRATIONS 22000 22 WUStregon 2 2002 TONG eta ll m aud at fai ia bai ini atu 1 1 1 A 2 1022000 Power Tong DIMENSION s aere ama apa ie ana aie ai alta mata ial le aaa te d pa 1 2 Mili strat Or ZAT SURG A NONE si ceea ee imdb m iasa n alma a e ia ata aa aria Aa a aia aa tin 2 1 Illustration 2 B 1 Major Component Identification 01 2 4 Illustration 2 B 2 Major Component Identification 02 eee nana anna nea 2 5 Illustration 2 B 3 Major Component Identification 03 nea 2 6 TIBI ez Te WA ERN LT eei nana aaa alea 3 ind ee ai aa a Ni a ai Aa 2 7 Illustration 2 C 2 Hydraulic Component Identification 01 00015000000000002 000005550000 0 2 8 Illustration 2 C
4. 150 FLOW gpm 100 RPM 1000 1500 2000 2500 3000 PRESSURE psid 3500 4000 4500 HYDRAULIC Motor INFORMATION VANE CROSSING VANE With it s vane crossing vane design the Rineer motor produces much higher volumetric and mechanical efficiencies than is possible with a standard vane type design This design provides a sealing vane between stator cavities to improve mechanical and volumetric efficiencies Actual Torque and Power 125 CID 7000 6500 300 RPM 6000 5500 50 RPM 5000 5 4500 4000 400 3500 300 RPM 350 O 3000 250 300 2500 200 250 2000 200 1256 150 150 9 1000 100 100 500 50 50 0 500 1000 1500 2000 2500 3000 3500 4000 4500 CODE 61 62 PRESSURE Actual Flow 125 CID 190 180 300 RPM 170 160 150 250 RPM 140 130 ian 200 RPM 110 100 9 00 150 80 70 60 100 50 40 30 50 RPM 20 10 0 500 1000 1500 2000 2500 3000 3500 4000 4500 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 we
5. the sections NOTE VA valve the bolts thread into the outlet casting VC valve tie bolts pass through the entire hank requiring washers and hex nuts to be fastened at bath ends of the bolt Step 3 Section Seals The inlet mid inlet and cach parallel work section have four section seals Fig 1 1 amp 2 on the downstream mating face Series work sections and the salit flow mid have three section seals on the downstream mating face Fig items amp 3 These section seals should be removed and discarded REMINDER ALL WORK MUST PERFORMED IN A CLEAN AREA DRILLING amp 7 20 SECTION CONTENTS TECHNICAL MANUAL MCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD HYDRAULIC VALVE INFORMATION HD22000 22 Valve Disassembly Instructions 3 Step 4 Valve Back Cap Using a large Phallips head screwdinver remove the two screws Fig 1 dem 4 which fasten tbe back cap to the work section Lightly tap the end of the screwdriver handle with a hammer to break adhesive Remie the back cap Fig 1 51 Step 5 Control Spool and Seals Grasp the spring end of the spool with a clean lint free cloth and pull the spool out af the housing using im isting motion Generally the rear retarmer plate Fig itemm amp back up rang Fig item 7 and azal Fig item 8 wall come out with the spool CAUTION For detented spoo
6. Ee E Dn ERR EYE EE ai VER atei ia neta i 6 1 Illustration 6 A 4 Tension Load Cell 6 3 Illustration 6 A 5 Turn Counter Encoder Mount Exploded 2 002 0 0000000000000000000 eee 6 4 DRILLING amp TECHNICAL MANUAL ix MOVING GLOBAL ENERGY FORWARD HD22000 22 The information presented in this document will provide setup operating and maintenance instructions for your HD22000 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 guidelines together with an experienced manager to develop operating procedures that conform to all policies set forth by the operating authority ies IDENTIFICATION OF OF WARNINGS AND OTHER NOMENCLATURE OF IMPORTANCE USED IN THIS INSTALLATION GUIDE McCoy Drilling amp Completions uses three indicators to describe items of three degrees of importance A HAZARD to operators or equipment 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 cata strophic equipment damage or any combination of these A HAZARD may also indicate the potent
7. TECHNICAL MANUAL HD22000 22 55 9cm 80K Lbs Ft Hydraulic Power Tong Specifications Operation Maintenance Assembly 2011 McCoy Corporation All rights reserved Published by McCoy Corporation Technical Publications Department CCOYQ ele 14755 121A Avenue Edmonton AB Canada T5L 272 MOVING GLOBAL ENERGY FORWARD HD22000 22 This manual covers the following models MODEL NUMBER DESCRIPTION 80 1922 1 22 heavy duty hydraulic power tong equipped with hydraulic motor motor control valve lift cylinder control valve chain sling and safety door system NOTE Some illustrations used in this manual may not exactly match your model of tong PATENTED amp PATENTS PENDING DRILLING amp TECHNICAL MANUAL lii MOVING GLOBAL ENERGY FORWARD This page intentionally left blank HD22000 22 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 DR
8. DRILLING amp MCCOY COMPLETIONS TECHNICAL MANUAL 5 19 MOVING GLOBAL ENERGY FORWARD 2 T HD22000 22 SHIFTER ASSEMBLY DRILLING amp 5 20 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD SHIFTER ASSEMBLY 1 22000 22 Motor mount weldment shown without side body weldment for clarity Pat Baton sir ana sem Shing _ _ 3 8 UNC x 1 1 2 Bolt 5 16 x 1 1 2 Clevis La Weiner sitar ig Wetnent 3 1939 _ DRILLING amp MECOY TECHNICAL MANUAL 5 21 MOVING GLOBAL ENERGY FORWARD 22000 22 CAGE PLATE ASSEMBLY N Ps DRILLING amp 5 22 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD HD22000 22 Tone CAGE PLATE ASSEMBLY wm Type 8 fa _ G Pan _ H fm case Pe Space 2 195 shown 2 SwPRA _ e fm supporting SSS M fm Rota Gear om Backing 101 3695 Rear Cage Plate Bolt 101 3753 1 8 NPT Grease Fitting 02 0005 DRILLING amp MECOY TECHNICAL MANUAL 5 23 MOVING GLOBAL ENERGY FOR
9. step 5 Relief Valves Return relief valves to their proper posiions and borque do 75 fi lka install meu section seals Place section seals Fig amp 2 or stems amp 3 in the proper grooves Make certam amp cals stay in their eroic dunng assembly Step 6 Install Bolts Slide th through rhe inlet casumg IT cap screws are used place a washer on the cap screw prior to installation Place ibe valve sections on the tie bolts in iheir proper sequence see Step 4 Turmmg by hand engage several threads in the outlet If i is a series assembly assemble net and washer to either end the and follow above instractions the tic bolls im cross come r pacem Tie Bolt Torque Values VA20 23 ft iba 348 in 168 VG20 42 ft Ibs 504 in Ibs VA35 34 ft Ibs 408 in Ibs VG35 75 ft Ibs 900 in Ibs VGB0 150 ft Ibs 1800 in Ibs MOVING GLOBAL ENERGY FORWARD 7 26 SECTION CONTENTS TECHNICAL MANUAL VALVE INFORMATION TROUBLE Chl leaks between sections Chl leaks at either end of spool Troubleshooting PROBABLE CAUSE Pinched blown of missing section seal Stud fasteners not correctly torqued Mounting plate not level Contamination burrs on seal Cver pressurized tank core Wom or damaged spool seals Spring centered spools do not
10. 9 VL C Item gt Assembly Part Part Part Part Part Part Part Part Part SECTION CONTENTS Description Standard Turn Counter Encoder Mount 6 32 x 3 8 Hex Socket Head Set Screw Helical Flexible Encoder Shaft Coupling Internal Retainer Ring Bearing Encoder Housing Internal Retainer Ring Encoder Shaft Encoder Gear 10 24 x 1 1 4 Hex Socket Head Set Screw TT Qty Part Number 60 0001 60 0130N 1376 13 1376 05 1392 104A 01 0320A M 5 ms MR MB roni ILLUSTRATION 6 A 5 TURN COUNTER ENCODER Mount EXPLODED TECHNICAL MANUAL NCCOY MOVING GLOBAL ENERGY FORWARD 02 0436 i G 1392 103A 01 DRILLING COMPLETIONS HD22000 22 TORQUE MEASUREMENT 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 Symptom Possible Problem Solutions Possible Problem Solution Possible 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 Pr
11. VING GLOBAL ENERGY FORWARD 22000 22 GEAR TRAIN LAYOUT AIR 5 DRILLING amp 5 2 TECHNICAL MANUAL MECOY MOVING GLOBAL ENERGY FORWARD GEAR TRAIN LAYOUT HD22000 22 Tone Dmm mme Pam BEEN EE sgN NAE _ Pion assomby ee 556 857 i MEME Rotan 57 519 O Assembly Rotary ler Assombly Win Gear Pat 510 51 2 G Assembly Suppor Roler esas Rye Assembly Assomby ep 518 85 1 p 528 520 _ 1 E Assembly Support Roler Brake Band Pp 565 J gt lt am 1 E 41 TT LE m DRILLING amp AACCCON COMPLETIONS TECHNICAL MANUAL 5 3 MOVING GLOBAL ENERGY FORWARD HD22000 22 SUPPORT ROLLER ASSEMBLY 9 4 DRILLING amp SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 22000 22 SUPPORT ROLLER ASSEMBLY me ay _ 4 fm WeNFGemeF n 2 oor 8 fm ros eee os _ e rm pnew Tapered Rorer Bean rasare Re eem oo G a super eter acer aro Pan 85 0 7 DRILLING amp AACCCOY COMPLET
12. manganese bronze guide ring ring for gouges cracks and other damage Remove the top cage plate and move to a suitable storage location 22 Pull the top bearing cap and spacer for the pinion drive gear by removing the four 1 2 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 FARR SERVICE PERSONNEL RECOMMENDS LEAVING IT IN PLACE UNTIL THE TOP TONG PLATE IS REMOVED 23 Remove the top 1 1 2 nylock nuts and pads for the four rotary idler gears 24 Remove the nylock nuts from the top of the support roller shafts Use a soft alloy material e g brass rod etc to lightly tap the shafts downwards until they are flush with the top plate of the tong 25 Remove the hex head bolts and washers and countersunk socket head screws around the perimeter of the tong which secure the top plate to the gear case housing 26 With all the above steps taken the top tong plate weldment can be lifted off providing access to the inside of the gear case DRILLING amp AACCCOY TECHNICAL MANUAL 3 13 MOVING GLOBAL ENERGY FORWARD 22000 22 MAINTENANCE H ASSEMBLY PROCEDURES Assembly of Farr Hydraulic Power Tongs is simple and can be accomplished without the use of special tools The instructions on this pag
13. 3 Insert an inner support roller spacer PN 1393 134 into the centre of each support roller and insert a second bearing the other end of the support rollers 4 Slide a regular threaded support roller shaft PN 1393 131 through eight of the support roller assemblies centering as best as possible in the assembly 5 Slide a brake band coincidental support roller shaft PN 101 1917 through two of the support roller assemblies centering as best as possible in the assembly 6 Pressan idler bearing PN 1393 106 into each of the four rotary idler gears PN 1393 119 until it comes into contact with the inner lip of the gear orient the gear so the inner lip is on the bottom Insert an outer spacer PN 1393 109 into each gear until it comes into contact with the bearing 7 Ensure the rotary idler gears are oriented so that the lips on the gears are down Lightly grease the two rotary idler shafts PN 101 2229 intended for use with idler assemblies equipped with gear plates see Pp 5 10 5 11 and insert into bearing ensuring the bottom sides of the shafts are down the top of the idler shaft is threaded for a grease fitting Slide an inner spacer PN 1393 108 over each shaft until it comes into contact with the previously installed bearing 8 Slide an idler bearing PN 1393 106 over each of the two shafts installed in the previous step until they come into contact with the inner and outer spacers Secure bearings
14. SHIFTING TONG WHILE ROTATING THE MOTOR AND CAGE PLATE MAY RESULT IN CATASTROPHIC GEAR TRAIN FAILURE DRILLING amp 2 24 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD HD22000 22 Tone SETUP amp OPERATION Breaking A Connection Continued J motor control valve toward the operator to rotate the cage plate in the break out direction ILLUSTRATION 2 H 9 ROTATION CONTROL BREAK OuT When the tong jaws cam 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 m ILLUSTRATION 2 H 10 RELEASING TONG Jaws FOLLOWING BREAK OUT amp UN THREADING COY TECHNICAL MANUAL 2 25 MOVING GLOBAL ENERGY FORWARD HD22000 22 SETUP amp OPERATION Breaking A Connection Continued o 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 re
15. 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 ILLUSTRATION 3 D 8 SHIFTER SHAFT LUBRICATION COY TEcHNICAL MANUAL 3 9 MOVING GLOBAL ENERGY FORWARD 22000 22 MAINTENANCE 8 Motor Mount Housing Apply grease to the gears in this housing through the two grease fittings on the bearing cap on top of the motor mount in the area indicated by the red circle ILLUSTRATION 3 D 9 Motor Mount LUBRICATION 9 Tong Door Adjustment Cam Lubrication Apply grease to the door adjustment cams through the grease fittings mounted in the ends of the adjustment cam shafts on the top and bottoms of the door weldments four locations total i CP a j 7 nul Th ILLUSTRATION 3 D 10 DooR ADJUSTMENT CAM LUBRICATION 3 6 SECTION CONTENTS TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD MAINTENANCE 22000 22 10 Door Stop Spring Cylinder Periodically disassemble the door stop cylinders and coat the spring and cylinder with a general purpose lubricating oil ILLUSTRATION 3 D 11 DooR SPRING CYLINDER E ADJUSTMENTS 1 Brake Band Adjustment 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 c
16. assembled in Step 6 so that the lips on the gears are down Lightly grease the remaining two rotary idler shafts PN 1393 117 and insert through the bearings inside the gears ensuring the bottom sides of the shafts are down the of the idler shaft is threaded for a grease fitting Slide an inner spacer PN 1393 108 over each shaft until it comes into contact with the previously installed bearing 16 Slide an idler bearing PN 1393 106 over each of the two shafts until they come into contact with the inner and outer spacers Secure bearings and spacers in each idler gear with a retainer ring PN 1393 110 Center the gear and bearing assemblies as best as possible on the shafts 17 Slide a rotary idler spacer PN 1393 121 over the bottom end of the remaining two rotary idler assemblies and insert through bottom plate ensuring the idler spacer is between the bottom plate of the tong and the rotary idler gears Mesh the gears with the previously installed rotary idlers Slide the remaining two rotary idler spacers over the tops of the two rotary idler shafts 18 Press the remaining two gear plate bearings PN 1393 93 in to the two remaining gear plates PN 101 2227 Slide a gear plate over each of the two rotary idlers in contact with the rotary gear Slide a rotary idler gear spacer PN 101 2228 over the top end of each shaft and press against the gear plates 19 Use 1 1 2 UNF nylock amp 1 1 2 flat wash
17. four locations total DRILLING amp 3 22 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 22000 22 Assembly Procedures 74 Install grease fittings continued iii Install one 1 8 NPT grease fitting PN 02 0005 into each rotary idler shaft on the top of the tong four locations total and one 1 8 NPT grease fitting into each pinion idler shaft on the bottom of the tong two locations total iv Install one 1 8 NPT grease fitting PN 02 0005 into the end of the clutch shaft in the centre of the clutch bearing cap v Install eight 1 8 NPT grease fittings PN 02 0005 into the top cage plate and eight 1 8 NPT grease fittings into the bot tom cage plate 16 locations total vi Install two 1 8 NPT 90 grease fittings PN 02 0093 in each pinion bearing cap four locations total vil Install two 1 8 90 grease fittings PN 02 0093 in clutch bearing cap two locations total viii Install one 1 8 NPT 90 grease fitting PN 02 0093 in the top of the motor mount between the motor and the hydraulic support 75 Install the hydraulic valve assembly on to the valve mount weldments using one 1 2 UNC x 4 1 2 hex bolt and 1 2 lock washer per valve mount 76 Install main inlet and outlet lines using four hydraulic clamp plates PN 101 3777 and 1 2 UNC jam nuts to secure the inlet and outlet lines within the hydraulic l
18. 3283 015 391 0282 010 391 3581 130 391 2583 008 391 1432 021 391 3581 633 391 1642 013 391 3283 008 301 0282 009 301 3581 015 391 2583 006 391 1402 452 391 3581 330 391 1642 161 391 3384 310 391 0282 011 391 3581 316 391 3384 311 391 3782 208 TECHNICAL MANUAL SECTION CONTENTS 7 19 HD22000 22 HYDRAULIC VALVE INFORMATION 4 Valve Disassembly Instructions Reference exploded view and parts list wl page 2 and 3 for work section detail Step 1 Valve Bank This step s the most critical in the disassembly procedure It should be followed closely to ensure that the valve bank is properly reassembled after repairs have made With a waterproof quick drying marker mark each casing wath a sequential number Start by the inlet casting with the 1 and finish by marking the outlet with the highest number Next mark the port boss closest t the back cap on each work section with a for back end Then mark the port boss closest to the spool clevis on each work seccion with for clevis end Finally if relief valves are remove from the valve bank they must be marked with the conmesponding number of the casting and port location B or from which they were removed Inlet and mid inles relief valves are marked with a casting number Step 2 Tie Bolts Remove the four ie bolts that hold the bank together and
19. 34 SECTION CONTENTS TECHNICAL MANUAL AACCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD CHAIN SLING 22000 22 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 LOCTITE Par 02 0517 Part Hammer Lock Connector 4 per chain 02 0607 NEN 4 Assembly Chain Sling 101 3762 Master Link 4 Link Chain Set 0999 Part Part Part Part Part Part art DRILLING amp TECHNICAL MANuAL 9 35 MOVING GLOBAL ENERGY FORWARD This page intentionally left blank TORQUE MEASUREMENT HD22000 22 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 t
20. 3527 Oxidation stability psi ASTM D 942 Water washout percent ASTM D 1264 Rust and corrosion ASTM D 1743 Oil separation percent loss ASTM D 1742 24 hours 25 C 77 F Leakage g lost ASTM D 4290 Four ball wear test mm scar ASTM 2266 Fretting wear mg ASTM D 4170 Four ball EP kgf ASTM D 2596 Weld point Load wear index Timken OK load test 16 ASTM D 2509 Low temperature torque N m ASTM D 4693 40 C 40 F LT 37 pumpability g min 60 F 0 F 16 C 18 C Copper corrosion ASTM D 4048 Disc brake wheel bearing specifications Ford ESA M1C 198A Chrysler MS 3701 Oil viscosity 40 C 104 F cSt 100 C 212 F cSt Flash point F C ASTM 92 Lithium Complex 2 GC LB 265 295 minimum 550 288 minimum 160 minimum 100 hr 300 hr 0 3 1 8 max pass 1 1 max 1 0 max 0 40 max 3 4 max 400 minimum 50 minimum 50 1 3 max 360 7 1B Yes Yes 151 19 2 4501232 Use a premium quality hydraulic fluid that meets or exceeds the following specifications Typical Density kg m Viscosity cSt 40 C cSt 100 C Viscosity Index Pour Point F C Flash Point F C Colour ASTM Neutralization Number Rust Protection Distilled Water Sea Water Hydrolytic Stability Cu Mass Loss mg cm Copper Corrosion Test Filterability Denison Wet amp Dry Afnor Wet amp Dry Cincinatti Milacron Spec Approved Denison 0 Denison P 4
21. 5 POSSIBLE PROBLEM Shifter has malfunctioned and the tong is not shifting to high gear SOLUTION Inspect and repair shift mechanism as necessary 6 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 7 POSSIBLE PROBLEM Safety door system is not properly adjusted hydraulic fluid leak past Deltrol valve SOLUTION Check and adjust safety door system 8 POSSIBLE PROBLEM Hydraulic 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 9 POSSIBLE PROBLEM By pass valve not functioning SOLUTION Check and repair DRILLING amp 4 4 SECTION CONTENTS TECHNICAL MANUAL AACCCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD TROUBLESHOOTING HD22000 22 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 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 SOLUTIO
22. MAINTENANCE Assembly Procedures cont d 69 Install the safety door components on to the door weldments using the following procedure i Attach the LH safety door latch PN AE13 3015 to the LH latch plate PN 101 3759 using three 3 8 UNC x 1 hex socket flat head cap screws Attach the LH latch plate to the LH door weldment using four 3 8 x 1 hex socket UNC shoulder bolts ii Attach RH safety door latch PN AE13 302M to the safety door spacer plate PN 101 3760 using four 3 8 UNC x 1 hex bolts and 3 8 lock washers Attach spacer plate to the RH door weldment using four 3 8 UNC x 1 1 4 hex bolts and 3 8 lock washers Insert load plunger PN AE12 306 into LH safety door latch block which was installed in Step 69 1 iv Attach three 1 4 NPT JIC elbows to the Deltrol safety door valve PN 08 0337M Position a 15 16 valve lock nut as shown in illustration 3 H 8 and secure the safety door valve to the safety door latch block using the valve lock nut ILLUSTRATION 3 H 8 SAFETY Door VALVE INSTALLATION v Attach the safety door switch guard weldment PN 101 3761 to the LH tong door weldment using three 3 8 UNC x 1 hex bolts and 3 8 lock washers ASSEMBLY NOTE Ensure that the doors have been aligned and adjusted before the final safety door latch adjustment is made refer to Section 3 E 3 70 Install the four chain sling hanger weldments PN 101 3781 to the bottom side of the tong using two 1
23. MOVING GLOBAL ENERGY FORWARD 22000 22 TROUBLESHOOTING TONG WILL NOT DEVELOP SUFFICIENT TORQUE Cont d 10 POSSIBLE PROBLEM Load cell is measuring incorrectly SOLUTION Incorrect load cell is being used SOLUTION Air is trapped in torque measuring circuit load cell hydraulic 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 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 FARR CANADA CORP GUARANTEES CALIBRATION OF A LOAD CELL TORQUE GAUGE ASSEMBLY FOR A PERIOD OF ONE YEAR FARR CANADA CORP RECOMMENDS THAT THE LOAD CELL TORQUE GAUGE ASSEMBLY BE RETURNED TO THE FACTORY FOR RE CALIBRATION ONCE PER YEAR DRILLING amp 4 2 SECTION CONTENTS TECHNICAL MANUAL AACCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD TROUBLESHOOTING 22000 22 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
24. Replace hydraulic 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 hydraulic 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 DRILLING amp COMPLETIONS MOVING GLOBAL ENERGY FORWARD 6 5 TECHNICAL MANUAL SECTION CONTENTS 22000 22 ToRQUE MEASUREMENT C PERIODIC INSPECTION AND MAINTENANCE 1 6 6 Inspection The torque measurement system supplied with your equipment is designed and built to provide years of trouble free service with minimum maintenance Periodic inspections of the load cell hydraulic lines and fi
25. ai al dat Em aaa paleti 3 2 W ustrauon molan daler 3 3 PINON laler ina ami om inca oa tin si MER aiba rd au ea PA AR am aci tite ap oa aia tea aa 3 3 3 D 5 Pinion Lubrication Top Plate dna aaa ca aa aa aaa tu na dea pala ea aa 3 4 Illustration 3 D 6 Pinion Lubrication Bottom 3 4 TIPS Uo 3D 7 Clutch LUDICO ai te 3 5 Illusiration 3 D 6 Shifter Shaft uiui ie ore ttt am ta ea aa aa gata alai d al a ae a alu d a pana 3 5 Wustrauon 9 D 9 Molor Mouni LUDEICBIHOFP neam amarati ada ama lea aa dna ani ada 3 6 Illustration 3 0 10 Door Adjustment Cam Lubrication 3 6 TIPS Uo 3 0 Spring Ov 3 7 illustration SE T Brake band m isa aaa pita E aval lo ata 2 7 ustalona E Z Lateral DOOPAGIUSHNCHE ana ii oa 3 8 IE gc Ie M DOE ANGEL 3 9 Illustration 3 E 4 Shifter Detent Force Adjustment eese esses 3 9 Illustration 3 E 5 S
26. 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 and 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 22000 22 SETUP amp OPERATION 1 Inspection Of Slings McCoy Drilling amp Completions 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 damage 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 A load bearing device shall be removed from service if condition
27. be achieved the shifting shaft detent ball or detent spring or possibly all three may need to be replaced see Pp 5 16 5 17 ILLUSTRATION 3 E 4 SHIFTER DETENT FORCE ADJUSTMENT DRILLING amp AACCCOY COMPLETIONS TECHNICAL MANUAL 3 9 MOVING GLOBAL ENERGY FORWARD 22000 22 MAINTENANCE 5 Safety Door Switch Adjustment The safety door switch should interrupt hydraulic power to the motor when the tong door is opened or even slightly ajar This is a Critical safety system and proper adjustment is necessary to maintain the intended function If the rotary gear does not stop immediately and completely stop rotating when the door is opened remove the tong from service and perform the following adjustments PERFORM LATERAL DOOR ADJUSTMENT AND DOOR ALIGNMENT PROCEDURES BEFORE ATTEMPTING SAFETY DOOR SWITCH ALIGNMENT a Close the doors Ensure the two safety door claws are seated firmly together Tap the bottom mounting plate one way the other until the shoulder bolts installed in Step 7 are in the centre of the traveling slots in the floating plate Loosen four 3 8 bolts on the adjustment plate _ 3 10 Correct position shoulder bolts within the traveling slots ILLUSTRATION 3 E 5 SAFETY SwitcH ADJUSTMENT 01 b Mark the position of the mounting plate on the door weldment in the event it moves before it can be secured permanently c Remove the four should
28. both ends of the housing wiih LOCQUIC Primer Grade NF and let dry Spring Center Spool Assembly CAUTION Fellow the adhesive manufacturer s instructions for proper cleaning and curimg Failure n clean and prepare parts properly may result in assein biy failure DRILLING amp COMPLETIONS AACCCY gt MOVING GLOBAL ENERGY FORWARD CAUTION Failure to follow the recommended assembly instructions can result in poor performance or product malfunction Product should be thoroughly tested to ensure proper operation before the valve is placed back into service Step 1 Spool Assembly Spring Centered Clamp flat chevis end of the control spool im a soft jawed vise Apply Parker Super CO LubeTM to the spon seal Fig 1 8 and slide onte the ead of the spool away from the clevis Slide on the back up ring Fig 1 item 7 and retamer plate Fig item these onte the so thar they do interfere with the operator mechanism duning assembly Do nos allow the bo core m eantact wilh sharp edge of the spool notches Step 2 Attach Spring Guides and Spring Apply 2 3 drops of Loctite 262 or equivalent adhesive near the maldle of the female threads in spool Assemble the spring guides Fig 2 item 16 centering spring Fig 2 item 15 and stripper bolt Fig 2 item 14 onto the spool Reverse of Step 7 the st
29. for the diameter of pipe or casing being run 3 POSSIBLE PROBLEM Incorrect dies are being 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 TECHNICAL MANUAL 4 3 MOVING GLOBAL ENERGY FORWARD HD22000 22 Tone TROUBLESHOOTING C TONG RUNNING TOO SLOWLY 1 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 2 POSSIBLE PROBLEM Power unit is not producing adequate flow or pressure SOLUTION Troubleshoot power unit see user s manual for your particular unit 3 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 4 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
30. 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 the torque gauge Replace the brass cap on the gauge check valve fitting Repair And Calibration Load cell and indicator gauge should be returned to authorized repair facility for any repairs or calibration required DRILLING amp SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD HYDRAULIC INFORMATION 22000 22 AACCCOY 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 All original copyrights claimed by the manufacturer s apply DRILLING amp NALCO Y TECHNICAL MANUAL 7 1 MOVING GLOBAL ENERGY FORWARD This page intentionally left blank HD22000 22 Tone HYDRAULIC Motor INFORMATION lt gt RINEER POWER to be the Best HY DRAULGSHING MOTOR SELECTION GUIDE Features
31. 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 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 Make up female fitting to Marked point on male fitting ILLUSTRATION 2 D 2 HyDRAULIC CONNECTIONS 02 E TONG JAW AVAILABILITY amp INSTALLATION 1 Jaw Availability The following table lists all jaw die kits that are available as standard stocked sizes for this model of tong McCoy Drilling amp Completions Farr offers a good selection of standard jaw sizes However please note that we can custom engineer and manufacture any size of jaw within the range of the tong Jaw systems are available to allow use of die inserts intended for specialized applications Call our sales office for information on jaw and die systems designed for higher or lower grip or non marking applications The table lists standard contoured flat and wraparound die inserts that are available as spare parts However a wide variety of diamond tooth GRITFACE aluminium and wrap around fine tooth dies are available for specialized applications Please refer to our website for complete information http www mccoyglobal com index php dies inserts Description Part Number Description
32. limitation may vary with different applications When using the 125 Series standard motor above 300HP consult a Rineer Application Engineer FPL T1 32021X 30218X MOVING GLOBAL ENERGY FORWARD 21 32 DIA THRU 6 PLACES EQ SP ON A 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 COMBINED LOAD 3 000 HRS 1 10 BEARING LIFE PUSH Radial load located at center of effective output of the shaft 50 RPM 100 RPM 200 RPM 3 300 RPM 16 000 14 000 350 RPM 12 000 LLL Ye __ Thrust Push Ibf 0 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
33. not simply lift up and place in the correct position see Illustration 2 next page The cage plate opening must be aligned with the door opening when setting the backing pin position DRILLING amp MECOY TECHNICAL MANUAL 2 19 MOVING GLOBAL ENERGY FORWARD 22000 22 SETUP amp OPERATION Making A Connection Continued ILLUSTRATION 2 H 2 SETTING BACKING Pin To Make up PosiTION c Ensure the load and snub line s are properly configured for making up connections The 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 prevents the tong body from spinning in the opposite direction of the cage plate when torque begins to build in the joint The snub line 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 snub line is attached 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 must be perpendicular to the vertical and perpendicular to the centre line of the tong d Actuate the lift cylinder control valve to lift the assembly from the drill floor Pushing the valve toward the center of the tong will retr
34. rota irt a ara am a etu FEX alee nt na ata a KE 2 18 TIPS Ue NS NEN Master Lng LIK 2 19 Illustration 2 H 2 Setting Backing To Make up Position 4000 000000000000000 00000 8 2 20 Illustration 2 H 3 Lift Cylinder Control Raise eee eese 2 20 IRE Ho WM E 2 Opening TONG DOORS 2 21 Illustration 2 H 5 Motor Control 2 7 2 000000000000000 eee 2 22 Illustration 2 H 6 Motor Control Releasing JAWS 2 22 Illustration 2 H 7 Lift Cylinder Control 2 23 Illustration 2 H 8 Setting Backing Pin To Break Out 2 24 Illustration 2 H 9 Rotation Control Break Out sss essen nennen nena nnns nsns ann nn sess 2 25 Illustration 2 H 10 Releasing Tong Jaws Following Break out amp Un threading 0001000 2 25 Illustration 2 H 11 Lowering Tong Using Lift Cylinder ener 2 26 Illustration 3 D 1 Guide Support Ring Lubrication ertt trn tae adeo E EE ones 3 2 Illustration 3 D 2 Support Roller aa ea paine ema m aaa a
35. see illustration 3 E 3 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 AACCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 22000 22 MAINTENANCE Door Alignment continued Measurement i P Measurement Measurement 1 i 2 1 ILLUSTRATION 3 E 3 DOOR ALIGNMENT The three measurements should be equal If the centre measurement is less than the two outside measurements loosen all 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 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 4 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
36. 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 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 SEcTION CONTENTS TECHNICAL MANUAL MECOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Setup amp OPERATION HD22000 22 The following illustration demonstrates the type and effect of the hydraulic valves with which this tong is may be equipped TONG MOTOR This is a proportional valve Pushing the valve handle forward will cause the 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 counte
37. that any exposed hydraulic ports are protected from contamination 11 Remove the shifter handle weldment by removing both clevis pins and hitch pins securing it to the shifter shaft and mounting lug weldment The mounting lug weldment may be removed if desired but removal from the top plate of the motor mount is not required 12 Loosen the locking nut on the shifter detent force adjustment bolt see Section 3 E 4 and un thread the adjustment bolt to relieve compression on the detent spring Do not completely un thread the bolt from the detent tube 13 Remove the access panel on the left rear side of the body adjacent to the motor mount Remove the 3 4 nylock nut from the bottom of the shifting shaft to loosen the shifting fork The shifting shaft may now be carefully rotated and pulled straight up and out of the shifter bushings Use caution not to lose the detent ball which may become displaced from the detent tube on the top shifter bushing when the shifting shaft is removed 14 Remove the motor mount by removing the eight socket head cap screws The motor mount weldment can be lifted out of place Take care not to lose the two positioning dowel pins one or both may come off with the mount 15 Remove the 1 4 flat head countersunk machine screw and retainer plate that secures the top clutch gear to the clutch shaft Remove the top clutch gear use caution not to lose the two gear keys that may come off with the gear Remove the top clu
38. the RH door assembly to the open position Support the entire weight of the door assembly using a temporary lifting sling and crane using caution not to put any upward force on the door assembly Remove the nylock nuts securing the top and bot tom of the door pivot shaft followed by the narrow flat washers Use a soft alloy material e g brass rod etc to lightly tap the shaft up through the support roller assembly until it comes free at the top using caution not to damage the threads on the ends of the support roller shaft Use the crane to move the door assembly to a suitable storage location DISASSEMBLY NOTE The safety door switch components may be left in place on the door assemblies 8 Undo any restraints securing the flexible safety door hydraulic lines to the top plate Repeat Step 7 for the LH door assembly Use caution that the flexible safety door lines do not snag on any protruding object as the door assembly is moved to a suitable location and ensure the exposed connectors on the hydraulic lines are protected from contamination 9 Remove the torque gauge mounting plate from its holder if not already done 10 Remove the six 5 8 x 2 bolts securing the motor and lift the motor off the motor mount Inspect the motor gear located at the bottom of the motor shaft for gear clashing or tooth damage Confirm that the motor gear remains securely attached to the motor shaft Move the motor to a suitable clean storage location and ensure
39. the beams 1 7 have a minimum size of 4 x 4 x width of the tong Cover the tops of the wooden beams with more protective cloth to prevent paint damage 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 INBOTH 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 INBOTH DIRECTIONS to dissipate any residual pressure in the remainder of the hydraulic control system 7 Connect a low pressure air supply line 10 PSI or less to the hydraulic supply line and force a small amount of the re
40. 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 nation from residual hydraulic fluid dirty grease and cleaning agents Inspect all fasteners and fastener safety wires Replace any missing fasteners use Grade 8 bolts only Re torque all external fasteners to SAE specifications Inspect backing pin s If cracked broken or bent it they must be replaced Repair or replace any damaged or missing external body parts such as torque gauge mounts hydraulic supports safety door protectors etc Inspect all paint locations in which the paint has been damaged must be repaired prior to storage Prepare areas to be 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 Generously fill the gear train housing with grease through the access panel and also through the opening in the rotary gear 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 Energize power unit Rotate tong for one minute st
41. 0 psi V A models cast from gray iron and are rated al 2500 psi These open center directional control valves are available in parallel tandem and series circuitry As needed the sectional stack type construction provides flexibility for the addition of subtraction of work sections to an existing valve bank This design also the combination of parallel tandem and series circuitry in a single bank The internal coring of each valve section determines 115 circuitry and the number of gasket seals required All sections with optional features such as port relief valves crossover relief valves and anti cavitation checks are dimensionally larger when measured from the top of the port to the bottom of the housing These are referred to as hi boy sections Those without work port options can use the low profile castings which are called boy sections AACCCOY MOVING GLOBAL ENERGY FORWARD REPLACEMENT PARTS The illustrations and instructions in this manual apply only to the V A VG series assemblies subassemblies and components All valve components except for spools and housings are available as replacement parts or subassemblies Spools are hone fitted to their individual housings so damage to either of these components means the entire section must be replaced We recommend that you use only genuine V A VG senes replacement parts in your service program Manufactured to the sa
42. 2 UNC x 2 1 4 hex bolts and 1 2 lock washers per weldment Slide a hanger bracket base PN 101 3783 over the top of each hanger and secure to the top plate using two 1 2 UNC x 2 1 4 hex bolts and 1 2 lock washers per bracket base 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 LOCTITE 71 Install shifting handle weldment PN 101 1749 Secure the handle to the shifter shaft using 5 16 x 1 clevis pin and 0 093 1 125 hitch pin and secure the handle to the shifter pivot lug weldment using a 5 16 x1 1 2 clevis pin and 0 093 x 1 125 hitch pin 72 Install three hydraulic valve mount weldments PN 101 1442 to the top plate using one 3 8 UNC x 1 hex bolt and 3 8 lock washer per weldment Ensure the tabs on the weldments are pointed toward the back of the tong 73 Attach the hydraulic line support base weldment 101 3779 to the top plate of the motor mount using four 3 8 UNC x 1 1 2 hex bolts and 3 8 lock washers 74 Install grease fittings i Install one 1 4 straight thread grease fitting PN 02 0097 into the top and bottom of each support roller shaft including the door pivot rollers 24 locations total ii Install one 1 4 straight thread grease fitting PN 02 0097 into each door latch adjustment cam
43. 2000 22 HYDRAULIC VALVE INFORMATION hydraulics _ Pr Capacity Pilot to open spring biased closed unbalanced 60 gpm 240 L min poppet logic element Functional Group Products Cartridges Corrosion Resistant Logic Element Unbalanced Poppet Model Pilot to open Switching Element Spring biased closed External Pilot Port 3 LKHC pilot source Product Description These unbalanced poppet logic valves are 2 way switching elements that are spring biased closed Pressure at either work port 1 or 2 will further bias the valve to the closed position while pressure at port 3 will tend to open it The force generated at port 3 must be greater than the sum of the forces acting at port 1 and port 2 plus the spring force for the valve to open NOTE The pilot area port 3 is 1 8 times the area at port 1 and 2 25 times the area at port 2 LOCATING SHOULDER A 1 81 46 0 1 81 46 0 CONTROL SHOWA INSTALLED CAVITY DIMENSION ACROSS FLATS 1 1 4 31 8 PILOT PORT in Technical Features e Because these valves are unbalanced e These valves are pressure responsive operation is pressure dependent at all three ports therefore it is Opening and closing of the poppet are essential to consider all aspects of functions of the force balances on three system operation through a complete areas 1 Port 1 100 Port 2 80 cycle Pressure changes at any one and Po
44. 22000 22 WARNING RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION Assembly of Motor HYDRAULIC Motor INFORMATION 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 STATOR Normal wear results in polishing of cam form which does not impair motor performance Noticeable wear may be apparent along the corner of one side of the stator vane slot This does not necessarily require replacement of the stator but may slightly affect volumetric efficiency 4 Measure the rotor and Stator length to the fourth decimal point and supply measurement when ordering rotor stator or vanes SECTION CONTENTS TECHNICAL MANUAL 1 Reverse the procedures in steps 13 12 11 and 10 Before installing timing plate onto completed sides of rotating group pour a small amount of hydraulic oil onto rotor surface 2 NOTE Make sure that the radiused edge of each stator vane po
45. 3 Hydraulic Component Identification 02 2 8 Illustration 2 C 4 Hydraulic Component Identification 03 1 0000000000000002000000555000 2 9 TIBI ez Te WA Connections UT 2 9 Illustration 2 D 2 Hydraulic Connections 02 siana aa ama ina aaa ana im sata aa tie ana ai MR E AL FEL 2 10 Jaw ss aa aa ai 2 11 lllustration 2 E 2 Jaw Die FReblacemehl aaa am a avarie e anatema aa led net alle mail a a EYE aa rai ad aa aria EE AF 2 11 Illustration 2 E 3 Alignment Block Adjustment 01 For 22 Jaws Ontly sss eee 2 12 Illustration 2 E 4 Alignment Block Adjustment 02 For 22 Jaws 2 2 00 0000000000000005000000 nnns 2 12 Illustration 2 F 1 Tong Suspension Relative To Axial Centre esses nnne nnn nnne annees 2 14 Illustration 2 F 2 Tong Suspension Relative To Vertical 2 14 Illustration 2 F 3 Tong Leveling Using 2 15 Illustration 2 6 1 Tong Rotation Control naa sans sna nn nnns 2 17 Illustration 2 6 2 Tong Lift Cylinder Control 2 17 Illustration 2 6 3 Tong Manual SHUT a ia oo ttti
46. 33 Install the low clutch gear PN 1393 52 ensuring the smaller diameter portion of the gear is oriented so it is next to the centre gear on the clutch shaft followed by a clutch shaft spacer PN 1393 50 01 34 Assemble the shifting fork shifting shaft and the 3 4 NC nylock nut to secure the fork to the shaft Position the shifting fork with the shifting collar in its final position as best as possible ILLUSTRATION 3 H 3 SHIFTING PLACEMENT DURING INSTALLATION 35 Install low pinion gear PN 1393 88 followed by the remaining pinion gear spacer PN 1393 94 ensuring the non machined side is flat against the gear 36 Ensure each of the ten support roller assemblies has a support roller bearing spacer PN 1393 140 placed over the support roller bearing before top plate installation Ensure each of the rotary idlers in contact with the pinion idlers have a idler gear spacer PN 1393 121 placed over the top rotary idler bearing before top plate installation COY TECHNICAL MANUAL 3 17 MOVING GLOBAL ENERGY FORWARD 22000 22 MAINTENANCE Assembly Procedures cont d 37 Clean the three non threaded holes for the dowel pins in the side body one on either side of the opening and one just to the right of centre at the rear of the side body 38 Use a temporary sling and crane to carefully position and install the top plate The plate must be installed parallel to the top of the side body to avoid binding on
47. 6 Piston Pump Denison T6C Vane Pump Vickers 35VQ25 Vane Pump Test 104 105C Vane Pump Test Vane pump test total ring and vane wear mg Oxidation Stability Turbine Oil Stability Test Life hours Rotary Bomb Oxidation Test minutes FZG Spur Gear Test Failure Load Stage FLS 1 4 TECHNICAL MANUAL SECTION CONTENTS 878 68 8 8 7 97 22 30 432 222 1 5 0 40 No Rust No Rust 0 04 1A Pass Pass P69 Approved Pass Pass Pass No Data Available lt 10 2500 325 12 DRILLING amp COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION 22000 22 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 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 PAR
48. 8 11 200 ft Ibs Standard 125 drill motor seal kit Seal Plate 3 8 16 45 ft 108 KT SE1250947 Grease used for bolt threads Standard 125 double stack seal kit and o ring retention KT SE1250948DS Pennzoil 7071 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 2 5 Series seals amp O rings unique to that motor Cross Section NL i ig INS N 422 ur r S G TT 2 d DRILLING 8 7 14 SECTION CONTENTS TECHNICAL MANUAL MCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD HYDRAULIC VALVE INFORMATION 22000 22 Inlets 2500 psi End Inlet ipali ans machine tor a main in FUN ar Ri and ara hures with closures q Te Mo Soo Socios G Page 22 iniet port plugs Ay Adjustable Relief Valve Cartridges For Inlets and Mid section Inlets Code Deserigtian DwWA35 MRV 1 pressure range 800 2000 psi Factory set 1500 psi 50 DwWA35 MRV 2 Maan pressure range 2001 2500 psi Factory set 422500 pe 50 gpm DWASG MRVP robot valve plug SA8 Sechon 3 Posibon Hold in Neutral Cylinder Spool MAS Double Acting Sector 4 a 3 Pom
49. A 1 ToRQUE GAUGE FoR ILLUSTRATION PURPOSES ONLY ILLUSTRATION 6 A 3 COMPRESSION Loap CELL Torque gauges and load cells are supplied as a matched calibrated pair Substituting one 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 MECOY TECHNICAL MANUAL 6 1 MOVING GLOBAL ENERGY FORWARD 22000 22 ToRQUE 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 T
50. ANT AACCCY MOVING GLOBAL ENERGY FORWARD BEARING LIFE FOR RADIAL LOAD AT 2 8 FROM MOUNTING FACE TO CENTER OF OUTPUT SHAFT BEARING LIFE 3 000 HRS L19 AT DISTANCE FROM MOUNTING PLATE DRILLING amp COMPLETIONS HYDRAULIC Motor INFORMATION 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 10 06 pe 18 7 00 382 STD SAE 1 4 BOLT FLANGE HD22000 22 CASE DRAIN AND CROSS PORT LEAKAGE The combined case drain and 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 r
51. COMBINED LOAD 3 000 HRS 10 BEARING LIFE PULL Radial load located at center of effective output of the shaft _ 100 RPM A 200 RPM LI 300 RPM E gt o o ENS Thrust Pull Ibf 1174 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 TECHNICAL MANUAL SECTION CONTENTS 7 5 HYDRAULIC Motor INFORMATION HD22000 22 Model Code M125 2 4 15 31 T1 TBB 000 M125 Motor Series Port Options A2 Std 2 port w 4 Bolt Flange ports A4 4 Port model w 4 Bolt Flange ports C2 Std 2 port w O Ring Boss ports C4 4 Port model w O Ring Boss ports Rotary Group Designation 15 Code 61 Standard 1L Code 61 Low Speed Displacement Options SINGLE STACK 060 60 in 983cc rev 068 68 in 1115cc rev 082 82 in 1344cc rev 098 98 in 1606cc rev 113 113 in 1852cc rev 125 125 in 2049cc rev Bearing Package Selection DOUBLE STK 4 PORT 120 120 in 1967cc rev 136 136 in 2229 150 150 in 2459cc rev 164 164 in 2688cc rev 180 180 in 2950cc rev 196 lt 196 in 3212 211 211 in 3458cc rev 226 226 in 3704cc rev 238 238 in 3901cc rev 250 250 in 4098 Special Code Designator Seal Package Select
52. D 22000 22 Pinion ASSEMBLY M DRILLING amp 5 16 SECTION CONTENTS TECHNICAL MANUAL MCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD HD22000 22 Tone Pinion ASSEMBLY A 1 2 NC x 1 3 4 Hex Bolt 09 2172 1 2 Lock Washers 09 5110 Top Pinion Bearing Cap 1455 89 oam High Pinion Gear Pinion Gear Shaft 1455 86 Bottom Pinion Bearing Cap 1393 89A 1 8 NPT 90 Grease Fitting 02 0093 DRILLING amp NCCOY COMPLETIONS TECHNICAL MANUAL 5 17 MOVING GLOBAL ENERGY FORWARD 22000 22 CLUTCH ASSEMBLY A B C DRILLING amp 5 18 SECTION CONTENTS TECHNICAL MANUAL AACCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD CLUTCH ASSEMBLY HD22000 22 4 a md m 5 i __ 1 Hu ue emm 1 4 UNC x 1 Hex Socket Flat Head Cap Screw 55 B Square Key 1 2 x 1 2 x 1 1 2 2 ar Pat Bearing pan Sha Spacer 888 80 07 no erg Tse Pare co Pan Hin Caton Gear Pm es Pan Shan Spacer RR 3 8 1 3 4 Parker Countersunk Hex Head Plug 219P 219P 8 1 1
53. E SELF SEALING SUPPLY AND RETURN LINES ARE 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 1 6 Ensure that supply pressure is at or above the tong s specified operating pressure and that the return pressure is less than 350 psi 1 f Perform a visual inspection of pressurized hydraulic lines Document and correct any hydraulic fluid leaks 1 8 Perform full functional test of the tong Report and correct any hydraulic leaks from the hydraulic valve bank from 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 1 9 ponents including links and chains If using a compression load cell replace any component that has been crushed otherwise distorted through compression 2 0 If applicable inspect load cell anchor pins tension load only Replace the anchor pins if cracking or metal distortion is seen If applicable the weld securing
54. ENANCE HD22000 22 Tone Assembly Procedures cont d 59 60 67 62 63 64 65 66 67 68 Slide the pivot end of each of the four lined brake band weldments PN 1455 29 01 over each of the brake band coincidental support roller shafts Secure each weldment to the shafts using a 1 external snap ring Assemble each adjustment end using a 1 2 NC x 12 hex bolt 1 2 narrow washer 1 2 thin nylock nut and an adjustment spring PN 1404 131 04 W ILLUSTRATION 3 H 7 BRAKE INSTALLATION Thread two 7 8 UNC hex nuts on to the rear cage plate bolt far enough down the threads that an additional nut can be threaded on Insert the backing pin PN 101 3695 into one of the two backing pin holes in the top cage plate Slide the backing pin retainer PN 101 3752 over the rear cage plate bolt and backing pin Thread a 7 8 UNC nylock nut onto the rear cage plate bolt until the top of the nylock nut is flush with the top of the rear cage plate bolt Hold the backing pin retainer against the bottom of the nylock nut Back thread the upper 7 8 UNC hex nut installed in Step 60 up the rear cage plate bolt until it is almost in contact with the retainer but not quite touching Tighten the next lower 7 8 nut up against the top nut locking it in place The backing bin retainer should be able to rotate freely around the rear cage plate bolt but not be floppy Thread the backing
55. Ensure the flat on the pinion bearing cap is oriented toward the motor mount location 45 Slide top clutch bearing PN 1393 56 over the clutch shaft and press against the low clutch gear followed by the remaining clutch shaft spacer PN 1393 50 03 46 Install the clutch bearing plate PN 1393 57 and secure with four 3 8 UNC x 3 4 hex socket flat head countersunk machine Screws 47 Slide the clutch drive gear PN 1455 61 over the top of the clutch shaft Insert two 1 1 2 x 1 2 x 1 2 gear keys into the machined slots in the gear and shaft Secure the drive gear to the clutch shaft using a gear retainer plate PN 1393 50 04 and a 1 4 UNC x 1 hex socket flat head countersunk machine screw DRILLING amp 3 18 SECTION CONTENTS TECHNICAL MANUAL MCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE HD22000 22 48 Slide the bottom shifter bushing PN 1393 78 over the shifting shaft and insert into top plate Secure the bushing in place with a 3 8 NC x 1 flange head cap screw ILLUSTRATION 3 H 5 LowER SHIFTER BUSHING INSTALLATION 49 Clean the dowel pin holes on either side of the clutch drive gear 50 Place the motor mount weldment PN 101 3754 on to the top plate over the clutch assembly Tap the chamfered ends of two 3 8 x 1 1 2 dowel pins PN 09 0092 into the dowel pin locations on both sides of the motor mount weldment to finalize the position on the top plate Insert unti
56. G amp AACCCOY TECHNICAL MANUAL 2 15 MOVING GLOBAL ENERGY FORWARD HD22000 22 SETUP amp OPERATION 2 2 16 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 e 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 bearing failure e Switch to low gear and operate for an additional one half hour at full speed Run the backup if equipped through several clamp un clamp sequences to ensure functionality e Inspect all components and hydraulic fittings for possible defects following completion of the tests All FARR Tongs 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
57. HE FOLLOWING TABLE ARE CORRECT FOR ACCURATELY MEASURING TORQUE USING THE EQUIPMENT FOR WHICH THIS MANUAL IS SUPPLIED 1 1 1 1 60 0364 1 1 1 1 4 NPT Street Elbow 1 4 NPT Cap 5 Ft Hose Assembly 1 02 0069 08 0023 08 0424 Lr fm TU SS mm m DRILLING amp 6 2 Section CONTENTS TECHNICAL MANUAL AACCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD TORQUE MEASUREMENT Item Type Description Qty Part Number Assembly Tension Load Cell 4 08 in 1 10 0008T A Part O Ring 1 02 0800 B Part Load Cell Body 1 LC99 104 C Part 1 4 NC x 1 2 Binding Head Machine Screw 1 09 0045A D Part Stat O Seal 1 02 0307 E Part 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 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 HD22000 22 This ts the standard tension load cell sup plied by McCoy Drilling amp Completions Farr Contact our sales department for information about optional application specific tension load cells ILLUSTRATION 6 A 4 TENSION LOAD CELL ExPLODED MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL SECTION CONTENTS 6 3 HD22000 22 Tone 6 4 TORQUE MEASUREMENT
58. ICAL MANUAL pi pi seen HD22000 22 Tone SETUP amp OPERATION 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 BF ILLUSTRATION 2 H 7 LIFT CYLINDER CONTROL LOWER p Repeat steps through until the desired number of connections are made DRILLING amp MCCOY COMPLETIONS TECHNICAL MANUAL 2 23 MOVING GLOBAL ENERGY FORWARD 22000 22 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 rigid sling must be used to suspend the tong Do not suspend the tong from any other point See Illustration 2 1 b Set the backing pin for breakout operation Lift up 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 Illustr
59. ILLING 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 THE 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 IN 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 COMPLETIONS TECHNICAL MANUAL V MOVING GLOBAL ENERGY FORWARD This page intentionally left blank HD22000 22 Copyright 2012 McCoy Drilling amp Completions all rights reserved This document is the property of McCoy Drilling amp Completions 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 storage media without the express written consent of McCoy Drilling amp Completions McCoy Drilling
60. ING GLOBAL ENERGY FORWARD 22000 22 Perform a visual inspection of all lifting points if visible 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 service Refer to Section 2A of j 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 1 4 pins if necessary If the pins are welded in place remove and quarantine the jaw until the weld is repaired Ensure dies are secure in the jaw rep
61. IONS TECHNICAL MANUAL 5 5 MOVING GLOBAL ENERGY FORWARD HD22000 22 SUPPORT RoLLER ASSEMBLY BRAKE BAND 5 6 NP AN DRILLING amp SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 22000 22 SUPPORT ROLLER ASSEMBLY BRAKE BAND Dm mme _ a _ 2 mal ep b Tapered RolorBeamng 2 19415 DRILLING amp NCCOY COMPLETIONS TECHNICAL MANUAL 5 7 MOVING GLOBAL ENERGY FORWARD HD22000 22 SUPPORT RoLLER ASSEMBLY Door Pivot Nl d DRILLING amp 5 8 SECTION CONTENTS TECHNICAL MANUAL MCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SUPPORT RoLLER ASSEMBLY Door Pivot 22000 22 wm npe 8 Pan 2 oor gt rm 2 gt 2 new Tapered Rorer Bean 2 rasare LE pone NE 2 E Pat DRILLING amp AACCCON COMPLETIONS TECHNICAL MANUAL 5 0 MOVING GLOBAL ENERGY FORWARD HD22000 22 Rotary IpLER AssEMBLY WitH GEAR PLATE D D DRILLING amp 5 10 SECTION CONTENTS TECHNICAL MANUAL AACCCN COMPLETIONS VING GLOBAL ENERGY FORWARD 22000 22 Rotary IpLER ASSEMBLY WITH GEAR PLATE Reine Grease Fitting 1 8 NPT Pan UNE Nyce a
62. Initial Release DRILLING amp MECOY TECHNICAL MANUAL Vil MOVING GLOBAL ENERGY FORWARD 22000 22 TABLE OF CONTENTS Introduction amp Specifications deterrere Eta aaa email e pn aa datele iu be Section One Introduction and Contact Information nana noa anna aan nana 1 1 16148 eee 1 2 L bricaton MERERI 1 4 SEUD amp OEI EL ON Section Two Sling Load Bearing Device 2 1 Major Component IOGNUNCAU ON EET 2 4 Hydraulic Schematic Hydraulic Valve Identification sss 2 7 FIV ai 2 9 Tong Jaw Availability amp Installation sata ana aa manie a ani ba a d at aa I a an ll aa aa a 2 10 Tong Rig Up amp Leveling 1 SUS penson amp TRO SUA LM 2 13 5 TOT VE c Pm 2 15 Tong Operation 1 2 15 2 inal Stan up amp 2 16 217246012219 2 PERII N IRI RR NT me ree 2 16 at dim anina E 2 18 5 General Operational 2 18 Making and Breaking Connections 1 MARIREA tei ea
63. L MANUAL 2 13 MOVING GLOBAL ENERGY FORWARD HD22000 22 SETUP amp OPERATION Suspension amp Restraint continued ILLUSTRATION 2 1 TONG SUSPENSION RELATIVE To AXIAL CENTRE ILLUSTRATION 2 2 TONG SUSPENSION RELATIVE VERTICAL CENTRE DRILLING amp 2 14 SECTION CONTENTS TECHNICAL MANUAL AACCCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION 22000 22 2 Tong Leveling The tong must be leveled side to side and front to rear before placing into service The following guidelines will assist you when leveling your tong 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 hand 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 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 t
64. 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 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 Sus
65. N Reposition yoke and re tighten locking nuts 6 POSSIBLE PROBLEM Shifting yoke has come 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 MECOY TECHNICAL MANUAL 4 5 MOVING GLOBAL ENERGY FORWARD HD22000 22 Two 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 understanding 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 AACCODY MOVING GLOBAL ENERGY FORWARD 46 SECTION CONTENTS TECHNICAL MANUAL HD22000 22 Tone HD22000 80K Tong Parts amp Assemblies AACCODY vic 2 COMPLETIONS TECHNICAL MANUAL 5 1
66. NG GLOBAL ENERGY FORWARD HD22000 22 Tone B MAJOR COMPONENT IDENTIFICATION SETUP amp OPERATION 2 4 ILLUSTRATION 2 B 1 COMPONENT IDENTIFICATION 01 Wm SSC 9 5 Door Spring Cylinder LH Door Assembly RH Door Assembly SECTION CONTENTS TECHNICAL MANUAL MECOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS HD22000 22 Tone SETUP amp OPERATION ILLUSTRATION 2 2 MAJOR COMPONENT IDENTIFICATION 02 pn Co BekmpPnAsemy SSS COY TECHNICAL MANUAL 2 5 MOVING GLOBAL ENERGY FORWARD HD22000 22 Tone SETUP amp OPERATION 2 6 ILLUSTRATION 2 B 3 COMPONENT IDENTIFICATION 03 wm _ Hydraulic Inlet Hydraulic Outlet Motor Mount SECTION CONTENTS TECHNICAL MANUAL MECOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS SETUP amp OPERATION 22000 22 HYDRAULIC SCHEMATICS amp VALVE IDENTIFICATION DUMP VALVE 13 OPTIONAL 14 gt LIFT E BACKUP e OPTIONAL oo 6 ILLUSTRATION 2 1 HyDRAULIC SCHEMATIC Inlet Section Motor Valve Section Backup Valve Section Optional 75 Lit GyinderVatve Section 177 6 OutetSecion 1098 28 _ 78 Piorro operae Carnage Vane O 085 28 _ Ls sett Dore Beek ze 11 1 2 FN
67. 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 pressure 2 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 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 15 CARRIED OUT BY 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 adeq
68. OMMISSIONING PROCEDURE Perform the following decommissioning procedures when removing tubular connection equipment from service with the intent of short to long 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 2 3 4 5 7 8 1 2 10 11 12 _ 3 30 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 De energize the power unit Repeatedly actuate the tong motor control valve lever IN BOTH DIRECTIONS to dissipate any residual pressure in the valve and motor Remove the hydraulic SUPPLY line from the equ
69. PT Check Valve DRILLING amp TECHNICAL MANUAL 2 7 MOVING GLOBAL ENERGY FORWARD HD22000 22 Setup amp OPERATION 1 P Le ILLUSTRATION 2 C 3 HYDRAULIC COMPONENT IDENTIFICATION 02 DRILLING amp 2 8 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD HD22000 22 Tone SETUP amp OPERATION ILLUSTRATION 2 C 4 HyDRAULIC COMPONENT IDENTIFICATION 03 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 1 Hydraulic Supply 74 ln z m a A E Y i 0 S Lg ILLUSTRATION 2 D 1 HyDRAULIC 5 01 DRILLING amp NCCOY COMPLETIONS TECHNICAL MANUAL 2 9 MOVING GLOBAL ENERGY FORWARD 22000 22 SETUP amp OPERATION Hydraulic Connections continued These
70. Part Number 9 5 8 Jaw Die Kit 1455 JDK 545 14 Jaw Die Kit 1455 JDK 560 9 7 8 Jaw Die Kit 1455 JDK 547 16 Jaw Die Kit 1455 JDK 565 10 3 4 Jaw Die Kit 1455 JDK 550 17 7 8 Jaw Die Kit 1455 JDK 566 11 3 4 Jaw Die Kit 1455 JDK 555 18 Jaw Die Kit 1455 JDK 567 11 7 8 Jaw Die Kit 1455 JDK 556 18 5 8 Jaw Die Kit 1455 JDK 570 13 3 8 Jaw Die Kit 1455 JDK 558 20 Jaw Die Kit 1455 JDK 575 13 5 8 Jaw Die Kit 1455 JDK 559 22 Jaw Die Kit 1455 JDK 576 Standard 5 Replacement Die 12 1005 ISOLATE TONG FROM HYDRAULIC POWER BEFORE PROCEEDING WITH JAW OR JAW DIE REPLACEMENT If necessary the entire jaw may be removed Support the jaw from the bottom and remove the jaw pivot bolt The jaw may then be slid out of and away from the cage plate Reverse this procedure to replace the jaw assemblies see Illustration 2 E 1 DRILLING amp 2 10 Section CONTENTS TECHNICAL MANUAL AACCCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 22000 22 SETUP amp OPERATION ILLUSTRATION 2 E 1 Jaw REPLACEMENT The two die may be removed my removing the flanged bolts and sliding them up and out of the jaw They may have to be tapped lightly with a hammer ILLUSTRATION 2 E 2 Jaw REPLACEMENT DRILLING amp AACCCON COMPLETIONS TECHNICAL MANUAL 2 11 MOVING GLOBAL ENERGY FORWARD 22000 22 SETUP amp OPERATION Jaw Jaw Die Replacement When using
71. RD Motor INFORMATION HD22000 22 Tone WARNING RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION Motor Assembly Tips MECOY MOVING GLOBAL ENERGY FORWARD 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 DRILLING amp COMPLETIONS TECHNICAL MANUAL SECTION CONTENTS 7 13 HD22000 22 Tone HYDRAULIC INFORMATION Information Standard 125 series seal Bolt Torque 5 1250948 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 158 KT SE1250947 4 Port Main Bolts 5
72. S TECHNICAL MANUAL SECTION CONTENTS HD22000 22 SERIES 125 PC EXPLODED VIEW usw 1 e 1251168 FRONTHOUSING 1 o orneman a usosis __ TIMING PC 41580 2 1 usosae wwe fre usw smog usw stator eco usws smronsco usw __ 5 usw stator Em usowo STATOR VANE fo NO 7 9 HD22000 22 HYDRAULIC INFORMATION WARNING RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION Removal of Seal Plate Front and Rear Loosen and remove 6 or 12 3 8 16 seal plate bolts Front bearing can be inspected in place on the shaft or pressed off to be inspected or replaced 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 The 125 motors should be positioned as shown in a 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
73. T 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 as 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 horizontal 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
74. TECHNICAL MANUAL Motor amp Motor Mount HD22000 22 tem Type Destin Part ar Pai 5 Pat MEMS _ Part 1 2 UNF x 3 4 Hex Socket Flat Head Countersunk Cap Screw 09 4164 3 8 UNC x 1 1 2 Hex Bolt 09 1553 3 8 Lock Washer 09 5106 Weldment Torque Gauge 1800060 Pan HITCHPIN 1482938 1 8 NPT 90 Grease Fitting not shown Part 101 3777 Wi W Part Part Part Part Part Part DRILLING amp MCCOY COMPLETIONS TECHNICAL MANUAL 5 29 MOVING GLOBAL ENERGY FORWARD 22000 22 Door ASSEMBLY y i NI qlo DRILLING 8 5 30 CONTENTS TECHNICAL MANUAL 1 COMPLETIONS MOVING GLOBAL ENERGY FORWARD HD22000 22 Tone ASSEMBLY Hors _ Weldment Left Hand Door Weldment 101 5513 DRILLING amp MECOY TECHNICAL MANUAL 5 31 MOVING GLOBAL ENERGY FORWARD 22000 22 SAFETY Door COMPONENTS 4 F 5 32 SECTION CONTENTS TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD 22000 22 SAFETY Door COMPONENTS A Weldment Safety Door Switch Guard Weldment LX 101 3761 Number DRILLING amp AACCCOY TECHNICAL MANUAL 5 33 MOVING GLOBAL ENERGY FORWARD 22000 22 CHAIN SLING DRILLING amp 5
75. UNLESS YOU HAVE CONFIRMED THAT THE POWER HAS BEEN DISCONNECTED AND LOCKED OUT 2 Visually inspect main electrical between main power source and power unit ALL 5 5 Perform a visual inspection of all parts Check to ensure there are no loose or missing fasteners 6 Check hydraulic fluid level ensure cold level is approximately half way up the sight glass the hydraulic fluid res ervoir f Perform a visual inspection to ensure there no hydraulic fluid leaks correct if necessary 8 Check that main supply and lines on the hydraulic fluid reservoir are both fully open 9 C 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 1 0 Ensure supply and return connections power unit and the equipment use fully made up FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES ARE FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE 1 1 C Check hydraulic 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 the unit is shut down DRILLING amp AACCCOY TECHNICAL MANUAL 3 29 MOVING GLOBAL ENERGY FORWARD 22000 22 MAINTENANCE L TUBULAR CONNECTION EQUIPMENT DE C
76. WARD HD22000 22 ASSEMBLY DRILLING 8 5 24 CONTENTS TECHNICAL MANUAL COMPLETIONS VING GLOBAL ENERGY FORWARD HD22000 22 Tone Tonc Bopy ASSEMBLY Te r arr Pat oer Cynder Sd _ gt Pan toma mor 2 Brake Band Welinent Seo tp 52652 4 4652007 0 1 2 UNC x 2 1 4 Hex Bolt 09 1175 Pat SSS Pat oare cap tg Prion Bearing Cap 1 Pan varon pw axza rat shown 2 PI Pat are coca Washer e 9588 1 2 NC x 1 1 4 Hex Socket Head Cap Screw DRILLING amp TECHNICAL MANuAL 9 29 MOVING GLOBAL ENERGY FORWARD zF HD22000 22 BRAKE BANDS 2 7 DRILLING amp 5 26 SECTION CONTENTS TECHNICAL MANUAL MCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Brake BANDS HD22000 22 Tone 1 2 NC x 11 Hex Bolt Weldment Lined Brake Band Weldment Part Number 09 1208 1455 29 01 Adjustment Spring 1 2 UNC Thin Nylock Nut Part 1 2 Narrow Flat Washer 1404 29 04 09 5610S 09 5119 1404 131 04 MCCOY MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL 5 27 22000 22 Motor amp Motor Mount DRILLING amp COMPLETIONS 5 28 SECTION CONTENTS
77. 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 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 Remove seal plate o ring from groove in seal plate 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 Press shaft and front bearing out of motor through front housing leaving rear bearing in place DRILLING amp 7 10 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD HYDRAULIC INFORMATION 22000 22 WARNING RINEER RECOMMENDS FOLLOWING ALL STANDARD 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 Replace plate on rotor stator cartridge 2 Turn rotor stator cartridge over 3 Repeat steps 11 amp 12 1 Remove rotating group from rear housing as shown Place the rotating group on a clean surface for disassembly and inspection 2 Remove dowel pins a
78. act the lift cylinder to lift the assembly see lllustration 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 Eu ILLUSTRATION 2 H 3 CYLINDER CONTROL RAISE 2 20 SECTION CONTENTS TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD Setup amp OPERATION HD22000 22 Making Connection Continued e Grasp the handle on the RH door weldment and pull to open the door After the RH door is open grasp the handle on the LH door weldment and swing open Since your equipment is equipped with safety doors opening the door will inhibit rota tion of the cage plate OPEN THIS SIDE SECOND OPEN THIS SIDE FIRST ILLUSTRATION 2 H 4 OPENING Doors 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 Firmly close the LH tong door followed by the RH tong door i Ensure tubing is roughly centered within the tong jaws rig personnel are required to stabilize the tong above connec tion until the jaws have been cammed on to the pipe or casing J Begin rotation with the tong high gear high
79. afety Door Switch Adjustment 01 000 000 0 01000002000000000050000 3 10 Illustration 3 E 6 Safety Door Switch Adjustment 02 esses essen 3 11 Illustration 3 H 1 Rotary Gear Installato aceia aa ama mate area a ate ama aie la ag aa tai A ME red aaa aaa 3 15 Illustration 3 H 2 Support Roller amp Rotary Idler Installation 2 000005000000000 3 16 Illustration 3 H 3 Shifting Fork Placement During 00 006000000000000000000000 8 3 17 Illustration 3 H 4 Top Plate Fastener Installation 3 18 Illustration 3 H 5 Lower Shifter BUSHING Installation nenea nana 3 19 Illustration 3 H 6 Cage Plate Installation etnia ho hn ohne nu tu a aa Hag E SR da pala AER 3 20 Wlustration 3 71 7 Brake ue ana am aaa RR OFFRE rd ata Au ERR ME DE RREA FUR aiva o aaa 3 21 Illustration 3 H 8 Safety Door Valve Installation sisse essen 3 22 Illustration 6 A 1 Torque Gauge For Illustration Purposes Only sisse 6 1 Tension Load 6 1 Illustration 6 A 3 Compression Load
80. amp Completions 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 Drilling amp Completions does not warrant or guarantee that the information is either complete or accurate in every respect and the user of the manual shall protect indemnify and hold harmless McCoy Drilling amp Completions and all their 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 authority 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 January 2012
81. ance 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 are 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 Check engine oil levels add if necessary 2 Check diesel fuel tank fill if necessary 3 Visually inspect all fan belts 4 Activate mechanical shut off device ensure that shut off switch on engine is engaging when manual shut off switch is actuated ELECTRIC ONLY Visually inspect all electrical lines and visible connections If your unit is NOT explosion proof open the electrical en 1 closure and VISUALLY inspect contacts and connections signs of corrosion arcing not open explosion proof enclosures NEVER PLACE HANDS INSIDE AN ELECTRICAL ENCLOSURE
82. and spacers in each idler gear with a retainer ring PN 1393 110 Center the gear and bearing assemblies on the shafts as best as possible 9 Press a gear plate bearing PN 1393 106 into each of the four gear plates PN 101 2227 until the bearings come into contact with the inner lips Slide a gear plate assembly over the bottom of each end of the idler assemblies assembled in Step 8 until they come into contact with the idler gears note that the lip on each gear plate faces towards the idler gear see Pp 5 10 5 11 for correct orientation Slide a rotary idler gear spacer PN 101 2228 over the bottom end of each shaft and press against the gear plates Do not install the top idler gear plates and gear spacers at this time 10 Slide a support roller shaft spacer PN 1393 140 over the end of the the ten support roller assemblies with installed shafts Install three standard support roller assemblies and one brake band coincidental roller assembly in the correct location along one side of the body case see lllustration 3 H 1 ensuring the shaft spacer is between the bottom plate and the support roller 11 Use a temporary lifting sling and a crane to maneuver the rotary gear in to place on the tong making sure the backing slots are on the side facing up Support one side using the support rollers installed in Step 10 and have the opening in the rotary gear oriented as shown in illustration 3 H 1 Brake Band Coincidental Suppo
83. asing 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 Note that the top and bottom brake bands must be adjusted simultaneously and equally 5 E ir ae 4 BRAKE BAND ADJUSTMENT BOLT AND NYLOCK NUT ILLUSTRATION 3 E 1 BRAKE BAND ADJUSTMENT TOP AND BOTTOM BRAKE BANDS MUST BE ADJUSTED EQUALLY AND SIMULTANEOUSLY MOVING GLOBAL ENERGY FORWARD COY TECHNICAL MANUAL 3 7 HD22000 22 MAINTENANCE 2 Lateral Door Adjustment THE DOOR IS AN IMPORTANT PART OF THE STRUCTURAL INTEGRITY OF THE TONG IT IS 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 If the double doors develop a space where they meet when the doors are closed the doors may be adjusted laterally by turning one or both of the cam bushings Remove the 3 8 bolts securing the cam bushings and loosen the 1 nylock support roller nuts just enough to allow the bushing to turn Adjust doors so that they open and close smoothly and the RH door and LH door come into slight and even when clos
84. ation 2 8 ILLUSTRATION 2 H 8 SETTING BAcKING Pin BREAK OuT 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 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 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 g Firmly close the tong door against the latch post Ensure tubing is roughly centered within the tong jaws rig personnel are required to stabilize the tong above 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
85. ben Fia in Neutral Mator Outlets Tank Return Type NOTE See Secbon G Page 32 for Port Plugs AACCCOY P R pi TECHNICAL MANUAL SECTION CONTENTS 7 15 HD22000 22 Tone Brief Circuit Descriptions Series Circuit Available in VAJO sections only machines work cyche requires simul laneous as well a3 separate operation of werk functions a 5 nes is right for the job through the open center when spools ang in neutral There is no parallel passage lead diracty from the open center pas If more than one spool operated inlet Fatum flow Irom ihe first Dewnsheam sections can be senes parallel or tandem and will operate in In series circuits operating pressure is pressures in the circus can not exceed the circuit or main relief valve Parallel Circuits Parallel circuits ang the most common on neously and at random H two more functions ane fully operated at the same tene thee with tha load will Ine paih a resistance Howse functions by metering spools Paver of tha spool meters shuts off the flow of oil thru fe open center pis Sigt CN is then at the operators discretion ip all work ports connecbed to the passage VALVE INFORMATION Tandem Circuits Tandem circuits sometimes called pnornty or stan
86. ckup components lift cylinder and float frame com ponents Report and correct any hydraulic leaks from the hydraulic valve bank or from any hydraulic cylinders that are used 36 Test safety door feature if equipped Begin rotating the tong at low speed and open the tong door s If rotation does not immediately stop this is an indication that the safety door mechanism is not operating correctly and the tong must 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 37 NEVER OPERATE YOUR EQUIPMENT WITH A BYPASSED OR MALFUNCTIONING SAFETY DOOR Farr recommends that an anti corrosive agent such as Tectyl 506 be applied to all external unpainted surfaces and 38 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 28 SECTION CONTENTS TECHNICAL MANUAL AACCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 22000 22 K DAILY INSPECTION amp MAINTENANCE CHECKLIST POWER UNIT Farr recommends that the following inspections and mainten
87. dard circus by olhei manufacturers Tandem sectons feed rom the open cantar passage like series but thes nedum Mow i danscted tbe tank passage ard is not avad tandem secton is by p sara or tandem section operating the bandam Typical Work Section Schematics Standard Cylinder D A Cylinder Series SECTION CONTENTS 7 16 Parallel TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD D A Motor S A Cylinder DA Cylinder Standard Parallel Parnilel Tandem Tank Return Outlet DRILLING COMPLETIONS VALVE INFORMATION HD22000 22 Tone VA VG Valve Service Instructions INTRODUCTION This manual has been prepared to assist you in the proper maintenance of the VA20 YVAIS and VO2I0 VGIS YVOSO directional control valves Before any work 15 done we suggest that you read the assembly and disassembly instructions completely The first rule of good maintenance is cleanliness which includes a clean environment MAKE SURE YOU DISASSEMBLE AND ASSEMBLE YOUR HYDRAULIC EQUIPMENT IN A CLEAN AREA Dirt is the natural enemy of any hydraulic system GENERAL INFORMATION The VA and VG model valves are updated versions of our proven and A35TM units The VGi models are cast from compacted graphite a high strength iron alloy which allows the valve to be rated to 35
88. dvertently 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 recommends that disconnection of hydraulic connectors be performed with the power unit off and the hydraulic circuit depres surized 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 regulations 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 Regular maintenance programs are necessary and must be establish
89. e IC o oo Pant Rotary ter Gear Spacer o tee _ Meme o2 _ rem Rota ter Stat tran _ ens um lt DRILLING amp NMCCOY COMPLETIONS TECHNICAL MANUAL 5 11 MOVING GLOBAL ENERGY FORWARD 22000 22 Rotary IDLER ASSEMBLY A B MN C D DRILLING amp 5 12 SECTION CONTENTS TECHNICAL MANUAL MCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 22000 22 Rotary IDLER ASSEMBLY Dmm Wm aa A Part Grease Fitting 1 8 NPT e pmmyHesme E ro 7 rip II Pat eter ing DRILLING NCCOY COMPLETIONS TECHNICAL MANUAL 5 13 MOVING GLOBAL ENERGY FORWARD HD22000 22 Pinion IDLER ASSEMBLY A DRILLING amp 5 14 SECTION CONTENTS TECHNICAL MANUAL MCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 22000 22 Pinion IDLER ASSEMBLY wm 4 fm Rote Rn 0 8 en PmoerGer 199420 p fa eter E Pat Fmoerhasmt 995 fa 8 _ e TK 8 WOT Gree une 0005 DRILLING amp NCCOY COMPLETIONS TECHNICAL MANUAL 5 15 MOVING GLOBAL ENERGY FORWAR
90. e are presented as a guide only and are similar to the assembly sequence our technician would use while assembling the tong in our plant NOTE ON INSTALLATION PRACTICES Ensure all bearings are liberally greased before installing over a shaft or into gears or bearing caps When inserting a shaft through a support roller assembly ensure shaft is greased Also ensure all metal to metal contact in the gear train is adequately greased When graphics are not used in the assembly process please refer to the relevant exploded diagrams in Section 5 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 LOCTITE TIGHTENING TORQUE GUIDE SAE GRADE 8 FINE THREAD SAE GRADE 8 COARSE THREAD REPLACEMENT FASTENER BOLTS NUTS CAP SCREWS MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHER WISE SPECIFIED DRILLING amp 3 14 SECTION CONTENTS TECHNICAL MANUAL MCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 22000 22 Assembly Procedure Continued 1 Position the tong body gear case on a suitable stationary support such that the bottom body plate is accessible 2 Press a support roller bearing PN 1393 136 into one side of each of the support rollers PN 1393 135 12 total
91. e 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 resistance the equipment should be removed from storage and exercised on a regular basis depending on the stor age 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 Re place desiccant packs at this time depleted desiccant packs may be treated as regular dunnage DRILLING amp 3 32 SECTION CONTENTS TECHNICAL MANUAL AACCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 22000 22 TUBULAR CONNECTION EQUIPMENT RECOMMISSIONING 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 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 grea
92. e ring into the bottom cage plate 101 2670 using fifteen 1 2 NC x 2 1 4 hex socket head cap screws MOVING GLOBAL ENERGY FORWARD COY TEcHNICAL MANUAL 3 19 22000 22 MAINTENANCE Assembly Procedures cont d 58 3 20 Install the cage plates lii Vi Liberally grease the two guide rings Position and support the bottom cage plate assembly against the bottom of the rotary gear Insert the rear cage plate bolt PN 101 3753 in to the hole in the rear of the bottom cage plate and secure it with a 7 8 UNC hex nylock nut and 7 8 narrow flat washer Place the top cage plate over the rotary gear inserting the top of the rear cage plate bolt through the hole in the rear of the top cage plate and ensuring the guide ring on the rotary gear engages with the slot in the bottom of the top cage plate Insert the two front cage plate spacers PN 101 1899 between the top and bottom cage plates Secure the cage plates together Thread a 7 8 UNC hex nut over the top of the rear cage plate bolt and tighten against the top cage plate Insert 1 UNC x 8 hex bolts through the top and bottom cage plates and front cage plate spacers and secure the bolts to the bottom cage plate using 1 UNC hex nylock nuts and 1 narrow flat washers i _ ILLUSTRATION 3 H 6 CAGE PLATE INSTALLATION DRILLING amp SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINT
93. e spool vertically in a soft jawed wise clamping on the fas post cleme and remove the stripper bali Fig HYDRAULIC VALVE INFORMATION Valve Disassembly Instructions Spool Disassembly Spring Centered Spool 14 Lightly tap the stripper bolt with a hammer amd a punch break the adbesive Cautious application of heat may be requured to free the stripper bolt since an thre adhesive was used assembly CAUTION Too much heat may distort the spool As the stripper hbolt threads disengage the spring Fig 2 item 15 and spring guides Fig 2 item 16 will release abrupilv rom che spool Detent Spool The detent assembly should not be removed from the spool anless these parts need io be replaced Wrap ihe detent sieeve Fig 2 intem 17 with clean Imt free cloth the cloth covered skeve and pull finmly As the sleeve moves backwards the detent balls Fig 2 15 and the detent spring Fig 2 dem 19 will release ahrupily The cloth should captare these parts amd prevent their loss Next clamp the spool in 30ft jawed vase and remove the debent poppet retainer Fig 2 item 20 Place an undersized bar through the detent ball bore to serve as a wrench Lighrlv rap the detent poppet retainer with hammer and a punch to help break the adhesive Cautious application of heat may be required again sanie gn mnaenohic adhes
94. ear 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 SHAFT DIMENSIONS ARE 5 75 TYPICAL BOTH ENDS EM 30 STD 7 8 KEYWAY EXTERNAL CASE DRAIN 1 2 O RING BOSS 2 PLACES SAE FLAT ROOT SIDE FIT 20T 6 12 DP 30 INVOLUTE SPLINE OPTIONAL SHAFT 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 1 32021X 30218X 18 000 BEARING LOADING THRUST CAPABLE The bearings in the 125 Series Thrust capable motor 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
95. ed ADJUST UPPER AND LOWER BUSHINGS ON THE SAME DOOR SIMULTANEOUSLY AND EQUALLY Note that once the adjustment is finished the 3 8 bolt needs to be replaced securing the door cam bushing Do not neglect to re tighten the nylock nut on the support roller but do not overtighten as this may cause the door to bind see illustration 3 E 2 ADJUST UPPER AND LOWER DOOR LATCH CAMS SIMULTANEOUSLY ROTATE BOTH LATCH CAMS THE SAME AMOUNT IN THE SAME DIRECTION DOOR ADJUSTMENT o Sco ILLUSTRATION 3 E 2 LATERAL DooR ADJUSTMENT 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 aligns 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
96. ed alta ec el dea cata iti bl 2 19 2 BIO camara E 2 24 Extreme Cold Weather Operation 2 26 To RR RR EI ARON RR Section Three General Maintenance Safety 3 1 Gy ete A 3 1 lica um iic __ 3 1 f a _ 3 2 Adjustments Deane DO AG USUI CG T 2 7 CAPE Door A duS INEI p 3 8 gt 3 8 4 Shifter Detent Force Adjustment eee eee 3 9 5 Safety Door Switch Adjustmoent is iie aaa oa aa aaa ae aaa aa aaa 3 10 Recommended Periodic ae 3 11 Disassembly amp Overhaul eee eee nana 3 12 SUG S acci necs eta a a 3 14 Daily Inspection amp Maintenance Checklist Power 3 24 Monthly Inspection amp Maintenance Checklist Power Tong esses esee 3 26 Daily Inspection amp Maintenance Checklist Power Unit
97. ed to assure safe dependable operation of your Hydraulic Tubular Connection System and to avoid costly breakdown maintenance The following maintenance procedures provide information 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 McCoy has also provided recommended maintenance check lists The intervals in the maintenance checklists are designed for equipment operating at 10 C to 35 C ambient temperature for 10 hours per day McCoy recommends that the inspection and maintenance procedures in this section be performed as recommended in the maintenance checklists or in conjunction with your maintenance foreman s experience and best estimate of when your equip ment is due for this maintenance Purchased components included with your hydraulic tubular connection equipment for example motors valves etc may specify maintenance tasks and intervals over and above what McCoy 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 Completions amp Drilling recom
98. efer to manufacturer data sheets for drying times at room tempera ture 2 4 Wrap entire assembly 100 gauge 1 mil corrosion inhibiting wrap at least 3 layers thick Attempt ensure that tool 8 is well sealed within the wrapping including the bottom DRILLING amp AACCODY TECHNICAL MANUAL 3 31 MOVING GLOBAL ENERGY FORWARD 22000 22 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 OF 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 1 87 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 x 66 ft equaling 231 g Several manufactur ers offer silica gel desiccant in packaged quantities of 125 grams per bag so two packages of desiccant would b
99. embly into the housing Use castion to avoid causimg burrs Be careful net pinch roll or damage the seals Make sure that the spoal and housing in the proper onientation see Step 1 page disassembly Step 2 Spool Seal and Back up Apply Parker Super CO L the spool seal Fig 8 and slide onto the spe Slade on the back up ring Fig 1 nem 7 Push both items into the counter until they bottom out Assemble the twi front retainer plates Fig iem sare tbe rac short fallistee screws Fig 1 aem 9 Check retainer plates for proper alignment Tighten to a imal torque of 14 an Ibs 2 in Ibs Step 3 Back cap 151211 the hack using Ehe fed long Allister screws Fig 1 4 Tighten to a final torque of H n Ies 5 2 Camion Excessive torque will damage the hack cap ears TECHNICAL MANUAL 7 25 MOVING GLOBAL ENERGY FORWARD 22000 22 HYDRAULIC VALVE INFORMATION 10 Valve Assembly Instructions Step 4 Install Transition Check Trahan check components for eleanlimess Install check poppet Fig nem 13 into the tr nsition Check cavity Align the check spring Fig 1 item 12 square bo the poppei then carefully place the check cap Fig 1 over the poppa ond spring Turning by hand engage several threads Tighten to a final torque af 75 Iba Aft
100. eners and fastener safety wires if equipped Replace any missing fasteners use Grade 8 bolts only less otherwise specified Re torque all external fasteners to SAE specifications 7 Repair or replace any damaged or 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 10 service Prepare areas to be painted to ensure they are free of grease dirt or solvent Touch up using a solvent based s 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 C Inspect all external welds Any weld that is cracked or separating must be repaired and repainted before returning the tong to service DRILLING amp 3 26 SEcTION CONTENTS TECHNICAL MANUAL AACCCOY COMPLETIONS MOV
101. ep 2 Spool Assembly Detent Thread the detent ball retainer Fig 2 20 the spool end Torque the detent ball retainer to 175 in lbs 74 1n jbs This be accomplished by using a erows fox soeke on the Mats of the clevis and holding the spool hy inserting a round steel rod or screwdriver through the hole im the ball retaimer otep 3 Detent Balls and Spring Next light coat the detent balls Fig 2 item 18 detent spring Fig 2 19 and entire anside diameter of the detent sleeve Fig 2 item 17 wnh Erase inscri the detenti spring mto the through hole in tbe detent ball retainer Place the steel balls on the ends of spring Compress the balls and sprisg then slip on the slecve Note The detent sleeve it net symnsetrical one end of the sleeve has a lead in chamfer This chamfer must fice the spool clevis when assembled Move the detent sleeve to che neutral or middle position io prevent the subassembly fros separating during subsequent steps 7 24 SECTION CONTENTS TECHNICAL MANUAL COY MOVING GLOBAL ENERGY FORWARD HYDRAULIC VALVE INFORMATION HD22000 22 Valve Assembly Instructions Step 1 Spool Subassembly Apply 2 3 drops of Loctite 262 or equivalent po the Allister screw holes on both ends of the bousing Apply a light coating of clean hy raulic oil to the valve spool insert the spool ass
102. er bolts to remove the safety door switch and the floating plate Use caution to avoid moving the mounting base during the float plate removal d Ensure the mounting base has not changed position on the top plate of the door weldment Temporarily tighten two socket head cap screws on opposite sides of the mounting base Remove the other two socket head cap screws coat the threads with blue Loctite reinstall and tighten refer to appropriate charts for correct tightening torque Repeat for the remaining two socket head cap screws e Coat the threads of the four shoulder bolts used to secure the floating switch plate with blue Loctite Install the floating plate and tighten the shoulder bolts Ensure the floating moves freely on the mounting base following installation f Open the RH door Slide the floating plate to one extreme then slowly close the RH door Observe the safety door claw on the floating plate to ensure it will still engage correctly with the fixed claw on the RH door Open the RH door and slide the floating plate to the other extreme Slowly close the RH door and ensure the claw on the floating plate still engages correctly with the fixed claw on the RH door DRILLING amp SECTION CONTENTS TECHNICAL MANUAL MECOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE HD22000 22 Safety Door Switch Adjustment continued Incorrect engagement at one floating plate extreme position Incorrect engageme
103. er to secure the bottom of each of the four rotary idlers to the bottom plate of the tong 20 Press pinion bearing PN 1393 93 into bottom pinion bearing cap PN 1393 89A and install bearing cap into bottom plate of tong using four 1 2 UNC x 1 3 4 hex bolts and 1 2 lock washers 21 Press lower clutch bearing PN 1393 55 into clutch bearing cap PN 1393 54 and install bearing cap into bottom plate of tong using four 3 8 UNC x 1 3 4 hex bolts and 3 8 lock washers DRILLING amp 3 16 SECTION CONTENTS TECHNICAL MANUAL AACCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 22000 22 Assembly Procedures 22 Insert a retainer ring PN 1393 110 into each pinion idler gear PN 1393 120 Install two idler bearings PN 1393 106 into each gear and press against retainer ring 23 Insert a pinion idler half shaft PN 1393 105 into each pinion idler assembly ensuring that the gear is oriented so that the side with the retainer ring is next to the half moon plate on the half shaft 24 Secure the half shafts to the gear and bearing assemblies with retainer rings PN 1374 110 25 Insert each pinion idler assembly into the bottom plate meshing with the gears of the rotary idlers and secure each with five 3 4 UNC x 2 hex bolts and 3 4 lock washers 26 Slide a pinion idler spacer PN 1455 105 02 over the end of each pinion idler shaft and secure with a 1 1 2 UNF nylock
104. ft 1000 6 89 2200 20000 27116 1500 10 34 4400 40000 54233 2000 13 79 6560 60100 81485 2500 17 24 8750 80100 108600 MAXIMUM RATED TORQUE 80000 LBS FT 108450 Nm Low Gear RP These are ideal values Actual achieved torque is highly dependant upon tong efficiency and final position of rotary gear when full torque load is reached Maximum Hydraulic Requirements 3000 PSI 20 68 MPa 60 GPM 227 1 LPM Maximum torque is only available in low gear Length 85 1 2 inches 217 2 cm Maximum Width 54 3 4 inches 139 1 Height Excluding Chain Sling 36 inches 91 44 cm Space Required On Pipe 8 inches 20 32 Torque arm length 55 inches 139 7 cm Pipe Centre Line to Load Cell Centre Weight Approximate 4200 Ib 1909 kg Recommended Spring Hanger Capacity 4500 Ib 2045 kg McCoy P N 85 0106XXXH Jaws available inches Pg 2 10 REPLACEMENT FASTENERS BoLrs NUTS CAP SCREWS MACHINE SCREWS ETC MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHERWISE SPECIFIED DRILLING amp AACCQDY TECHNICAL MANUAL L3 MOVING GLOBAL ENERGY FORWARD HD22000 22 SPECIFICATIONS Use an EP synthetic grease that meets or exceeds the following specifications Thickener NLGI consistency grade NLGI performance grade Penetration ASTM D 217 25 C 77 F 0 1 mm worked 60 strokes Dropping point F C ASTM D2265 High temperature life hours ASTM D
105. fting 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 4 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 DRILLING amp MECOY TECHNICAL MANUAL 3 11 MOVING GLOBAL ENERGY FORWARD 22000 22 MAINTENANCE G OVERHAUL PROCEDURES The tong may be overhauled following the disassembly instructions in the following procedure Remove the top plate to access the gear train for the purpose of maintenance and overhaul by following the procedure in this section 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 SCREWS MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT Ensure the tong is placed on supports that provide adequate support but still allows access to the bottom cage plate a
106. he 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 a large adjustment to make Place a level lengthwise front to back along the tong ensuring that it is parallel with the surface of the tong If 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 3 LEVELING USING TURNBUCKLES G TONG OPERATION 1 Operator Training Many companies set qualification standards that must be met before equipment is may be operated without supervision McCoy Drilling amp Completions recommends operator training which typically consists of operation of the equipment under the supervi sion of a trained equipment operator until a satisfactory level of competence is achieved Typical operator training should include Introduction to and general description of equipment Technical specifications and performance data Operating instructions Control systems and interlocks Operating hazards Checks and inspections DRILLIN
107. he 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 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
108. hould 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 circumstances Guidelines for the interval are Normal Service yearly Severe Service monthly to quarterly e Special Service as recommended by a qualified person 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 DRILLING amp 2 2 SECTION CONTENTS TECHNICAL MANUAL AACCCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION 22000 22 Test Examination Non DESTRUCTIVE EXAMINATION THOROUGH VisuAL Surrix To BE MARKED Time INTERVAL LIFTING NDE or LirrinG Points EXAMINATION PLATE ATTACHED To UNIT Initial Certification By Farr Superior Interval Not Exceeding 12 At the discretion of At the discretion of inspec YES T or VN Months inspection body tion body Interval Not Exceeding 60 At the discretion of YES YES T or VN Months inspection body Following Substantial Repair or Alteration 1
109. ial for dangerous envi ronmental 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 per sonnel to a potential safety hazard that is not life threatening A WARNING may also serve to alert the user to information 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 not made during assembly or operation of your equipment This identifies a CAUTION to users Observance of the following 15 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 operation safety or integrity of the equipment that overrules the content of this document any legal or other mandatory regulation in force governing accident prevention or environmental protection DRILLING amp X SEcTION CONTENTS TECHNICAL MANUAL AACCCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD INTRODUCTION HD22000 22 Congratulations on the purchase of your FARR HD22000 tong This unit will provide you with years of outs
110. ightly 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 EN PULL HANDLE AWAY FROM TONG PUSH HANDLE TOWARD TONG CENTRE SHIFT TO HIGH GEAR CENTRE TO SHIFT TO LOW GEAR ILLUSTRATION 2 G 3 MANUAL SHIFT CONTROL 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 c DO NOT 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 ex
111. ine support base weldment Install the remainder of the hydraulic connections 77 Attach four leg weldments 101 3685 to the bottom of the tong using three 1 2 NC x 2 1 4 hex bolts and 1 2 lock washers per leg 78 Use a crane to support the chain sling PN 101 3762 by the master link Position over the tong and attach the chain sling to the hanger weldments using 1 2 Crosby bolt type shackle at each mounting point four total 79 Install the side access panel PN 1455 7 01 adjacent to the motor mount on the left hand rear side of the tong side body Secure in place with four 3 8 UNC x 3 4 hex socket head cap screws 80 When installing the load cell and load cell tie off use LC anchor tie off PN AX07 003 ANY REPLACEMENT FASTENER BOLTS NUTS CAP SCREWS MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHER WISE SPECIFIED DO NOT EXCEED THE SPECIFIED LENGTH OF ANY FASTENER DRILLING amp TECHNICAL MANUAL 3 23 MOVING GLOBAL ENERGY FORWARD 22000 22 MAINTENANCE I DAILY INSPECTION amp 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 opening in rotary gear faces towards rear of the tong DO
112. ing full fluid flow Check to ensure no other restrictions exist contaminated catch screens or filters for example 5 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 6 POSSIBLE PROBLEM Worn or damaged tong motor causing slippage SOLUTION Replace or repair worn or damaged motor 7 POSSIBLE PROBLEM Damaged bearings or gears causing excessive drag SOLUTION Replace or repair worn or damaged gears or bearings 8 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 9 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 in dependant system DRILLING amp MECOY TECHNICAL MANUAL 4 1
113. ints to the rotor and the radiused edge of each rotor vane points to the stator 3 NOTE Make sure T are seated in the bottom of the spring ocket in both the rotor and stator OTE Do not allow the coil of any spring catch on the edge of the 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 stone lightly dress all machine surfaces to remove any raised metal or burrs Pay 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 of the front and rear housing containing two or three o rings is 002 003 below the outer machined surface Dress these surfaces independently Assemble the motor by reversing the previous procedures Insure that the main body and pedestal o rings are held in place by using an adequate amount of grease in the o ring grooves Line up the housings and rotating group with the paint line made on the motor in Step 6 MOVING GLOBAL ENERGY FORWA
114. ion 30 Keyed Shaft 31 lt Splined Shaft 34 Double Key 35 Female Key 36 Female Spline 40 Double Spline 41 Tapered Thrust 42 Keyed w Opt 43 Splined w Opt 44 Tapered w Opt 52 Smooth Shaft 53 Thread Applications 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 MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL 7 6 SECTION CONTENTS HYDRAULIC INFORMATION 22000 22 Repair Manual 125 Series HYDRAULIGSHING Key Spline 125 Double Stack Key Spline 4 Port Key ILLI COY Thru Key une 7 7 Drill Motor API Series MOVING GLOBAL ENERGY FORWARD HD22000 22 HYDRAULIC INFORMATION DRILLING amp 7 8 SECTION CONTENTS TECHNICAL MANUAL AACCCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD HYDRAULIC Motor INFORMATION PARTS SUBSTITUTED IN 60 68 C I D ROTATING GROUPS 1250317 ROTOR VANE 1250323 SPRING OUTER ROTOR HD 1250324 SPRING INNER ROTOR HD 0370410 STATOR VANE MECOY MOVING GLOBAL ENERGY FORWARD 26 11250442 WAVE SPRING 14 1250619 TIMING PLATE PC EXT SLOT 60 68 CID ONLY DRILLING amp COMPLETION
115. ipment Repeatedly actuate the remaining control valve levers IN BOTH DIRECTIONS to dissipate any residual pressure in the remain der of the hydraulic control system Disconnect the hydraulic RETURN line from the equipment 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 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 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 15 in place to prevent environmental 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
116. ive was also ised in the retnimer assemhly CAUTION Too much heat may distort the spool CLEANING INSPECTION AND REPAIR bore transiliaa check sent and span from each section for deep scratches gouges or excessive wear any of these conditions exist replace ihe section Minor dre on the control spool and check poppet cam be polished away with a very fine crocus cloth 2 Exarnane the machined surfaces of the valve housang for nicks ard burrs that could cause leakage between sections Lightly stone ihese surfaces to remove any rough spots CAUTION shallew milled relief area extends across the O ring face of tho valva housing This should net be stoned or ground off 7 22 SECTION CONTENTS TECHNICAL MANUAL 3 Wash all parts thoroughly in a cleaning solvent and How dry before beginning rexssembly Pay special attention to the number and letters marked on the parts in Step 1 If amy marks are removed during c kaning re mask immeidusiely 4 Clean adhesive from threads of spool stripper bolt housing cap screws amd hex nui with Loctiiet Chisel Gasket Remover AACCCOY MOVING GLOBAL ENERGY FORWARD VALVE INFORMATION HD22000 22 Tone Valve Assembly Instructions T Preparation of Parts Spray the 1hreads of 1he new stripper Fig 2 item 14 tapped dhreaded spool end all screws and screw holes on
117. l models be careful nat ta remove the detent pappet sleeve Fig 2 item 17 unless it is ta be serviced Using a lange Phillips head screw driver remove the two screws Fig 9 from the spool Cleves end of the work section Laghily tap the end of the screwdriver handle with hammer break the adhesive Remove the two retainer plates Fie 1 nem 6 the back up nng Fig 7 and the spool seal Fig item 8 Tag or mark with the appropriate work sectiod identification number Ser Step Spool seals Fig 1 itcm 8 and back up gings Fig 1 nem 7 should d candid Step 6 Transitlon Check he transition check is located im the bottom center of the work section hoasimg Carefully clamp the work section an a vise with ports down Do not clamp on the machaned surface Remove the check valve cap Fig 10 and its O ring seal Fig 1 item 111 Discard seal Remove the check spring Fig 1 inem 12 and the check valve poppei Fig 1 12 NOTE Only cylinder work sections ports blocked in negiral have a transition check Motor sections have only a cap plug TECHNICAL MANUAL 7 21 MOVING GLOBAL ENERGY FORWARD HD22000 22 The spring assembly should be removed from the speed unless these parts need to be replaced Once the 15 Free of the work section bousamg must be handled carefully to avoid damage Place th
118. l the pins are flush with the top of the flange on the weldment Secure motor mount to the top plate with eight 1 2 UNC x 1 1 4 hex socket head cap screws 51 Insert the shifting shaft through the top shifter bushing typically welded to the top plate of the motor mount through the man ganese bronze lower shifter bushing into the shifting fork Secure the shifting shaft to the shifting fork using a 3 4 UNC hex nylock nut 52 Insert the shifter detent ball PN 02 0018 into the detent tube on the top shifter bushing followed by the detent spring PN 997 0 64 Thread a 7 16 UNF hex jam nut onto a 7 16 UNF x 1 1 4 hex nut then thread the 7 16 bolt into the detent tube 53 Bolt the shifter lug weldment PN 101 3757 to the top plate of the motor mount with four 3 8 UNC x 1 1 2 hex bolts and 3 8 lock washers 54 Slide the motor gear PN 1455 149S over the splined shaft of the hydraulic motor PN 87 0150 shoulder toward the motor Secure the motor gear in place with the motor gear retainer plate PN 101 2200 and a 1 2 UNF x 3 4 hex socket flat head countersunk machine screw 55 Install the motor onto the motor mount Secure the motor in place with six 5 8 UNC x 2 hex bolts and 5 8 lock washers 56 Install a manganese bronze guide ring PN 101 2669 into the groove on top of the rotary gear using fifteen 1 2 UNC x 2 hex socket head cap screws 57 Install the second manganese bronze guid
119. lace worn dies if necessary Ensure that the jaw rollers rotate freely 15 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 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 C 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 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 sufficient tension to adequately support backup Ensure that neither of the front leg springs have been pressed and still retain enough spring strength to support the front of the backup 19 Extend hydraulic cylinders and inspect cylinder rods signs of mechanical damage or rust Farr 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 fatiqued or have 2 0 visible signs of wear from contact with rigid objec
120. ll as greater reliability at higher pressures This patented design has been in effect for over 5 years Bearing Data Standard Motor 77 2 N S 7 Ka E j L 0 N S 1 2 ZN 55 w N FA IVA 2 DUUM SK BEARING LOADING The bearings in 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 different applications When using the 125 Series standard motor above 300HP consult a Rineer Application Engineer 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 7 4 SECTION CONTENTS TECHNICAL MANUAL B1 218 218 3000 hrs 1500 hrs 1000 hrs Radial Load Ibf Speed rpm B1 218 218 14000 C
121. maining 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 temperatures 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 are leaking they must be repaired 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 gt may remain in place 2 1 Apply grease or heavy oil to all exposed cylinder rods 2 2 Farr recommends that anti corrosive agent such 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 anti corrosive coating ample to dry r
122. me exacting tolerances and quality controls as the original equipment genuine V A VG replacement parts may help prevent premarure component failure and costly downtime Service parts and assemblies are availahle through your original equipment dealer or any authorized distributor MAINTENANCE Valves are often used in hazardous environments Inspect them frequently for damage due to improper use corrosion or normal wear If needed repairs should be made immediately Always refer to the machine manual for the proper procedure to remove the valve from the machine Remove the valve bank from the equipment disconnecting all hoses fittings control handles and linkage connectors that might be attached to the valve Plug all ports and thoroughly clean the extersor of the valve bank then the port plugs can be removed TECHNICAL MANUAL SECTION CONTENTS 7 17 HD22000 22 HYDRAULIC VALVE INFORMATION Exploded View of Work Section Figure 1 Lo Boy Work Section O 0 i 1 10 ne Parts List For Work Section Item Description Oty VA VG20 Part Mo VANGIS Part No VG80 No Parallel Section Seals See Figure 1 1 Square Seals 391 2881 206 391 2881 200 391 2881 433 2 Square Seal 1 391 2881 200 391 268 1403 391 2788 1 070 Series Section Seals i Square Seals 2 391 2881 206 391 2881 200 3 Square Seal 1 394 7881 627 81 2 1 528 Parallel and Series Section Compo
123. mends 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 3 1 MOVING GLOBAL ENERGY FORWARD 22000 22 D LUBRICATION MAINTENANCE Use a quality multipurpose bearing lubricant that will remain within its viscosity range at expected operating temperatures In addition Farr recommends the following lubrication procedure at the completion of each job prior to storage 1 Cage Plate Guide Support Rings Lubricate the guide support rings through the grease fittings in the top and bottom cage plates 16 locations total m ILLUSTRATION 3 0 1 SUPPORT RING LUBRICATION 2 Support Roller Bearings Supply grease to these bearings through the grease fittings in the top ends of the support roller shafts and door pivot roller shafts located around the perimeter of the cage plate on the top of the tong 12 locations top 12 locations bottom iit 7 ow 7 ILLUSTRATION 3 0 2 SuPPoRT ROLLER LUBRICATION 3 2 SECTION CONTENTS TECHNICAL MANUAL COY MOVING GLOBAL ENERGY FORWARD MAINTENANCE HD22000 22 3 Rotary Idler Bearings Apply grease t
124. n of the suspension line is the complete responsibility of the customer McCoy Drilling amp Completions recommends using dual backup Snub lines of sufficient strength to withstand the force imparted by the maximum rated torque of the tong and backup assembly in use The snub lines will arrest uncontrolled movement of the tong and backup in the event slipping of the backup jaws 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 80 000 Ibs ft tong with a 55 inch 4 58 ft torque arm will generate 17467 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 responsibility of the customer To ensure accurate torque measurement the backup line must be connected perpendicular to the lengthwise axis of the tong and perpendicular to the hang line see illustrations 2 F 1 amp 2 F 2 on next page FARR CANADA CORP 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 DRILLING amp AACCCOY TECHNICA
125. nd 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 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 so that vanes can be reassembled in the same vane slot 3 Separate parts and rinse in solvent tank 1 Place cartridge on any object which will hold it off the table 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 2 Remove two each 10 32 plate screws 3 Remove timing plate VANES Normal wear results in slight flattening of vane tips which does not impair motor performance Replace vane if radius is reduced by 5090 Clearance between the rotor vane and rotor vane slot varies with the vane selection The design allows the vane to lean slightly in the slot providing the required mechanical seal Using a small screwdriver or pick remove o ring and all rotor and stator springs Note Some series rotating groups may contain additional wave springs in the stator vane slot see inset DRILLING amp AACCCON COMPLETIONS TECHNICAL MANUAL 7 11 MOVING GLOBAL ENERGY FORWARD HD
126. ne 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 unit and perform another generous lubrication of the gear train including the gear housing 2 6 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 third generous lubrication of the gear train including the gear housing DRILLING amp AACCCOY TECHNICAL MANUAL 3 27 MOVING GLOBAL ENERGY FORWARD 22000 22 MAINTENANCE 2 8 Re energize power unit and extend hydraulic cylinders Inspect cylinder rods for signs of mechanical damage flak ing rust recommends that damaged cylinders be replaced 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 29 30 Rotate tong in high gear for 5 minutes while monitoring temperature of top and bottom bearing caps If the bearing caps are hot to the touch higher than approximately 50 C replace the applicable bearings Likewise if the tong is making unusual noises check for damaged bearings see Maintenance Manual for all bearing locatio
127. nent Parts See Figure 1 4 Back Cap Screws 2 301 1433 020 391 1433 009 4 391 1402 068 AA Lock washers dali vehi ihnen 391 37 83 039 5 1 341 2000 100 312 6000 100 341 0585 099 6 Holamer Plates 3 391 2183 001 391 2183 005 391 2183 157 Back up Rings 391 2581 378 391 2581 426 3591 2581 285 8 spool Seals 2 391 1965 014 391 2887 212 291 2881 0986 9 Retainer Plate Screws 2 391 1433 015 391 1433 002 4 291 140 015 10 Check 1 391 0561 044 391 0561 044 391 0585 099 Or Cap F I N 1 391 2281 015 391 2281 015 PE oce 11 O Ring Sea 1 391 2881 204 391 266 1 204 391 2881 2497 12 Check Spring 1 391 3581 713 391 3581 713 391 3581 778 13 Check Valve Poppet 1 301 241 0609 301 2481 069 494 2387 091 Paralle Sealing Face includes inlets and mid in ets required in Float in neutral Sections AACCCODY MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL 7 18 SECTION CONTENTS 22000 22 VALVE INFORMATION TES ar Petru d gt T Spring Centered Detent Spool Operators See Figure 2 14 5 Bolt 1 15 Centering Spring 1 16 Spring Guides 2 17 Detent Sleeve 1 18 Detent Balls 2 19 Detent Spring 1 20 Detent Poppet Retainer 1 21 Detent Spacer 1 AAC COY DRILLING amp COMPLETIONS MOVING GLOBAL ENERGY FORWARD 391 1432 022 391 3581 508 391 1642 045 391
128. ng run Install load cell If using a tension load cell perform a visual inspection and replace any cracked broken or distorted 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 15 seen 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 18 19 Re energize power unit DRILLING amp AACCCOY TECHNICAL MANUAL 3 33 MOVING GLOBAL ENERGY FORWARD HD22000 22 2 0 Perform a full functional test of the equipment including if applicable backup components and float components Report and correct any hydraulic leaks from hydraulic valve bank 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
129. ns Install load cell If using a tension load cell perform a visual inspection and replace any cracked broken or distorted components including links and chains If using a compression load cell replace any component that has been crushed or otherwise distorted through compression 37 If applicable inspect the load cell anchor pins tension load cell only Replace the anchor pins if cracking metal distortion is seen 32 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 33 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 34 While rotating the cage plate ensure that the jaws properly cam If the jaws do not cam properly the brake bands 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 35 Perform a full functional test of the tong including if applicable ba
130. nt at second floating plate extreme position switch impacts and binds on fixed safety door components claws do not engage ILLUSTRATION 3 E 6 SAFETY Door SwitcH ADJUSTMENT 02 g Connect hydraulic power to the tong h Ensure the door is closed and all personnel are clear Begin rotating the cage plate Open the tong door the cage plate should immediately and completely stop Release all controls and close the tong door again Ensure the cage plate rotates with the door closed j If cage plate continues to rotate with the door open re adjustment of the safety door switch is necessary If safety door func tion can not be reliably restored within the adjustment range of the safety door switch contact McCoy Drilling amp Completions Farr for technical assistance NEVER OPERATE YOUR HYDRAULIC POWER TONG WITH A MALFUNCTIONING OR OPERATIONAL SAFETY DOOR SYSTEM F RECOMMENDED PERIODIC CHECKS 1 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 2 Backing Pin Perform a visual inspection of the backing pin after each job Replace the pin if stress cracks or excessive wear is found or if either pin is bent 3 Shifting Shaft The shi
131. nut 27 Slide a pinion gear spacer PN 1393 94 over the bottom end of the pinion gear shaft PN 1455 86 ensuring the flat side of the spacer is flush to the gear and the stepped side is oriented to rest against the bearing Place the bottom of the main pinion gear into the previously installed bearing and bearing cap and mesh with the two pinion idlers 28 Slide 2 needle bearings PN 1393 53 over the bottom end of the clutch shaft PN 1393 50 ASSEMBLY NOTE The bottom end of the clutch shaft is machined and threaded for a 1 8 NPT grease fitting Press both bearings tightly against centre gear 29 Slide high clutch gear PN 1455 51 over the bottom end of the clutch shaft onto the two needle bearings ensuring the smaller diameter part of the gear is next to the centre gear on the clutch shaft 30 Place the machined stepped side of bottom clutch shaft spacer PN 1393 50 02 over the lower clutch bearing and place bottom end of clutch shaft through the clutch shaft spacer into the lower clutch bearing that has been pre mounted in the lower body plate 31 Slide a needle bearing PN 1393 53 over the top of the clutch shaft and press against the centre gear followed by an inner clutch spacer PN 193 52 01 Slide the remaining needle bearing over the top of the clutch shaft and press against the inner spacer 32 Install shifting collar PN 1393 62 which will slip over clutch shaft and mesh with low or high clutch gear
132. o these bearings through the grease fittings in the top ends of the rotary idler shafts located on the left and right sides of the tong 4 locations total ILLUSTRATION 3 0 3 ROTARY IDLER LUBRICATION 4 Pinion 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 ee i F F Li 1 ILLUSTRATION 3 0 4 Pinion IDLER LUBRICATION COY TEcHNICAL MANUAL 3 3 MOVING GLOBAL ENERGY FORWARD HD22000 22 5 Pinion Bearings Apply grease to these bearings through the grease fittings in the pinion bearing caps located on the top of the tong directly beneath the valve bank and on bottom of the tong in the center of the stiffener plate total of four locations ILLUSTRATION 3 0 5 Pinion LUBRICATION PLATE LL Le bh b ee T L i LI ILLUSTRATION 3 0 6 LuBRICATION Borrom PLATE 3 4 SECTION CONTENTS TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD HD22000 22 Tone 6 Clutch Shaft Apply grease to these bearings through the two grease fittings in the clutch bearing cap and the single grease fitting in the end of the clutch shaft located beneath the removable brass dust cap in the centre of the bearing cap NIT bi bth j ILLUSTRATION 3 D 7 CLUTCH LUBRICATION 7
133. oblem Solution Symptom Possible Problem Solution Possible Problem Solution Possible Problem Solution Possible Problem Solution 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 No indication on gauge Obstruction in hydraulic hose Check hydraulic hose for kinks Replace hydraulic hose Loss of hydraulic fluid Recharge hydraulic 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 procedure 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 hydraulic 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 Obstruction in hydraulic hose Check hyaraulic hose for kinks
134. 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 94 of theoretical torque Speed to 350 RPM continuous Up to 300 HP continuous Compact envelope sizes Weighs 225 105 to 280 105 ENVELOPE 3 4 10UNC x 1 1 2 DP 5 8 11UNC 2B x 1 25 DP 6 PLACES EQ SP ONA 8 75 B C REAR FACE STD SAE 15 COBE 61 21 32 DIA THRU CE res 1 1 2 24 6 PLACES EQ SP RING BOSS PORT ON A 11 75 B C EXTERNAL CASE SAE FLAT ROOT SIDE FIT 20 T 6 12 DP 30 2 PLACES INVOLUTE SPLINE Made in USA PUBLICATION DS1251005 3 04 DRILLING amp TECHNICAL MANUAL 7 3 MOVING GLOBAL ENERGY FORWARD HD22000 22 TORQUE ft Ibf Performance Data Charts shown are for 98 and 125 CID See website at www rineer com for additional charts Performance data obtained at 140 F with ISO 46 DTE 25 Code 61 and 62 data shown Code 62 extended data applies only to Code 62 High Pressure Series motor Actual Torque and Power 98 CID 300 RPM 50 RPM 0 1000 1500 2000 2500 3000 3500 4500 CODE 61 PRESSURE psid m Actual Flow 98 CID 4000 300 RPM 250 RPM
135. op and reverse the direction of rotation for another minute ending with the opening of the rotary gear facing the gear train De energize the power unit and perform another generous lubrication of the gear train including the gear housing DRILLING amp SECTION CONTENTS TECHNICAL MANUAL MECOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 22000 22 1 3 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 1 4 De energize the power unit and perform third generous lubrication of the gear train including the gear housing 1 5 Energize power unit and rotate the tong final time one minute in one direction stop and reverse the direction of s 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 or rust 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
136. pended 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 residual solvent Farr recommends that an anti corrosive agent such as Tectyl8 506 be applied to all external surfaces Refer to manufacturer data sheets for proper application and safety information Allow the anti corrosive coating ample time to dry refer to manu facturer data sheets for drying times at room temperature e 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 TECHNICAL MANUAL 2 3 MOVI
137. pin knob PN 02 0017 on to the backing pin Install door latch cams PN 101 2251 in to the top and bottom of the RH door weldment PN 101 5510 and the LH door weldment PN 101 5513 Secure the four adjustment cams with a 3 8 UNC x 1 hex bolt and 3 8 lock washer Thread a 1 2 UNC jam nut onto four 1 2 UNC x 1 1 2 flat point set screws Thread two of the set screws into the front of each door weldment until the tip of each set screw becomes visible on the inside of the door weldment Temporarily lock the positions of the set screws using the jam nuts Use a temporary lifting sling and crane to support each door weldment as they re being installed Align the adjustment cams with the pivot holes in the top and bottom plates Insert the door pivot roller shafts from the top they may have to be tapped lightly with a soft metal or rubber hammer Use caution when sliding the shaft through the support roller components Once the shafts have been tapped all the way through and are centered secure with 1 thin flat washers and 1 UNS thin nylock nuts top and bottom Install door cylinder mounting lugs PN 101 1796 into the threaded locations directly adjacent to the brake band pivot points on the top side of the tong see Illustration 3 H 4 Install the door stop cylinder assemblies PN 1037 A4 144 using 5 8 x 3 4 UNC shoulder bolts COY TECHNICAL MANUAL 3 21 MOVING GLOBAL ENERGY FORWARD 22000 22
138. protective cloths inspect the paint on top of the backup and the bottom of the tong to ensure it has not been dam aged 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 C in both directions makeup and breakout If cage plate begins rotating the safety door mechanism is not functional and 1 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 24 When of the previous steps are completed you may return your re commissioned equipment to service DRILLING amp 3 34 SECTION CONTENTS TECHNICAL MANUAL AACCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD TROUBLESHOOTING HD22000 22 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 troubleshoo
139. quired 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 H 11 LoweRING UsinG LIFT CYLINDER CONTROL p Use your rig s standard pipe handling procedures to remove and rack the freed tubing stand q Repeat steps 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 hydraulic fluid to circulate for approximately 20 minutes after starting the power unit prior to activating 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 AACCCODY 2 26 SECTION CONTENTS TECHNICAL MANUAL 0422 MAINTENANCE 22000 22 McCoy Completions amp Drilling recognizes that minor on site repairs and modifications are req
140. r clockwise rotation which 15 the desired direction of rotation for breaking out a joint Ta E ET f p ILLUSTRATION 2 6 1 TONG ROTATION CONTROL VALVE LIFT CYLINDER This is a direct acting 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 G 2 LIFT CYLINDER CONTROL VALVE DRILLING amp TECHNICAL MANUAL 2 17 MOVING GLOBAL ENERGY FORWARD 22000 22 SETUP amp OPERATION 4 2 18 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 toward tong centre from neutral position To shift to the low speed gear move the shifting handle away from tong centre through the neutral detent to its lowest position Note that the high 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 Sl
141. retum to neutral Load wall not hold Load drops when spom moved from neutral MOVING GLOBAL ENERGY FORWARD No motion slow or system operation Broken centering spring Misalignment of operating linkage Foreign particles in system EE Cylinder leaking or worn Port relief valve not holding Spool or housing scored or worm excessively Dirt or foreign particles lodged between check valve poppet and seat Scored or sticking check valve poppet Defective cylinder or motor Relief valve not properly Relief valve poppet or seat scored amp sticking open Valve spool not shufted to full stroke DRILLING amp COMPLETIONS HD22000 22 Tone REMEDY Replace section seal Replace section seals and re torque Loosen mounting bolts and shim as required Clean seal groove replace section sel Correct high back pressure condition Replace seals and seal zi Replace centermg spring Check linkage for mechanical binding Clean valve and system Check cylinder repair Remove and clean or replace Replace section Disassemble clean amp reassemble Replace poppet Check flow amp pressure Repair replace Add oil to specifications Clean replace Check lines Check pressure setting Replace relief valve Check spool linkage travel TECHNICAL MANUAL SECTION CONTENTS 7 27 HD2
142. ring hanger compensates for the downward movement 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 e a double spring hanger typically applies 840 Ibs 382 kg to the suspension line for every inch of thread made up 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 McCoy Drilling amp Completions will not guarantee or specify spring hangers other than what has been supplied by McCoy Many applications use a lift cylinder for adjusting the height of the tong 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 selectio
143. ripper bolt to 175 im 6 4 in CAUTION Care must be taken to ensure that the spring retainer is not pinched under the shoulder bolt during assembly This result in burrs that may cause spool binding Check for binding by compressing the spring and guides by rotating the spring guide nearest the Lightly coat the centering spring with high temperature grease to preveni masting Set the spool assembly and lett cure for a minimum of 1 hour After cung feat ihe stripper to make certam cam withstand 125 in Ibs of breakaway torque TECHNICAL MANUAL SECTION CONTENTS 7 23 22000 22 1 HYDRAULIC VALVE INFORMATION Valve Assembly Instructions Detent Spool Assembly Step 1 Spool Assembly Detent Apply Parker Super O LubeTM 15 the spool seal Fig nem and slide it onto the spool Slide te back up Fig 1 item 7 and one retainer plate Fig 1 utem 6 onto the spool Poston these items onto the spool that they do mor inserfere with the spool operarar mechanism during xssemolv Do allow the O ring to come in contact with the sharp edge of the spon noches Apply 2 3 dropa of Loctite 262 or an equivalent amaerobic adhesive mear ihe middle of the female threads im the spool CAUTION Follow the adhesive manufacturer s instructions For proper cleanimg and curing Failure to clean and prepare parts properly may result in assembly fuilure St
144. rt 3 180 port may cause a valve to switch from a closed to an open position or vice versa All possible pressure changes in the complete circuit must be considered to assure a safe functional system design 7 28 SECTION CONTENTS TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD HYDRAULIC VALVE INFORMATION e These valves have positive seals between port 3 and port 2 e Incorporates the Sun floating style construction to eliminate the effects of internal parts binding due to excessive installation torque and or cavity cartridge machining variations Technical Data avit apacit Area Ratio A3 to A1 Area Ratio A3 to A2 Pressure ilot Volume Displacement eries from Cavit S Patent alve Hex Size alve Installation Torque c Full Open Pressure Drop P bar Option Selection Preferred Options Control Standard Options X Not Adjustable MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS Area Ratio A3 to Area 052 2 Cracking Pressure HD22000 22 Stainless steel cartridge options W are intended for use within corrosive environments with all external components manufactured in stainless steel or titanium Internal working components remain the same as the standard valves T 17A 240 L min 10 drops min 70 bar 4 795 129 1 1 4 150 160 Buna 990 017 007 Viton 990 017 006 200 215 Nm
145. rt Roller ILLUSTRATION 3 H 1 RorARY GEAR INSTALLATION DRILLING amp TECHNICAL MANUAL 3 15 MOVING GLOBAL ENERGY FORWARD HD22000 22 MAINTENANCE Assembly Procedure Continued 12 Install support roller assemblies in the locations exposed by the opening in the rotary gear Continue to rotate the rotary gear installing four support roller assemblies on the other side of the tong in the rotary gear opening as it is rotated Ensure the second brake band coincidental support roller is installed in the correct location and that the shaft spacer on each assembly is placed between the bottom plate and the support rollers 13 As the rotary idler locations are exposed install the rotary idler assemblies with gear plates assembled in Step 9 into their proper locations Ensure that rotary idler gear spacers are installed so that they rest between the bottom gear plate and the bottom plate of the tong ILLUSTRATION 3 H 2 SuPPoRT ROLLER amp ROTARY IDLER INSTALLATION 14 Continue to rotate the rotary gear until all ten support roller assemblies and the second gear plate equipped rotary idler have been installed in their correct locations Finish with the rotary gear aligned with the opening in the bottom plate Do not install the two door pivot support roller assemblies at this time 15 Assemble and install the remaining two rotary idler assemblies Orient the two remaining rotary idler gears and bearing assem blies
146. s 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 parts that are rubbing bare metal where there used to be is a 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 visible signs of wear from contact with a rigid object DRILLING amp 3 24 SECTION CONTENTS TECHNICAL MANUAL MCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 22000 22 1 3 C 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 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 TH
147. s must be replaced before the equipment is returned to service Perform a thorough inspection of all seals Any seal that is leaking or weeping must be replaced before the equipment is returned to service Rotate tong in low gear 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 signs of wear blistering or any other signs of potential failure replace if signs of potential failure are identified Inspect the gear train housing 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 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 14 15 16 Re install access panel Install set of pre inspected jaws that are the correct size for the pipe casing bei
148. s such as the following are present Missing or illegible sling identification Cracks or breaks e Evidence of tampering is seen sling tag has been modified or obscured or tamper proof nuts are missing e 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 69 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 and 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 s
149. se 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 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 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 W O LILILI 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 fitting
150. speed low torque See Section to properly set the tong to high gear not shift gears while the tong is rotating SHIFTING TONG WHILE ROTATING THE MOTORAND CAGE PLATE MAY RESULTIN CATASTROPHIC GEAR TRAIN FAILURE DRILLING amp AACCCON COMPLETIONS TECHNICAL MANUAL 2 21 MOVING GLOBAL ENERGY FORWARD 22000 22 SETUP amp OPERATION Making A Connection Continued Push the motor control valve toward the tong to rotate the cage plate in the make up direction E ILLUSTRATION 2 H 5 Motor CONTROL MAKE UP 1 When the tong jaws cam on to the tubing push the rotation control handle all the way in to 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 set motor to low speed 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 specification n Push 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 ILLUSTRATION 2 H 6 Motor CONTROL RELEASING JAWS 2 22 SECTION CONTENTS TECHN
151. ssembly 2 Connect the master link of the chain sling to a crane and raise until most but not all of the slack has been taken up by the crane Disconnect the four shackle assemblies at the lifting lugs to free the chain sling assembly from the tong and use the crane to move the chain sling to a secure storage location see Section 2 A for proper chain sling storage recommendations 3 Remove the four top chain sling hanger plates from the top plate of the tong followed by the four hanger lug weldments that are bolted to the bottom plate of the tong 4 Disconnect at the hydraulic valve assembly all flexible hydraulic lines running from the safety door switch and motor Disconnect both 1 hydraulic lines at the motor Remove the bolts securing hydraulic inlet outlet support base weldment to the top plate of the motor mount Remove the three 1 2 x 4 1 2 bolts securing the hydraulic valve assembly to the valve support posts Use a temporary sling and crane to lift the hydraulic valve section up and away from the top plate of the tong If the hydraulic valve assembly does not require service ensure it is stored in a clean secure location Cover all exposed connections Remove the three valve support post weldments from the top plate of the tong Remove the two tong door stop cylinders Use caution as the door springs may be retain energy from being compressed Remove both rear door cylinder support posts from the top plate of the tong 7 Swing
152. t If your tong is equipped with rigid hydraulic lines replace any line that is dented or appears to be stressed or cracked 21 Generously fill the gear train housing with grease through the access panel and also through the opening in the rotary s gear Perform a full lubrication refer to Maintenance section of manual to determine lubrication points 2 2 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 ARE 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 C Ensure that supply pressure is at or above the tong s specified operating pressure and that the return pressure is less than 350 psi 2 4 Perform a visual inspection of pressurized hydraulic lines If any hydraulic fittings or hoses are leaking they must be repaired or replaced before proceeding Rotate tong for o
153. tanding performance Simple maintenance and care will extend its life and ensure years of excellent performance and reliability The setup operating and maintenance 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 272 Phone 780 453 3277 Fax 780 455 2432 Sales Fax 780 481 9246 Email Engineering engFarr mccoyglobal com Email Sales salesFarr mccoyglobal com Customer Care customerCareFarr mccoyglobal com Website http www mccoyglobal com index php arilling completions ILLUSTRATION 1 4 1 HD22000 Power DRILLING amp MCCOY COMPLETIONS TECHNICAL MANUAL 1 1 MOVING GLOBAL ENERGY FORWARD HD22000 22 SPECIFICATIONS 85 1 2 ILLUSTRATION 1 2 HD22000 Power DIMENSIONS DRILLING amp 1 2 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD SPECIFICATIONS 22000 22 Torque Table Pressure High Gear Low Gear PSI MPa Lbs ft Lbs
154. tch shaft spacer 16 Remove the four 3 8 flat head countersunk machine screws securing the clutch bearing plate to the top plate and remove the clutch bearing plate DRILLING amp 3 12 Section CONTENTS TECHNICAL MANUAL AACCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 22000 22 Plate Removal Cont d 17 If not already done remove the two jaws and jaw pivot bolts 18 Remove the 7 8 nylock nut from the top of the rear cage plate bolt and remove the backing pin backing pin knob and backing pin retainer 19 Loosen both brake bands see Section 3 E 1 by backing off the top and bottom brake band adjustment bolts until the brake bands completely release the top and bottom cage plates Completely remove the adjustment nut and bolt for the top brake band weldments Remove the external retaining rings securing the brake band pivots to the support roller shafts and remove both top brake band weldments 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 20 Support the bottom cage plate Remove the two front cage plate bolts washers and nylock nuts and the rear cage plate bolt Remove the cage plate spacers Remove the bottom cage plate assembly and move to a suitable storage location Inspect the
155. 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 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
156. the 22 jaw die kit the top and bottom jaw alignment blocks need to be removed and rotated 180 degrees in order to provide adequate clearance between the jaws and the rotary gear Simply remove the socket head cap screws rotate the alignment blocks 180 degrees and re secure with the socket head cap screws before installing the jaw die kit ILLUSTRATION 2 E 3 ALIGNMENT BLOCK ADJUSTMENT 01 Fon 22 Jaws ONLY The illustration below shows the alignment blocks ready for installation of the 22 jaw die kit E _ ILLUSTRATION 2 E 4 ALIGNMENT BLOCK ADJUSTMENT 02 Fon 22 Jaws ONLY TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 2 12 SECTION CONTENTS SETUP amp OPERATION 22000 22 TONG RIG UP amp LEVELING 1 Suspension amp Restraint Suspend the tong and backup 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 and backup or simply tied off in the derrick to form a dead line When using a dead line arrangement it is necessary to use a FARR spring hanger assembly see specification page for recommended spring hanger This sp
157. 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 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 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 and 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 MOVING GLOBAL ENERGY FORWARD DRILLING amp MECOY TECHNICAL MANUAL 3 25 22000 22 MAINTENANCE J MONTHLY MAINTENANCE CHECKLIST POWER TONG The following maintenance checklist is intended as a guideline rather than a defini
158. the support roller shafts as it is lowered Use caution not to damage the threads on the tops of the rotary idler and support roller shafts 39 Place the two remaining support roller assemblies less the shafts and fasteners in the door pivot locations Ensure that the top and bottom roller bearing spacers are properly installed between the bearings and top and bottom plates 40 Tap the chamfered ends of three 1 2 x 1 1 2 top plate positioning dowel pins PN 09 0172 into the dowel pin locations to finalize the position of the top plate Insert until the pins are flush with the top plate 41 Secure the top plate with 33 1 2 UNC x 1 3 4 hex bolts and 1 2 lock washers and eight 1 2 UNC x 1 1 4 hex socket head cap screws Do not install fasteners at the four chain sling hanger locations indicated by red circles or the two door spring cylinder lug mount locations indicated by green circles ILLUSTRATION 3 H 4 Top PLATE FASTENER INSTALLATION 42 Secure the tops of the four rotary idler shafts with 1 1 2 flat washers and 1 1 2 UNF nylock nuts 43 Secure the eight threaded support roller shafts with 1 narrow flat washers and 1 UNS nylock nuts Ensure the support roller shafts are centered top to bottom 44 Press the remaining pinion bearing PN 1393 93 into the top pinion bearing cap and install over the top of the pinion gear shaft Secure with four 1 2 UNC x 1 3 4 hex bolts and 1 2 lock washers
159. ting instructions are intended to be guidelines only Any faults not solved through the use of this guide should be referred to our engineering department for their evaluation and recommendations A TONG WILL NOT DEVELOP SUFFICIENT TORQUE 1 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 2 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 3 POSSIBLE PROBLEM Power unit is not producing adequate pressure SOLUTION Troubleshoot power unit see user s manual for your particular unit 4 POSSIBLE PROBLEM Poor hydraulic 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 allow
160. tive maintenance schedule Your equipment may require more or less maintenance depending upon the frequency of use the percentage of maximum 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 opening in rotary gear faces towards 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 pressure in 2 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 resid
161. tremely high stress placed on the gear train frequently causes gear breakage USING THE SNAP BREAK METHOD TO BREAK OUT A JOINT ENDANGERS RIG PERSONNEL AND MAY CAUSE IRREPARABLE DAMAGE TO EQUIPMENT MOVING GLOBAL ENERGY FORWARD SECTION CONTENTS TECHNICAL MANUAL SETUP amp OPERATION 22000 22 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 D Hydraulic Connections 2 Tong Jaw Installation e 2 F 1 Tong Rig up and Leveling Suspension e 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 chain sling must be used to suspend the tong Do not suspend the tong from any other point ILLUSTRATION 2 H 1 MASTER LirriNG 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
162. ttings 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 b Connect the hand pump to the check valve fitting c 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 MCCOY DRILLING amp COMPLETIONS HIGHLY RECOMMENDS PLACING YOUR LOAD CELL IN A CONTAINMENT BASIN BEFORE PROCEEDING WITH THE BLEEDING amp REFILLING PROCESS d 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 H on Illustration 6 A 5 to allow trapped air to escape f Pump fluid into the system until no more air is seen escaping from the vent port
163. ual pressure 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 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 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 15 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 Inspect all fast
164. uate contain ment is in place to prevent environmental contamination from residual hydraulic fluid and dirty grease 4 Remove the access panel on the side 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 are 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 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 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 replace damaged part s before placing tong service Also inspect all chains master links and turnbuckle
165. uired 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 e 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 Completions amp Drilling Replaced fasteners must be Grade 8 or equivalent or whatever fastener is specified by McCoy 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 qualified 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 ina

Manual HD22000 - Texas International Oilfield Tools LTD

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