MCCOY FARR SL-4500 Technical Manual

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SL-4500

" (11.43cm) 8K Lbs.-Ft. "Slim"

Hydraulic Power Tong & Backup

• Specifications

• Operation

• Maintenance

• Assembly

Published by McCoy Corporation, Technical Publications Department

14755 - 121A Avenue • Edmonton, AB, Canada, T5L 2T2

TECHNICAL MANUAL

mccoyglobal.com

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Summary of Contents for MCCOY FARR SL-4500

Page 1 TECHNICAL MANUAL SL-4500 ” (11.43cm) 8K Lbs.-Ft. “Slim” Hydraulic Power Tong & Backup • Specifications • Operation • Maintenance • Assembly ©2011 McCoy Corporation. All rights reserved. mccoyglobal.com Published by McCoy Corporation, Technical Publications Department 14755 - 121A Avenue • Edmonton, AB, Canada, T5L 2T2...
Page 3 ” “ S ” T SL4500 4- This manual covers the following models: moDeL DeScRiPTion 4-1/2” 6500 lb.-ft. “Slim” Tong with integrated backup & support structure, standard 2-arm sling, motor 80-2001-6 valve, backup valve, & safety door. 4-1/2” 8000 lb.-ft. “Slim” Tong with integrated backup & support structure, standard 2-arm sling, motor 80-2001-8 valve, backup valve, lift valve, & safety door. 4-1/2” 8000 lb.-ft. “Slim” Tong with integrated backup & support structure, short 2-arm sling, motor valve, 80-2001-10 backup valve, lift valve, & safety door. 4-1/2” 8000 lb.-ft. “Slim” Tong with integrated backup & support structure, standard 2-arm sling, motor 80-2001-13 valve, backup valve, lift valve, safety door, & dump valve NOTE:...
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Page 5 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 & COMPLETIONS IS DESIGNED TO SUP- PORT THE EQUIPMENT DESCRIBED IN THIS MANUAL. MCCOY DRILLING & COMPLETIONS WILL NOT GUARANTEE THE ABILITY OF THE LOAD-BEARING DEVICE TO SUPPORT ANY OTHER PART, ASSEM- BLY OR COMBINATION OF PARTS AND ASSEMBLIES.
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Page 7 ” “ S ” T SL4500 4- Copyright © 2009 - 2011 McCoy Corporation, including its wholly owned subsidiaries, (“McCoy”), all rights reserved. This document is the property of McCoy and is supplied as reference information for users of our products. This document and the contents within are consid- ered 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. McCoy has made every effort to ensure the information contained in this document is accurate and current. This manual is intended to provide equipment operation and safety instructions for your equipment. However, McCoy does not warrant or guarantee that the informa- tion is either complete or accurate in every respect and the user of the manual should consult with its McCoy sales representative for any clarifications and updates. The user of the manual shall protect, indemnify, and hold harmless McCoy and its directors, officers, employees, and agents from and against all liability for personal injury, death, or property damage resulting directly or indirectly from the use of the information contained in this manual. Observance of all descriptions, information and instructions set out in this manual is the full responsibility of the user. This manual is intended for guidance and informational purposes and must be used in association with adequate training and on-the-job supervision to provide safe and effective equipment use. It is the responsibility of the user to conform to all regulations and requirements issued by an 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 May 2009 Initial Release Sep 2009 Intro 1.2 & 1.3 Corrected dimensions on the specification pages...
Page 8: Table Of Contents
” “ S ” T SL4500 4- abLe of onTenTS Introduction & Specifications ............................ Section One Introduction & Contact Information ........................ 1.1 Equipment Specifications ............................. 1.2 Lubrication Specifications ............................. 1.4 Setup & Operation ..............................Section Two Sling / Load Bearing Device Safety ........................ 2.1 Major Component Identification .......................... 2.4 Hydraulic Schematic / Hydraulic Valve Identification ................... 2.8 Hydraulic Connections ............................ 2.11 Tong / Backup Jaw Availability & Installation ....................... 2.12...
Page 9 ” “ S ” T SL4500 4- iST of LLuSTRaTionS Illustration 1.A.1: SL4500 Tong & Backup ............................ 1.1 Illustration 1.A.2: SL4500 Dimensions............................ 1.2 Illustration 2.A.1: Sling Angle................................ 2.1 Illustration 2.B.1: Component Identification 01 .......................... 2.4 Illustration 2.B.2: Component Identification 02 .......................... 2.5 Illustration 2.B.3: Component Identification 03 .......................... 2.6 Illustration 2.B.4: Component Identification 04 .......................... 2.6 Illustration 2.B.5: Component Identification 05 .......................... 2.7 Illustration 2.C.1: Hydraulic Schematic 01 ............................ 2.8 Illustration 2.C.2: Hydraulic Component Identification 01 ...................... 2.9 Illustration 2.C.3: Hydraulic Component Identification 02 ...................... 2.9 Illustration 2.C.4: Hydraulic Component Identification 03 .
Page 10 ” “ S ” T SL4500 4- The information presented in this document will provide setup, operating, and maintenance instructions for your SL4500 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 op- erating authority (ies). IDENTIFICATION OF OF WARNINGS AND OTHER NOMENCLATURE OF IMPORTANCE USED IN THIS INSTALLATION GUIDE Farr Canada Corp. 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 and identifies items of the highest importance. Failure to heed information identified by a HAZARD symbol may result in bodily injury, death, catastrophic equipment damage, or any combination of these. A HAZARD may also indicate the potential for dangerous environmental contamination.
Page 11: Illustration 1.A.1: Sl4500 Tong & Backup
” “ S ” T SL4500 4- nTRoDucTion Congratulations on the purchase of your FARR® SL4500 4-1/2” “Slim” tong. This unit will provide you with years of outstanding perfor- mance. 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 & Completions | FARR in Edmon- ton 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 & Completions | FARR 14755 121A Avenue Edmonton, Alberta Canada T5L 2T2 Phone: 780.453.3277 Fax: 780.455.2432 Sales Fax: 780.481.9246 Email Engineering: engFarr@mccoyglobal.com Email Sales: salesFarr@mccoyglobal.com Website: http://www.mccoyglobal.com/index.php/drilling-completions 1.a.1: sl4500 t & B llustratIon ackup echnicaL anuaL ecTion onTenTS...
Page 12: Illustration 1.A.2: Sl4500 Dimensions
” “ S ” T SL4500 4- PecificaTionS 39-7/8” 1.a.2: sl4500 D llustratIon ImensIons PLEASE NOTE: AREAS SHOWN HIGHLIGHTED ARE POTENTIAL PINCH/HAZARD AREAS. EXERCISE CAUTION AROUND THESE AREAS DURING TONG OPERATION. ecTion onTenTS echnicaL anuaL...
Page 13 ” “ S ” T SL4500 4- PecificaTionS Torque Table (Low Torque) ** Pressure (PSI) Hi Speed (lbs.-ft.) Lo Speed (lbs.-ft.) 1000 2300 1500 1060 3700 2000 1485 5200 2500 1885 6500 MAXIMUM RATED TORQUE: 6500 LBS.-FT. Speed Table (Low Torque) ** Flow (US GPM) Lo Speed (RPM) Hi Speed (RPM)
Page 14 ” “ S ” T SL4500 4- PecificaTionS Use an EP synthetic grease that meets or exceeds the following specifications: Thickener Lithium Complex NLGI consistency grade NLGI performance grade GC-LB Penetration - ASTM D 217 (25°C [77°F] 265-295 minimum 0.1 mm) worked 60 strokes Dropping point, °F[°C] - ASTM D2265 550 [288] minimum High temperature life, hours - ASTM D 3527 160 minimum Oxidation stability, psi - ASTM D 942 (100 hr/300 hr) 0/3 Water washout, percent - ASTM D 1264 1.8 max Rust and corrosion - ASTM D 1743 pass Oil separation, percent loss - ASTM D 1742 1.1 max (24 hours, 25°C [77°F] Leakage, g lost - ASTM D 4290 1.0 max Four ball wear test, mm scar - ASTM D 2266 0.40 max Fretting wear, mg - ASTM D 4170 3.4 max Four ball EP, kgf - ASTM D 2596 Weld point 400 minimum Load wear index 50 minimum Timken OK load test, lbs - ASTM D 2509...
Page 15: Setup & Operation
THIS MANUAL THAT ADD WEIGHT TO THE EQUIPMENT, UNLESS SUPPLIED BY FARR CANADA CORP.. FARR CANADA CORP. DOES NOT GUARANTEE THE INTEGRITY OF MODIFIED OR DAMAGED LOAD-BEARING DEVICES, UNLESS THOSE MODIFICATIONS ARE PERFORMED BY FARR CAN- ADA CORP.. McCoy Drilling & 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.
Page 16 ” “ S ” T SL4500 4- & o eTuP PeRaTion Inspection Of Slings Farr Canada Corp. 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 Criteria: A load-bearing device shall be removed from service if conditions such as the following are present: ● Missing or illegible sling identification. ● Cracks or breaks ● Evidence of tampering is seen - sling tag has been modified or obscured, or tamper-proof nuts are missing. ● Signs of impact on load-bearing components, including spreader bars, lifting lugs, rigid slings & rigid sling weldments, and legs & leg mounts. ● Broken or damaged welds. ●...
Page 17 ” “ S ” T & o SL4500 4- eTuP PeRaTion Units designed and manufactured in accordance with EN 12079 and DNV 2.7-1 should be tested and examined in accordance with the following schedule of examination and test. The user of the load-bearing device shall place a permanent placard or plate upon which the type and date of the last test shall be recorded. To avoid confusion, the plate shall not carry the date of the next test or examination, only the most recent. Test / Examination esTrucTive horough uffix arkeD (nDe) xaminaTion isual laTe TTacheD nTerval ifTing esTs ifTing oinTs xaminaTion Initial Certification By Farr / Superior Interval Not Exceeding At the discretion of At the discretion of T or VN 12 Months inspection body inspection body Interval Not Exceeding...
Page 18: Major Component Identification
” “ S ” T SL4500 4- & o eTuP PeRaTion MAJOR COMPONENT IDENTIFICATION 2.B.1: c llustratIon omponent DentIfIcatIon Item Description Rigid Sling Tong Backup Front Leg Assembly Hydraulic Valve Assembly & Mounting Plate Rear Leg Assembly ecTion onTenTS echnicaL anuaL...
Page 19: Illustration 2.B.2: Component Identification
” “ S ” T & o SL4500 4- eTuP PeRaTion 2.B.2: c llustratIon omponent DentIfIcatIon Item Description Backing Pin Assembly Cage Plate Assembly Tong Jaws with Die Inserts Safety Door Plunger & Guard Tong Door Latch Tong Door Tong Leveling Adjustment echnicaL anuaL ecTion onTenTS...
Page 20: Illustration 2.B.3: Component Identification
” “ S ” T SL4500 4- & o eTuP PeRaTion 2.B.3: c llustratIon omponent DentIfIcatIon 2.B.4: c llustratIon omponent DentIfIcatIon Item Description Safety Door Valve Hydraulic Motor Brake Band Brake Band Adjustment ecTion onTenTS echnicaL anuaL...
Page 21 ” “ S ” T & o SL4500 4- eTuP PeRaTion 2.B.5: c llustratIon omponent DentIfIcatIon Item Description Compression Load Cell Rear Backup Float Spring Assembly Load Cell Spacer echnicaL anuaL ecTion onTenTS...
Page 22: Hydraulic Schematic / Hydraulic Valve Identification
” “ S ” T SL4500 4- & o eTuP PeRaTion HYDRAULIC SCHEMATIC & VALVE IDENTIFICATION The following hydraulic schematic illustrates the hydraulic controls of a fully equipped tong and backup assembly. Your specific equip- ment may or may not have all hydraulic controls as illustrated. BACKUP OPTIONAL OPTIONAL OPTIONAL TO LIFT OPTIONAL OPTIONAL 2.c.1: h llustratIon yDraulIc chematIc Item Description Part Number Page Inlet Valve c/w safety door cartridge 101-3927A 2.10 Relief Valve (type varies with model) 2.10 Pilot-To-Open Valve, Sun LKHC-XDN 08-1625...
Page 23 ” “ S ” T & o SL4500 4- eTuP PeRaTion 2.c.2: h llustratIon yDraulIc omponent DentIfIcatIon 2.c.3: h llustratIon yDraulIc omponent DentIfIcatIon echnicaL anuaL ecTion onTenTS...
Page 24 ” “ S ” T SL4500 4- & o eTuP PeRaTion 2.c.4: h llustratIon yDraulIc omponent DentIfIcatIon 2.10 ecTion onTenTS echnicaL anuaL...
Page 25: Hydraulic Connections
” “ S ” T & o SL4500 4- eTuP PeRaTion 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. THE INLET & OUTLET HYDRAULIC HOSES ANTI-WHIPLASH LANYARDS MUST BE ATTACHED TO THE TONG WITH ANTI-WHIPLASH LANYARDS 1” Hydraulic Inlet 1-1/4” Hydraulic Outlet 2.D.1: h llustratIon...
Page 26: Illustration 2.E.1: Tong Jaw Removal
Jaw Availability The following table lists all jaw die kits that are available as standard stocked sizes for this model of tong. McCoy Drilling & 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...
Page 27: Tong Rig-Up & Leveling
Suspension & 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 spring 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 lbs. (191 kg.) to the suspension line for every inch of thread made up ● a “double spring” hanger typically applies 840 lbs. (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 & 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. 2.13 echnicaL anuaL ecTion onTenTS...
Page 28: Illustration 2.F.1: Master Link
Suspension & Restraint (continued): All forces upon the suspension line must be considered when calculating necessary strength of the suspension line. The weight of the tong, the weight of the lift cylinder, the weight of the spring hanger, and the force imparted on the suspension line by the spring hanger must all be added together in order to arrive at the total force supported by the suspension line. Select your suspension line based upon the total force and the margins of safety dictated by the policies of your company and by estab- lished engineering practices. Ultimately, calculating the force on the suspension line and selection of the suspension line is the complete responsibility of the customer. McCoy Drilling & 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 8,000 lbs.-ft. tong with an 18 inch (1.5 ft.) torque arm will generate 5333 lbs. 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.
Page 29: Illustration 2.F.2: Tong Leveling
” “ S ” T & o SL4500 4- eTuP PeRaTion ii. Place a level lengthwise (front to back) along the tong, ensuring that it is parallel with the surface of the tong. Loosen the 1/2” locking nuts on the adjusting bolts on rigid sling brackets. Completely loosen the adjusting bolts. Turn each adjusting bolt equally until tong hangs level front-to-back. Lock adjusting bolts in place with the lock nuts. Loosen locking nut before Leveling adjustment bolt. rotating adjustment bolt. 2.f.2: t llustratIon evelIng 2.15 echnicaL anuaL ecTion onTenTS...
Page 30: Illustration 2.F.3: Load Cell Configuration
” “ S ” T SL4500 4- & o eTuP PeRaTion Load Cell Configuration The backup is directly coupled to the compression load cell via the backup body paddle. The load cell hanger is simply hung in its slot on the paddle, and in normal operation does not need to be adjusted or removed. The assembly in the first of the following two illustrations has been configured in the “make-up” configuration; to convert the assembly to the “break-out” con- figuration simply lift the load cell holder / spacer assembly off the paddle, rotate it 180 , and replace - no tools are required for this operation. Load Cell - Makeup Configuration Load Cell - Breakout Configuration 2.f.3: l llustratIon onfIguratIon 2.16 ecTion onTenTS echnicaL anuaL...
Page 31: Tong Operation
” “ S ” T & o SL4500 4- eTuP PeRaTion TONG OPERATION Operator Training Many companies set qualification standards that must be met before equipment is may be operated without supervision. McCoy Drilling & 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 Initial Start-up and Break-in Procedure YOUR EQUIPMENT HAS BEEN THOROUGHLY TESTED AND INSPECTED AT THE FACTORY.
Page 32: Illustration 2.G.1: Tong Motor Control
” “ S ” T SL4500 4- & o eTuP PeRaTion Valve Operation 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 for- ward there is an effect, and when the valve is pulled back, there is an opposite effect. These valves feature proportional control, 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 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 counter-clockwise rotation, which is the desired direction of rotation for breaking out a joint. 2.g.1: t llustratIon otor ontrol 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. 2.g.2: l llustratIon ylInDer ontrol 2.18 ecTion onTenTS echnicaL anuaL...
Page 33: Illustration 2.G.3: Backup Clamp Control
” “ S ” T & o SL4500 4- eTuP PeRaTion BACKUP This is a two-way direct acting valve, without proportional control. Pushing the valve handle forward will cause the backup to engage. Pulling backward, towards the operator, reverses the operation. 2.g.3: B llustratIon ackup lamp ontrol TONG SPEED The motor speed valve offers safe and smooth adjustment of the tong speed without the need to manipulate gears in a gear train. Simply rotate the speed valve to change the speed of the motor. The simplicity of this system is particularly useful when making up or breaking out a joint. 2.g.4: m llustratIon otor peeD ontrol 2.19 echnicaL anuaL ecTion onTenTS...
Page 34: Extreme Cold Weather Operation Procedures
” “ S ” T SL4500 4- & o eTuP PeRaTion GENERAL COMMENTS Position rotary gear in contact with both idler gears when breaking out joints or collars where high torques are required. When making-up integral (shouldered) joints, it is essential to make up the last turn of the threads in low gear. This reduces the tendency of an instant stop or a sudden increase in torque, which induces extremely high stresses on the gear train. DO 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 extremely high stress placed on the gear train frequently causes gear breakage. THE “SNAP-BREAK” METHOD IS HAZARDOUS TO RIG PERSONNEL EXTREME COLD WEATHER OPERATION PROCEDURES Consult the power unit engine operator’s manual for all cold weather operating procedures and precautions.
Page 35: Making & Breaking Connections
” “ S ” T & o SL4500 4- eTuP PeRaTion MAKING AND BREAKING CONNECTIONS Set up and prepare your equipment for operation as per Section 2 of the SL-4500 Technical Manual. Refer to the following sections: • 2.D - Hydraulic Connections • 2.E - Tong & Backup Jaw Installation • 2.F.1 - Tong Rig-up and Leveling, Suspension • 2.F.2 - Tong Rig-up and Leveling, Leveling • 2.F.3 - Tong Rig-up and Leveling, Load Cell Configuration 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. THIS PROCEDURE ASSUMES THE USER HAS PROPERLY SET UP AND PREPARED THE EQUIP- MENT FOR OPERATION AS PER SECTION 2 OF THE TECHNICAL MANUAL Making Up A Connection Ensure hydraulic power supply to the tong and backup is energized. The master link on the rigid sling must be used to...
Page 36: Illustration 2.I.3: Backup Control
” “ S ” T SL4500 4- & o eTuP PeRaTion Making A Connection (continued): 2.I.2: s “m ” llustratIon ettIng ackIng In to Ensure the load cell is properly configured for making up connections. See Section 2.F.3 of the SL-4500 Technical Manual for correctly configuring your equipment. McCoy Drilling & Completions recommends that backup pressure be pre-set for the size of tubing before starting the job (no tubing is required for this procedure): • Backup clamping pressure is only displayed when the backup jaws are closed in the “clamp” position. Close the backup jaws using the backup control handle. 2.I.3: B llustratIon ackup ontrol 2.22 ecTion onTenTS echnicaL anuaL...
Page 37: Illustration 2.I.4: Clamp Pressure Gauge On Gauge Panel
” “ S ” T & o SL4500 4- eTuP PeRaTion Making A Connection (continued): Setting backup pressure (continued) • Observe the backup pressure as indicated on the “CLAMP” pressure gauge 2.I.4: clamp p llustratIon ressure auge on auge anel • Hydraulic pressure on the clamp cylinders must be relieved before the clamping pressure can be adjusted. Relieve pres- sure by pulling back on the backup control handle enough to actuate the relief, but not enough to retract the cylinder. • Use the backup pressure control knob to adjust the pressure. Turning the knob clockwise increases clamping pressure, and turning the control knob counter-clockwise decreases clamping pressure. 2.I.5: B llustratIon ackup ressure ontrol alve Turn the knob in small increments i.e. 1/4 turn at a time, and check clamping pressure after every pressure adjustment. Ensure the pressure on the clamp cylinders is relieved before re-adjusting pressure.
Page 38: Illustration 2.I.6: Unlatching & Opening Door
” “ S ” T SL4500 4- & o eTuP PeRaTion Making A Connection (continued): d) Setting backup pressure (continued) • If pressure data from previous jobs is unavailable, McCoy recommends setting the initial backup pressure to 1900 PSI and increase the pressure incrementally if required. If pressure data is available, set the final backup pressure to the pres- sure required for the job. Due to a wide variety of tubing wall thicknesses it is impossible to recommend optimum backup pressure settings from the factory for each size of tubing. • Retract clamp cylinders once backup pressure has been satisfactorily set. Open the tong door. If your equipment is equipped with a safety door, opening the door will inhibit rotation of the cage plate. 2.I.6: u & o llustratIon nlatchIng penIng Manually engage the threads of the tubing connection being made up. Ensure threads are not cross-threaded. 2.24 ecTion onTenTS echnicaL anuaL...
Page 39: Illustration 2.I.7: Lift Cylinder Control
” “ S ” T & o SL4500 4- eTuP PeRaTion Making A Connection (continued): Actuate the lift cylinder control valve to lift the assembly from the drill floor. Pushing the valve toward the center of the tong will retract the lift cylinder to lift the assembly (see illustration 2.I.7 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 AND BACKUP AS IT IS LIFTED FROM THE DRILL FLOOR 2.I.7: l llustratIon ylInDer ontrol Move the tong and backup assembly on to the tubing joint. Use the lift cylinder to ensure the assembly is at the correct height so that the backup jaws are located below the connection point, and the tong jaws are located above the connection joint.
Page 40: Illustration 2.I.8: Backup Control
” “ S ” T SL4500 4- & o eTuP PeRaTion Making A Connection (continued): 2.I.8: B llustratIon ackup ontrol The motor speed control valve may be in one of three positions: • UP - High speed selected • MIDDLE - Neutral position • DOWN - Low speed selected Motor Speed Control 2.I.9: m llustratIon otor peeD ontrol If not already in the “high speed” position grasp the motor speed control valve and firmly lift up until it “latches” into its detent position. Gently push the rotation control valve toward the centre of the tong to slowly rotate the cage plate until the tong jaws grip the tubing (see Illustration 2.I.10 next page). 2.26 ecTion onTenTS echnicaL...
Page 41: Illustration 2.I.10: Rotation Control - Makeup
” “ S ” T & o SL4500 4- eTuP PeRaTion Making A Connection (continued): 2.I.10: r llustratIon otatIon ontrol akeup m) When the tong jaws grip 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 system pressure and displayed torque will increase. 2.I.11: t & s llustratIon orque ystem ressure auges on auge anel 2.27 echnicaL anuaL ecTion onTenTS...
Page 42 ” “ S ” T SL4500 4- & o eTuP PeRaTion Making A Connection (continued): When system pressure and torque begin to rise, switch to low speed: • Do not release the rotation control • Grasp the speed control knob and firmly push it down to the low speed setting. Motor speed decreases by 50 percent, and available torque doubles. 2.I.12: s low speeD llustratIon wItchIng otor speeD wItch Observe the tubing in the backup as the joint is approaches the specified make-up torque. If the tubing begins to slip in the backup, increase the backup pressure in 50 psi increments until the tubing stops slipping. Makeup torque must be reached without any tubing rotation in the backup. When that has been achieved record the backup pressure for future reference. As you gain experience with your equipment make up a “pressure vs. tubing size” chart that can be referred to when making future connections, ensuring proper backup pressure settings without risking crushed tubing. When proper makeup torque has been reached reverse the rotation control valve to release the tong jaws from the tubing. 2.I.13: r llustratIon eversIng otatIon 2.28 ecTion...
Page 43: Illustration 2.I.14: Un-Clamping Backup Jaws
” “ S ” T & o SL4500 4- eTuP PeRaTion Making A Connection (continued): When tong jaws are free release the backup jaws by pulling the backup clamp control handle away from the tong toward the operator. 2.I.14: u llustratIon clampIng ackup Unlatch and open the tong door to free the assembly from the tubing. Note that rig personnel may be required to stabilize the equipment as it completely releases from the tubing. Guide the assembly away from the string and use the lift cylinder control to lower it to the drill floor. 2.I.15: l llustratIon owerIng ssemBly sIng ylInDer ontrol Repeat steps “e” through “r” until the desired number of connections are made up. 2.29 echnicaL anuaL ecTion onTenTS...
Page 44: Illustration 2.I.16: Setting Backing Pin To "Break-Out" Mode
” “ S ” T SL4500 4- & o eTuP PeRaTion Breaking A Connection 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 directly from the rigid sling. See Illustration 2.I.1. 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. Backing pin shown in the break-out position 2.I.16: s “B ” m llustratIon ettIng ackIng reak Pre-set the backup pressure before beginning your job. See Step 1 - d) of these operating procedures for detailed instruc- tions for setting backup clamping pressure. d) Ensure the load cell is configured for break-out operation. See Section 2.F.3 of the SL-4500 Technical Manual for detailed instructions for configuring the load cell on your equipment. Transfer the snub line to the off-driller’s side of the tong (the right-hand side as seen from the rear).
Page 45: Illustration 2.I.17: Rotation Control - Break-Out
” “ S ” T & o SL4500 4- eTuP PeRaTion Breaking A Connection (continued): Ensure tubing is roughly centered within the tong and backup jaws - rig personnel are required to stabilize the tong and backup around the connection until the jaws have been clamped shut. Actuate the backup clamping valve (push it toward the centre of the tong) to clamp the backup jaws on to the tubing below the connection point. Note that the backup control is “clamp and release”, meaning that once the backup jaws are clamped, the jaws remain under clamping pressure until the operator manipulates the backup control handle to release pressure (see Illustration 2.I.8). The motor speed control valve may be in one of three positions: • UP - High speed selected • MIDDLE - Neutral position • DOWN - Low speed selected Breakout torque is only available in the low-speed mode. If the motor speed control is not already in the “low speed” position grasp the motor speed control valve and firmly push down until it “latches” into its detent position. Gently pull the rotation control valve toward the operator to slowly rotate the cage plate until the tong jaws grip the tubing. 2.I.17: r llustratIon otatIon ontrol reak Pull the rotation control handle all the way out to ensure full breakout torque is being delivered to the joint. When the joint releases, switch to high speed to completely un-thread the connection: • Do not release the rotation control • Grasp the speed control knob and firmly pull it all the way up to the high speed setting (see Illustration 2.I.18).
Page 46 ” “ S ” T SL4500 4- & o eTuP PeRaTion Breaking A Connection (continued): 2.I.18: s hIgh speeD llustratIon wItchIng otor peeD ontrol m) Release the jaws from the tubing after the connection has been broken and un-threaded. Push the rotation control handle toward the centre of the tong to rotate the cage plate in the “makeup” direction and release the jaws from the tubing. 2.I.19: r & u llustratIon eleasIng ollowIng reak threaDIng 2.32 ecTion onTenTS echnicaL anuaL...
Page 47: Illustration 2.I.20: Un-Clamping Backup Jaws
” “ S ” T SL4500 4- Breaking A Connection (continued): When tong jaws are free release the backup jaws by pulling the backup clamp control handle away from the tong toward the operator. 2.I.20: u llustratIon clampIng ackup Unlatch and open the tong door to free the assembly from the tubing. Note that rig personnel may be required to stabilize the equipment as it completely releases from the tubing. Guide the assembly away from the string and use the lift cylinder control to lower it to the drill floor. 2.I.21: l llustratIon owerIng ssemBly sIng ylInDer ontrol Use your rig’s standard pipe handling procedures to remove and rack the freed tubing stand. Repeat steps “g” through “p” as many times as necessary to breakout and un-thread the desired number of connections. 2.33 echnicaL anuaL ecTion onTenTS...
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Page 49: General Maintenance Safety Practices
” “ S ” T SL4500 4- ainTenance McCoy Completions & Drilling recognizes that minor on-site repairs and modifications are required to maintain peak operating condition of your equipment, or to match your equipment with the operating environment. Examples of minor repairs are ● replacement of damaged hydraulic hoses and fittings. ● replacement of malfunctioning pressure gauges and valves. ● replacement of door cylinders ● replacement of fasteners Any replaced component must be an identical component supplied by McCoy Completions & Drilling. Replaced fasteners must be Grade 8 or equivalent, or whatever fastener is specified by McCoy. 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...
Page 50: Lubrication
” “ S ” T SL4500 4- ainTenance LUBRICATION 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. Cage Plate Rollers The cage plate cam followers are sealed units, and do not require lubrication. However, the cage plate and rotary gear grooves in which the cam followers ride should be lightly greased. When the cage plate is rotated as a unit, the cam followers are exposed, and can be greased. Continue rotating the cage plate assembly until all cam followers, top and bottom, are greased. 3.D.1: c llustratIon late oller...
Page 51 ” “ S ” T SL4500 4- ainTenance Reduction Gear Bearings Apply grease to these bearings through the grease fittings in the ends of the reduction gear shafts, located on the top of the tong directly under the main hydraulic support, and behind the motor (2 locations total). 3.D.3: r llustratIon eDuctIon earIng uBrIcatIon Tong Door Pivot Shaft Apply grease to the tong door pivot shaft through the grease fitting in the end of the shaft. 3.D.4: D llustratIon Ivot haft uBrIcatIon echnicaL anuaL ecTion onTenTS...
Page 52: Illustration 3.D.6: Jaw Assembly Lubrication
” “ S ” T SL4500 4- ainTenance Tong Door Latch Apply a thin layer of grease to the tong door latch claws, and the top and bottom of the door latch post to enable smooth latch- ing action. 3.D.5: D & p llustratIon atch uBrIcatIon Jaw Lubrication Apply a thin layer of grease to the metal-to-metal contact surfaces of the tong and backup jaws to enable them to slide smoothly. 3.D.6: J llustratIon ssemBly uBrIcatIon ecTion onTenTS echnicaL anuaL...
Page 53: Illustration 3.D.7: Load Cell Lubrication
” “ S ” T SL4500 4- ainTenance Backup / Load Cell Lubrication Grease must be added to both sides of the interface of the load cell and the rear leg of the backup. 3.D.7: l llustratIon uBrIcatIon ADJUSTMENTS Brake Band Adjustment (See Illustration 3.E.1): The brake bands must be periodically adjusted to continue to provide smooth and efficient jaw cam action. If the cage plate turns with the rotary gear, the jaws will not cam properly and, therefore, will not bite on the tubing or casing. Tightening the brake band against the cage plates will increase frictional resistance, allowing jaws to cam properly and grip the casing. Adjust the brake band using the adjustment nut and bolt set as shown in the illustration below. Do not over tighten, as this causes excessive wear to the brake bands.
Page 54: Adjustments
” “ S ” T SL4500 4- ainTenance Safety Door Switch Adjustment: The safety door switch is intended to 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 immediately and completely stop rotating when the door is opened, remove the tong from service and perform the following adjustments: Set the tong up in a controlled testing environment without connecting hydraulic power. Open the tong door and check operation of the safety door switch plunger. Depress and allow it spring back several times to ensure smooth operation. If the plunger binds or jams, remove the control cable guide mount at the door end, remove the control cable and plunger, and thoroughly clean and lubricate the plunger and control cable before reinstalling. Test the control cable after cleaning and reinstallation. The cable end should spring back when depressed. If the cable does not smoothly spring back, replace the control cable. Following reinstallation the plunger should extend 3/4 of an inch from the end of the control cable guide mount. 3.e.2: s llustratIon afety lunger DJustment Adjust plunger position using the positioning nut and locking nut on the control cable before proceeding. Loosen the locking nut, and adjust the positioning nut until the plunger extension measures approximately 3/4”. When position of the plunger is set, tighten the locking nut. Note that although the following illustration shows the tong door closed, the plunger extension must be performed with the door open. 3.e.3: s llustratIon afety lunger DJustment ecTion onTenTS echnicaL anuaL...
Page 55: Recommended Periodic Checks
” “ S ” T SL4500 4- ainTenance Safety Door Switch Adjustment Cont’d: Connect hydraulic power to the tong. 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. If cage plate continues to rotate with the door open, further adjustment of the safety door switch is necessary. Remove hydraulic power from the tong. Adjust the guide block first. Slightly loosen the two mounting bolts, and use a hammer to lightly tap the guide block toward the front of the tong. Adjust the block approximately 1/8” of an inch, and retighten the mounting bolts. 3.e.4: s llustratIon afety lunger DJustment 10. Repeat steps 5 through 8. 11. Make another adjustment of the guide block. Once the adjustment block can no longer be adjusted, further adjustment must be made using the cable positioning nuts (see Step 4). 12. Repeat steps 5 through 11 as many times as necessary to properly adjust the safety door switch. Once the switch has been satisfactorily adjusted the tong my be returned to service. RECOMMENDED PERIODIC CHECKS 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.
Page 56 ” “ S ” T SL4500 4- ainTenance OVERHAUL PROCEDURES The tong may be overhauled following the disassembly instructions in the following proceddure. Access to the gear train is possible by removing the top plate of the tong. ALL MAINTENANCE AND OVERHAUL SHOULD BE PERFORMED FROM THE TOP. THE BOTTOM PLATE OF THE TONG IS TYPICALLY WELDED TO THE SIDE BODY AND CANNOT BE REMOVED. REPLACEMENT FASTENERS (BOLTS, NUTS, CAP SCREWS, MACHINE SCREWS, ETC.) USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT.
Page 57 ” “ S ” T SL4500 4- ainTenance Overhaul Procedures (continued): 20. Remove the remainder of the 3/8” nuts and bolts from around the perimeter of the tong. Once the bolts are removed the top and bottom plate may be split apart - use caution to pull the top plate straight up from the bottom plate so that there is no binding on the dowel pins used for positioning. 21. For additional access to the gear train, the bottom gearbox cover may be removed by removing the remaining fasteners securing it to the bottom plate. ASSEMBLY PROCEDURES Assembly of Farr Hydraulic Power Tongs is simple, and can be accomplished without the use of special tools. The instructions on this page are presented as a guide only, and are similar to the assembly sequence our technician would use while assembling the tong in our plant. efer to the followIng torque specs when tIghtenIng hex Bolts anD hex heaD cap screws TIGHTENING TORQUE GUIDE SAE GRADE 8 - FINE THREAD SIZE CLAMP LOAD...
Page 58: Illustration 3.H.1: Gearbox Cover Installation
” “ S ” T SL4500 4- ainTenance 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 meta-to-metal contact in the gear train is adequately greased.
Page 59 ” “ S ” T SL4500 4- ainTenance Mechanical Assembly Procedures (continued): 3.h.2: I llustratIon Dler nstallatIon 11. Assemble rotary gear assembly gear as shown in Illustration 3.H.3. Refer to assembly drawing on page 5.12 for further informa- tion. 3.h.3: r llustratIon otary ssemBly 3.11 echnicaL anuaL ecTion onTenTS...
Page 60: Illustration 3.H.4: "Button Guide" Installation
” “ S ” T SL4500 4- ainTenance Mechanical Assembly Procedures (continued): 12. Install eight “button” guides (PN 101-3389) into the bottom plate using one 1/4” NC x 1/2” hex socket flat head machine screw per button. Install the remaining eight “button” guides on the underside of the top plate. 3.h.4: “B ” I llustratIon utton uIDe nstallatIon 13. Install rotary gear assembly over the “button” guides in the lower plate. Ensure the rotary gear is installed with the backing pin slots facing up. 14. Insert three 3/8” x 1” dowel pins into their respective locations in the lower body plate. 15. Lower the top plate into position over the bottom plate. Ensure the plate is lowered as horizontally as possible to prevent binding on the dowel pins. 16. Secure the top plate to the bottom plate and gear box with 3/8” NC x 3” hex cap screws (indicated by green) and 3/8” NC x 5” hex cap screws (indicated by red), and 3/8” NC hex nuts and 3/8” lock washers. 3.h.5: m llustratIon astener lacement 17. Position the lower cage plate (PN 101-3304) against the bottom side of the rotary gear assembly, ensuring the groove in the cage plate engages with the lower rollers. Place four cage plate spacers (PN 101-3333) on the inside of the bottom cage plate.
Page 61: Illustration 3.H.6: Door Latch Weldment Installation
” “ S ” T SL4500 4- ainTenance Mechanical Assembly Procedures (continued): 18. Place the top cage plate (PN 101-3303) over the top of the rotary gear assembly, ensuring the groove in the cage plate engages the rollers on the top of the rotary gear. Secure the top and bottom cage plates with four 3/8” NC x 4-1/2” hex cap screws, lock washers, and hex bolts. 19. Attach the motor gear to the motor shaft. Orient the motor gear so that the smaller diameter of the gear is toward the motor rather than the end of the motor shaft. The gear should be positioned 7/16” from the flat end of the motor shaft - secure with two 1/4” NC x 3/8” cone point hex socket head set screws. 20. Slide the motor thrust washer (PN 02-E0009) over the end of the motor shaft. Mount the motor to the top plate - the end of the motor shaft should rest within the circular cutout in the bottom plate. Secure the motor to the top plate with four 1/2” NC x 1-1/2” hex cap screws and 1/2” lock washers. 21. Insert the door latch pin (PN 101-3306) into its location and secure on the insides of the top and bottom plate with two external snap rings (PN 02-E0004). 22. Attach the door latch weldment to the door weldment (see Illustration 3.H.6): Insert a positioning 1/4” x 3/4” dowel pin into the front of the door weldment Slide the latch spring (C0460-0050-1125) over the pin welded to the front of the bottom door plate in the door weldment. iii. Attach the latch weldment (PN 101-3530) to the door weldment with a 3/8” x 3/4” hex socket shoulder bolt. Ensure a wave spring (PN 02-9267) is inserted between the latch weldment and the door weldment when the latch weldment is being at- tached. Positioning Dowel Pin Wave Spring Compression Spring 3.h.6: D...
Page 62: Illustration 3.H.7: Door Detent Installation
” “ S ” T SL4500 4- ainTenance Mechanical Assembly Procedures (continued): 24. Thread the door detent into the bottom of the top plate until the spring-loaded button protrudes through the top plate. Secure the detent from the bottom with a 3/8” NC hex nut. 3.h.7: D llustratIon etent nstallatIon 25. Position the door & latch assembly assembled in Step 22 in its location, and insert the door pin from the top through the door, the shoulder bushings, and the top and bottom plate. Secure the door pin with two 3/4” external snap rings (PN 02-E0004) to the insides of the shoulder bushings. 26. Attach the safety door cable guide holder (PN 101-4235) and cover (PN 101-4237) to the top plate with one 3/8” NC x 1-3/4” hex cap screw and 3/8” lock washer, and one 3/8” NC x 4-1/2” hex cap screw and lock washer. Note that the second fastener extends through the top and bottom plates and is secured on the bottom with a 3/8” lock washer and 3/8” NC hex nut. 27. Connect the two brake band weldments together, using a 3/8” NC x 3-1/4” hex cap screw, 3/8” lock washer, and 3/8” NC hex nut. Ensure that a Belleville 8-washer assembly (PN 101-3272ASSEM) is placed between the head of the cap screw and the brake band weldment. 28. Secure the brake band assembly to the bottom plate using two 3/8” x 16/25” shoulder bolts at the brake band pivots, and the brake band retainer (101-3975). Secure the brake band retainer to the bottom plate using a 3/8” NC x 3-1/2” hex cap screw, inserted from the top plate, a 3/8” lock washer, and a 3/8” NC hex nut. 29. Secure four rigid sling lifting lugs to the top plate using two 3/8” NC x 3-1/2” hex cap screws, two 3/8” lock washers, and two 3/8” NC hex nuts per lug (secure bolts from underneath the tong). 30. Slide the backing pin retainer (PN 101-4040) over the backing pin center pivot spacer (PN 101-4038), and secure the pivot spacer to the top cage plate using a 3/8” NC x 2-1/2” hex cap screw and 3/8” flat washer.
Page 63 ” “ S ” T SL4500 4- ainTenance Mechanical Assembly Procedures (continued): 34. Attach the front leg weldments to the tong using two 3/8” NC x 3-1/2” hex cap screws, 3/8” lock washers, and 3/8” NC hex nuts per side. 35. Support the backup on a structure that will support its complete weight, at least 16 inches (40 cm) off the floor. 36. Set the tong and leg assembly down over the backup, guiding the front legs through the front leg holes on the backup and guid- ing the rear “paddle” on the backup between the uprights in the rear leg weldment. Before the front legs reach the floor, slide a large, 1-5/8” washer over the bottom of each leg followed by a front leg spring (PN 02-0920) and a bottom spring support (PN 101-4339). Secure the leg springs with a 3/8” NC x 2” hex cap screw and 3/8” NC hex nut. 37. Insert two backup support plate weldments (PN 101-3885) between the uprights in the rear leg weldment so that they oppose each other (see exploded diagram Pp. 6.28 - 6.29). Insert two rear leg springs (PN 997-13) between the two support plates, and insert the rear leg support rod (PN 101-3891) beneath the two plates. Secure the rod with two small hitch pins. 38. Lift the tong and backup assembly away from any supporting structures and place flat on a sturdy surface. 39. Pre-mount the main valve bank to the valve mount weldment (PN 101-4101) using three 1/2” NC x 4-1/2” hex bolts, 1/2” narrow flat washers, and 1/2” NC thin nylock nuts. 40. Install the valve mount weldment on the top plate to the left of the motor. Secure with four 3/8” NC x 1” hex bolts and 3/8” lock washers. 41. Install grease fittings as follows: Install two 1/4” UNF straight thread grease fittings (PN 02-0097) into the top cage plate. ii. Install a 1/4” UNF straight thread grease fitting (PN 02-0097) in the top end of each gear shaft, located on the the top side of the tong (5 locations total). iii. Install a 1/4” UNF straight thread grease fitting (PN 02-0097) in the end of the door pivot shaft.
Page 64: Daily Inspection & Maintenance Checklist (Power Tong)
” “ S ” T SL4500 4- ainTenance DAILY INSPECTION & MAINTENANCE CHECKLIST (POWER TONG) Farr recommends that the following inspection and maintenance procedures be performed before each use, and at least once per day when the tong is in steady use, in the order in which they are listed. 1. Rotate cage plate/rotary gear until the opening in the rotary gear faces towards the rear of the tong. DO NOT PERFORM ANY FURTHER ACTIONS OR MAINTENANCE WHILE THE TONG IS CON- NECTED TO ANY HYDRAULIC POWER SUPPLY. FARR RECOMMENDS THAT ALL HYDRAULIC LINES ARE FULLY DISCONNECTED, AND RESIDUAL HYDRAULIC PRESSURE IS BLED OFF.
Page 65 ” “ S ” T SL4500 4- ainTenance 14. Perform a complete greasing of the tong - refer to Maintenance section of the technical manual Ensure main supply and return connections to the tong are fully made up. Re-connect the remainder of the hydraulic 15. 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. Ensure that supply pressure is at or above the tong’s specified operating pressure, and that the return pressure is less 16. than 350 psi. 17.
Page 66: Monthly Inspection & Maintenance Checklist (Power Tong)
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 & 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. Inspect tong for signs of premature wear, or moving parts that are rubbing (bare metal where there used to be paint is 9. 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 service. Prepare areas to be painted to ensure they are free of grease, dirt, or solvent. Touch up using a solvent-based 10. acrylic paint - “McCoy Grey” is paint color number RAL7015 (contact Farr sales for paint number for custom paint ap- plications). Allow sufficient time for paint to dry before proceeding. Inspect all external welds. Any weld that is cracked or separating must be repaired and repainted before returning the 11. tong to service. 3.18 ecTion onTenTS echnicaL anuaL...
Page 67 ” “ S ” T SL4500 4- ainTenance 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 turn- buckles - again, if any damage is noted replace the damaged part(s) before placing the tong in service. Refer to 12. Section 2A of the technical manual (Sling/Load Bearing Device Safety) for information on recommended testing and recertification. Please note that turnbuckles with part number 101-3086 (short turnbuckles) use a high-strength pin which must be supplied by Farr. “SHORT” TURNBUCKLES HAVING PART NUMBER 101-3086 EMPLOY HIGH-STRENGTH PINS WHICH MUST BE SUPPLIED BY FARR. Rotate the gear train by hand, and use a flashlight to perform a visual inspection of the gear train through the access panel and the opening of the rotary gear while the gear train is being rotated. If gear damage or chips of metal are 13. seen, the tong should be removed from service and overhauled to avoid further damage. Replace access panel when inspection is complete. Inspect all jaws and dies in use for the maintenance interval. Inspect the jaw roller pins for signs of damage - replace 14. pins if necessary. If the pins are welded in place, remove and quarantine the jaw until the weld is repaired. Ensure dies are secure in the jaw - replace worn dies if necessary. Ensure that the jaw rollers rotate freely.
Page 68 ” “ S ” T SL4500 4- ainTenance Re-energize power unit and extend all hydraulic cylinders. Inspect cylinder rods for signs of mechanical damage, 28. flaking, or rust. Farr recommends that damaged cylinders be replaced. 29. Rotate tong in low gear for 5 minutes while monitoring pressurized seals and hydraulic lines. If a seal, line, or fitting begins to leak while tong is rotating, it must be replaced before the equipment is returned to service. Rotate tong in high gear for 5 minutes while monitoring temperature of top and bottom bearing caps. If the bearing caps 30. are hot to the touch (higher than approximately 50 C) replace the applicable bearings. Likewise if the tong is making unusual noises check for damaged bearings (see Maintenance Manual for all bearing locations). Install load cell. If using a tension load cell, perform a visual inspection and replace any cracked, broken, or distorted 31. 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 32.
Page 69: Daily Inspection & Maintenance Checklist (Backup)
” “ S ” T SL4500 4- ainTenance DAILY INSPECTION & MAINTENANCE CHECKLIST (BACKUPS) Farr Canada recommends that the following inspection and maintenance procedures be performed before each use, and at least once per day when the backup is in steady use, in the order in which they are listed. Do not perform any maintenance while the tong and backup assembly is connected to any hydraulic power supply. Farr Canada recom- mends 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. nIts 1. Perform an initial wash of the backup in order to remove the majority of dirt and grease build-up. 2. Perform an external inspection. Check to ensure there are no loose or missing fasteners - replace if necessary. Check to see if backup is parallel to the tong - if the backup is resting at an angle, one of the front leg springs is likely 3. broken or fatigued to the point it must be replaced. eDge ackup Remove access cover from top plate. Perform a visual inspection ot the interior of the backup - use a flashlight if neces- 4. sary. Premature wear where there are moving parts (bare metal where there used to be paint, and metal shavings in the grease are good indicators) may show where a component needs to be adjusted, or if necessary, replaced. 5. Inspect latch mechanism to ensure the door latch plate completely engages the door. Adjust or replace if necessary. 6. Grease UC-300 slider pads, ram guides, door cylinder pivots, and door pivots. lIncher ackup Use a flashlight to perform a visual inspection of the interior of the backup - remove one side panel if necessary. Prema- ture wear where there are moving parts (bare metal where there used to be paint, and metal shavings in the grease are 4.
Page 70: Daily Inspection & Maintenance Checklist (Power Unit)
” “ S ” T SL4500 4- ainTenance DAILY INSPECTION & MAINTENANCE CHECKLIST (POWER UNIT) Farr recommends that the following inspections and maintenance procedures be performed before each use, and at least once per day when the equipment is in steady use, in the sequence in which they 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 electrical supply is locked out, or, if using a diesel power supply, ensure that the engine is locked out or the starting mechanism otherwise disabled. Iesel 1. Check engine oil levels - add if necessary 2. Check diesel fuel tank - fill if necessary. 3. Visually inspect all fan belts. Activate mechanical shut-off device - ensure that shut-off switch on engine is engaging when manual shut-off switch 4. is actuated. lectrIc Visually inspect all electrical lines and visible connections. If your unit is NOT explosion proof, open the electrical 1. enclosure and VISUALLY inspect contacts and connections for signs of corrosion or arcing. Do not open explosion- proof enclosures. NEVER PLACE HANDS INSIDE AN ELECTRICAL ENCLOSURE UNLESS YOU HAVE CON- FIRMED THAT THE POWER HAS BEEN DISCONNECTED AND LOCKED OUT 2.
Page 71 5. Inspect all fasteners and fastener safety wires. Replace any missing fasteners - use Grade 8 bolts only. Re-torque all external fasteners to SAE specifications. 6. Inspect backing pin(s). If cracked, broken, or bent it (they) must be replaced. Repair or replace any damaged or missing external body parts, such as torque gauge mounts, hydraulic supports, 7. 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 8. painted to ensure they are free of grease, dirt, or solvent. Touch up using a solvent-based acrylic paint - “McCoy Grey” is paint number RAL7015. Allow sufficient time for paint to dry before proceeding. Perform a liberal lubrication of the equipment - refer to Maintenance section of manual to determine lubrication points. 9. Generously fill the gear train housing with grease through the access panel, and also through the opening in the rotary gear. 10. 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. 11. Energize power unit. Rotate tong for one minute, stop, and reverse the direction of rotation for another minute, ending with the opening of 12.
Page 72 ” “ S ” T SL4500 4- ainTenance 14. De-energize the power unit, and perform a third generous lubrication of the gear train, including the gear housing. Energize power unit, and rotate the tong for a final time, one minute in one direction, stop, and reverse the direction of 15. rotation for another minute, this time ending with the rotary gear in the “open throat” position. 16. Extend all hydraulic cylinders, and inspect cylinder rods for signs of mechanical damage, flaking, or rust. Farr recom- mends that damaged cylinders be replaced prior to storage. If you are using a frame-mounted tool, the tong must be lowered onto the backup in order to remove the risk of sudden and catastrophic movement when pressure is removed from the float cylinders. Cover the top of the backup with pro- tective cloth to protect the paint on the backup. Place two wooden beams across the top of the tong, ensuring that the beams have a minimum size of 4” x 4” x the width of the tong. Cover the tops of the wooden beams with more protective 17. 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. epressurIzatIon roceDure torage 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.
Page 73 ” “ S ” T SL4500 4- ainTenance alculatIon equIreD esIccant 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 in , or 66 ft (1.87 m 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 g. 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 be required. Please keep in mind that this is a guideline only - more or less desiccant may be required in extreme environmental conditions. For best corrosion 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. 3.25 echnicaL anuaL ecTion onTenTS...
Page 74 ” “ S ” T SL4500 4- ainTenance TUBULAR CONNECTION EQUIPMENT RE-COMMISSIONING PROCEDURE Perform the following recommissioning procedures when removing tubular connection equipment from short or long-term storage back into regular service. These procedures are essential for ensuring proper equipment preparation and operation. The following procedures also assume that the decommissioning and storage procedures recommended by Farr have been strictly observed. Remove all protective plastic wrapping. If there are desiccant packs with the assembly, they may be disposed of with 1. the regular garbage. 2. Remove the access panel on the side of the tong directly adjacent to the shifter mechanism. 3. Wipe excess grease or heavy oil from exposed cylinder rods. If applicable, re-connect chain sling to lifting lugs. Perform a visual inspection of all lifting points - if visible damage is seen, including cracks, broken lugs, distorted metal, etc. replace damaged part(s) before placing tong in service. Also 4. 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.
Page 75 ” “ S ” T SL4500 4- ainTenance Perform a full functional test of the equipment including, if applicable, backup components and float frame components. 20. Report and correct any hydraulic leaks from the hydraulic valve bank, or from any hydraulic cylinders that are used. If using a frame-mounted tong and backup system, raise the tong off the beams that it is resting upon. Remove the 21. beams and protective cloths - inspect the paint on top of the backup and the bottom of the tong to ensure it has not been damaged 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) in both directions (makeup and breakout). If cage plate begins rotating, the safety door mechanism is not func- 22. 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. 24. When all of the previous steps are completed, you may return your re-commissioned equipment to service. 3.27 echnicaL anuaL ecTion onTenTS...
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Page 77: Troubleshooting
TONG WILL NOT DEVELOP SUFFICIENT TORQUE Malfunctioning relief valve on tong hydraulic circuit. 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. 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. POSSIBLE PROBLEM: Relief valve is leaking. SOLUTION: Check valve seat for scouring. Check oil seals. Check for particles stuck under the valve system. POSSIBLE PROBLEM: Directional valve is leaking. SOLUTION: Check directional valve. Neutral position should return fluid directly to the reservoir. Replace or repair valve to en- sure correct operation. POSSIBLE PROBLEM: Power unit is malfunctioning. SOLUTION: Troubleshoot power unit (see user’s manual for your particular unit). 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 allowing full fluid flow. Check to ensure no other restrictions exist (contaminated catch screens or filters, for example). POSSIBLE PROBLEM: Fluid viscosity is not appropriate (too high or too low). SOLUTION: Ensure hydraulic fluid being used is the viscosity recommended by McCoy Drilling & Completions. Power unit pump may not prime if fluid is too heavy, and the hydraulic system will overheat if fluid is too light. Replace with proper viscosity fluid. SOLUTION: Hydraulic fluid viscosity is affected by environmental conditions. Ensure the fluid being used is suitable for high or low temperatures. Replace with proper viscosity fluid for the operating conditions if necessary. POSSIBLE PROBLEM: Worn or damaged tong motor causing slippage. SOLUTION: Replace or repair worn or damaged motor. POSSIBLE PROBLEM: Damaged bearings or gears causing excessive drag. SOLUTION: Replace or repair worn or damaged gears or bearings. POSSIBLE PROBLEM: Jaws slipping on pipe. SOLUTION: Ensure jaw dies are not worn to the point that they cannot grip. Ensure the correct sized jaws are in use. POSSIBLE PROBLEM: Torque gauge is indicating incorrectly SOLUTION: Incorrect gauge is being used. Ensure gauge is the proper range, and has been properly calibrated for the arm length of the equipment in use. SOLUTION: Gauge has been damaged. Check gauge operation and calibration on independent system. 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.
Page 78 ” “ S ” T SL4500 4- RoubLeShooTing TONG WILL NOT DEVELOP SUFFICIENT TORQUE Cont’d: 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. SUGGESTS THAT THE LOAD CELL/TORQUE GAUGE ASSEMBLY BE RETURNED TO THE FACTORY FOR RE-CALIBRATION ON A YEARLY BASIS.
Page 79: Failure Of Jaws To Grip Pipe
” “ S ” T SL4500 4- RoubLeShooTing FAILURE OF JAWS TO GRIP PIPE POSSIBLE PROBLEM: Dies have become too dull to provide adequate grip. SOLUTION: Replace dies. POSSIBLE PROBLEM: Incorrect jaws are being used. SOLUTION: Double-check jaw size to ensure they are rated for the diameter of pipe or casing being run. 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. 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. POSSIBLE PROBLEM: Jaw roller broken or worn. SOLUTION: Remove jaw assembly and inspect. Replace rollers that are visibly “flat-spotted” or otherwise damaged. echnicaL anuaL ecTion onTenTS...
Page 80: Tong Running Too Slowly
” “ S ” T SL4500 4- RoubLeShooTing TONG RUNNING TOO SLOWLY POSSIBLE PROBLEM: Obstruction in tong hydraulic circuit preventing adequate flow. SOLUTION: Inspect self-sealing couplings to ensure they are properly engaged. SOLUTION: The main hydraulic lines (supply and discharge) to the tong are obstructed. Remove and clean if required. POSSIBLE PROBLEM: Power unit is not producing adequate flow or pressure. SOLUTION: Troubleshoot power unit (see user’s manual for your particular unit). POSSIBLE PROBLEM: Tong motor is excessively worn and is leaking hydraulic fluid past the vanes. SOLUTION: Replace motor, or rebuild as per Section 7 of this manual. POSSIBLE PROBLEM: Bearings in gear train and rotary section are excessively worn. SOLUTION: Overhaul tong. See Section 3 of this manual for tong overhaul procedures. POSSIBLE PROBLEM: Shifter has malfunctioned and the tong is not shifting to high gear. SOLUTION: Inspect and repair shift mechanism as necessary. POSSIBLE PROBLEM: Two-speed hydraulic motor (if equipped) is not set to correct speed. SOLUTION: Check motor, and set to the correct speed if required. POSSIBLE PROBLEM: Safety door system is not properly adjusted - hydraulic fluid leak past Deltrol valve. SOLUTION: Check and adjust safety door system. POSSIBLE PROBLEM: Hydraulic fluid viscosity too high. SOLUTION: Ensure hydraulic fluid meets McCoy Drilling & Completions specifications. SOLUTION: Ensure hydraulic fluid is appropriate for climatic conditions, especially during cold-weather operation.. POSSIBLE PROBLEM: By-pass valve not functioning. SOLUTION: Check and repair. ecTion onTenTS echnicaL anuaL...
Page 81: General Comments
” “ S ” T SL4500 4- RoubLeShooTing GENERAL COMMENTS The following factors generally contribute to poor hydraulic operation and premature wear of equipment: Contaminated hydraulic fluid due to overuse, overheating, or inadequate fluid filtration. Unsuitable hydraulic fluid, especially in extreme climatic conditions. Defective packing or seals in components of the hydraulic system. 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 & Drilling recom- mends construction of a test rig that can easily be connected to the main suction and discharge ports of the power unit. echnicaL anuaL ecTion onTenTS...
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Page 83 ” “ S ” T SL4500 4- Parts & Assemblies Model 80-2001-8 Shown Model 80-2001-10 Shown echnicaL anuaL ecTion onTenTS...
Page 84: Gear Train
” “ S ” T SL4500 4- Rain ayouT ecTion onTenTS echnicaL anuaL...
Page 85 ” “ S ” T SL4500 4- Rain ayouT Item Type Description Part Number Part Rotary Gear Assembly (See Pp. 5.12 - 5.13) Assembly Idler Gear Assembly (See Pp. 5.4 - 5.5) Part Motor Gear 101-4011 Assembly Reduction Gear Assembly (See Pp. 5.6 - 5.7) Assembly Reduction Gear Assembly (See Pp. 5.8 - 5.9) echnicaL anuaL ecTion onTenTS...
Page 86 ” “ S ” T SL4500 4- DLeR SSembLy ecTion onTenTS echnicaL anuaL...
Page 87 ” “ S ” T SL4500 4- DLeR SSembLy Item Type Description Part Number Part Grease Fitting, 1/4” straight thread 02-0097 Part Thrust Washer 02-E0001 Part Shaft 101-3297 Part Inner Ring 1” x 1-1/4” x 1-3/35” 02-9027 Part Needle Roller Bearing Drawn Cup 1-1/4” x 1-5/8” x 1-5/55” 02-9009 Part Idler Gear 101-3293 echnicaL anuaL ecTion onTenTS...
Page 88 ” “ S ” T SL4500 4- eDucTion SSembLy maLL ecTion onTenTS echnicaL anuaL...
Page 89: Reduction Gear Assembly (Small)
” “ S ” T SL4500 4- eDucTion SSembLy maLL Item Type Description Part Number Part Grease Fitting, 1/4” straight thread 02-0097 Part Thrust Washer 02-E0001 Part Gear Shaft 101-3296 Part Inner Ring 1” x 1-1/4” x 1-3/35” 02-9027 Part Needle Roller Bearing Drawn Cup 1-1/4” x 1-5/8” x 1-5/55” 02-9009 Part Bearing Spacer 101-3812 Part Reduction Gear 101-3291 echnicaL anuaL ecTion onTenTS...
Page 90 ” “ S ” T SL4500 4- eDucTion SSembLy aRge ecTion onTenTS echnicaL anuaL...
Page 91: Reduction Gear Assembly (Large)
” “ S ” T SL4500 4- eDucTion SSembLy aRge Item Type Description Part Number Part Grease Fitting, 1/4” straight thread 02-0097 Part Thrust Washer 02-E0001 Part Gear Shaft 101-3296 Part Needle Roller Bearing Drawn Cup 1-1/4” x 1-5/8” x 1-5/55” 02-9009 Part Inner Ring 1” x 1-1/4” x 1-3/35” 02-9027 Part Bearing Spacer 101-3812 Part Reduction Gear 101-3292 echnicaL anuaL ecTion onTenTS...
Page 92 ” “ S ” T SL4500 4- oTaRy SSembLy 5.10 ecTion onTenTS echnicaL anuaL...
Page 93: Rotary Assembly
” “ S ” T SL4500 4- oTaRy SSembLy Item Type Description Part Number Part 3/8” UNC x 2-1/2” Hex Cap Screw 09-1056 Part 3/8” Flat Washer 09-5006 Part 3/8” UNC x 4-1/2” Hex Cap Screw 09-1064 Part 3/8” X 1” UNC Shoulder Bolt 09-1118 Part 3/8” X 1/2” UNC Shoulder Bolt 09-9179 Part 2-211 O-Ring 02-0340 Part Top Cage Plate 101-3303 Part Cage Plate Spacer 101-3333 Assembly Jaw Die Kit (2-3/8” shown - see Pg. 2.8) Assembly Rotary Gear Assembly (See Pp. 5.12 - 5.13) Part...
Page 94 ” “ S ” T SL4500 4- oTaRy SSembLy 5.12 ecTion onTenTS echnicaL anuaL...
Page 95: Rotary Gear Assembly
” “ S ” T SL4500 4- oTaRy SSembLy Item Type Description Part Number Part 7/16” Hex Jam Nut 02-E0005 Part PTFE Thrust Washer 02-E0073 Part Cam Roller 101-4019 Part PTFE Shoulder Bushing 02-E0075 Part Roller Shaft 101-4655 Part Plain Bushing 02-E0074 Part Rotary Gear 101-3301 5.13 echnicaL anuaL ecTion onTenTS...
Page 96 ” “ S ” T SL4500 4- SSembLy A B C D D E F G H 5.14 ecTion onTenTS echnicaL anuaL...
Page 97 ” “ S ” T SL4500 4- SSembLy Item Type Description Part Number Assembly Door Assembly (See Pp. 5.22 - 5.23) Part External Snap Ring 02-E0004 Part Shoulder Bushing 02-E0003 Part Door Post 101-3306 Part 3/8” NC x 3” Hex Cap Screw 09-1058 Part 3/8” NC x 3-1/2” Hex Cap Screw 09-1060 Assembly Rigid Sling Assembly (See Pp. 5.24 - 5.25) Assembly Motor Assembly (See Pp. 5.18 - 5.19) Assembly Hydraulic Valve Assembly (See Pp. 5.16 - 5.17) Part 3/8” NC x 5” Hex Cap Screw 09-1066 Part Top Plate 101-3361 Part...
Page 98: Hydraulic Assembly
” “ S ” T SL4500 4- yDRauLic SSembLy A B C D E 5.16 ecTion onTenTS echnicaL anuaL...
Page 99 ” “ S ” T SL4500 4- yDRauLic SSembLy Item Type Description Part Number Part 1/4” NC x 3/4” Hex Cap Screw 09-1005 Part 1/2” NC Thin Nylock Nut 09-5610S Part 1/2” Narrow Washer 09-5119 Part Cable Guide Holder 101-4236 Part Cable Guide Holder Retainer 02-E0025 Part Safety Door Valve 08-0337 Part 1/4” NPT 90 Degree Fitting 08-0284 Weldment Valve Mount 101-4101 Weldment Torque Gauge Mount 101-4403 Assembly DVA35 Valve Assembly...
Page 100 ” “ S ” T SL4500 4- oToR SSembLy 5.18 ecTion onTenTS echnicaL anuaL...
Page 101: Motor Assembly
” “ S ” T SL4500 4- oToR SSembLy Item Type Description Part Number Part #20 (1-1/4”) Split Flange Kit 02-9217 Part O-Ring Part #20 (1-1/4”) Split Flange Part 7/16” Lock washer Part 7/16” NC x 1-1/2” Hex Bolt Part Flange Fitting 02-E0022 Part RINEER GA 15-13/6.5 (2 SPEED) Hydraulic Motor 87-0008 Part 1/2” Lock washer 09-5110 Part 1/2” NC x 1-1/2” Hex Cap Screw 09-1170 Part 90 Degree Flange Fitting 02-9216 Part 1/4” NC x 3/8” Hex Socket Set Screw 09-0107...
Page 102: Brake Bands
” “ S ” T SL4500 4- Rake anDS 5.20 ecTion onTenTS echnicaL anuaL...
Page 103 ” “ S ” T SL4500 4- Rake anDS Item Type Description Part Number Part 3/8” NC Hex Nut 09-5806 Part 3/8” Lock washer 09-5106 Weldment Lined Brake band Weldment 101-3393 Assembly Belleville Washer Assembly 101-3272 Part 3/8” NC x 3-1/4” Hex Cap Screw 09-1059 Part Brake band Retainer 101-3975 Part 3/8” x 5/8” Shoulder Bolt 02-E0045 5.21 echnicaL anuaL ecTion onTenTS...
Page 104 ” “ S ” T SL4500 4- SSembLy A B C L M L C K 5.22 ecTion onTenTS echnicaL anuaL...
Page 105: Door Assembly
” “ S ” T SL4500 4- SSembLy Item Type Description Part Number Part Cable Guide Holder 101-4235 Part Safety Door Plunger 101-4360 Part Push-Pull Control Cable 02-E0026 Part 7/16” UNF Hex Jam Nut 09-5508 Part Cable Guide Guard 101-4237 Part 3/8” Lock washer 09-5106 Part 3/8” NC x 1-3/4” Hex Cap Screw 09-1557 Part 3/8” NC x 4-1/2” Hex Cap Screw 09-1064 Part 1/4” Straight Thread Grease Fitting 02-0097 Part Shoulder Bushing 02-E0003...
Page 106 ” “ S ” T SL4500 4- igiD Ling SSembLy 5.24 ecTion onTenTS echnicaL anuaL...
Page 107: Rigid Sling Assembly
” “ S ” T SL4500 4- igiD Ling SSembLy Item Type Description Part Number Weldment Rigid Sling Weldment 101-4137 Part 0.148” x 2.938” Hitch Pin 02-0028 Part 3/4” Narrow Washer 09-5013 Part Rigid Sling Pin 02-E0008 Part 3/8” NC x 3-1/2” Hex Cap Screw 09-1060 Part Rigid Sling Leveling Bolt 02-E0038 Part 1/2” NC Hex Nut 09-9124 Part Rigid Sling Lifting Lug 101-3337 Part Rigid Sling Adjustment Bolt Spacer 101-4138 Part...
Page 108: Backup Assembly
” “ S ” T SL4500 4- ackuP SSembLy 5.26 ecTion onTenTS echnicaL anuaL...
Page 109 ” “ S ” T SL4500 4- ackuP SSembLy Item Type Description Part Number Assembly Hydraulic Cylinder Assembly 101-4336 Part Cylinder Pin 101-3676 Part External Retaining Ring 02-E0036 Part 3/4” Narrow Flat washer 09-5013 Weldment Backup Body Weldment 101-4337 Assembly Jaw Die Kit (2-3/8” shown - see Pg. 2.13) Part Cylinder Pin 101-4329 Part Jaw Retainer Bolt 101-4264 Part 3/8” x 1” UNC Socket Head Shoulder Screw 09-1118 Part External Retaining Ring 02-E0037...
Page 110 ” “ S ” T SL4500 4- SSembLy A B C D 5.28 ecTion onTenTS echnicaL anuaL...
Page 111: Rear Leg Assembly
” “ S ” T SL4500 4- SSembLy Item Type Description Part Number Part 3/4” Lock washer 09-5118 Part 3/4” NC x 3-1/2” Hex Cap Screw 09-1300 Part Rear Leg Spring 997-13 Weldment Backup Support Plate 101-3885 Part 3/4” NC x 5” Hex Cap Screw 09-1306 Weldment Rear Leg Weldment 101-3883 Part 3/4” Hex Nut 09-5818 Part 0.093” x 1.125” Hitch Pin 02-E0046 Part Support Rod 101-3891 5.29 echnicaL anuaL ecTion...
Page 112 ” “ S ” T SL4500 4- RonT SSembLy 5.30 ecTion onTenTS echnicaL anuaL...
Page 113 ” “ S ” T SL4500 4- RonT SSembLy Item Type Description Part Number Part 3/8” NC x 3-1/2” Hex Cap Screw 09-1060 Weldment Front Leg Weldment 101-3661 Part 3/8” Lock washer 09-5106 Part 3/8” NC Hex Nut 09-5806 Part 1-5/8” Plain Narrow Flat washer 101-4446 Part Leg Spring 02-0920 Part Bottom Spring Support 101-4339 Part 3/8” NC x 2” Hex Cap Screw 09-1054 5.31 echnicaL anuaL ecTion onTenTS...
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Page 115: Torque Measurement
” “ S ” T SL4500 4- oRque eaSuRemenT BASIC TORQUE MEASUREMENT Basic torque measurements are performed using a simple hydraulic measurement system. A hydraulic load cell connects to a cali- brated torque gauge through a reinforced flexible hydraulic hose. The torque gauge is factory-calibrated to display accurate torque measurements for a tong or tong and backup assembly with a particular arm length. The arm length is a measurement from the centre of the pipe or casing to the centre of the force being applied to the load cell. Two load cell options are available. A tension load cell is typically used with a suspended stand-alone tong. This application requires that the load cell be attached to the rear of the tong as part of the restraint line that opposes the force generated when the tong makes up or breaks out a joint. A compression load cell is used in a tong and backup assembly, and is typically located on the 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.
Page 116 ” “ S ” T SL4500 4- oRque eaSuRemenT BASIC TORQUE MEASUREMENT (Continued:) The images on the preceding page are for illustration purposes only and may not accurately represent the torque gauge and load cell that have been supplied with your equipment. Please note that the parts listed in the following table are correct for accurate torque measurement while using the equipment for which this manual is supplied. THE TORQUE GAUGE USED IS FULLY DEPENDANT UPON THE ARM LENGTH AND TORQUE RANGE OF THE EQUIPMENT IN USE. THE PART NUMBERS LISTED IN THE FOLLOWING TABLES ARE CORRECT FOR ACCURATELY MEASURING TORQUE USING THE EQUIPMENT FOR WHICH THIS MANUAL IS SUPPLIED.
Page 117: Illustration 6.A.4: Tension Load Cell Exploded
SL4500 4- oRque eaSuRemenT This is the standard tension load cell sup- Item Type Description Part Number plied by McCoy Drilling & Completions | Assembly Tension Load Cell, 4.08 in 10-0008T Farr. Contact our sales department for Part O-Ring 02-0800 information about optional application-...
Page 118: Illustration 6.A.5: Compression Load Cell Exploded
” T SL4500 4- oRque eaSuRemenT This is the standard hydraulic com- Item Type Description Part Number pression load cell supplied by McCoy Assembly Compression Load Cell, 8 in 10-0008C Drilling & Completions | Farr. Contact Part 5/16” UNC x 1” Hex Socket Head Cap Screw 09-2026 our sales department for information...
Page 119: Illustration 6.A.6: Turn Counter Encoder Mount Exploded
” “ S ” T SL4500 4- oRque eaSuRemenT Item Type Description Part Number Assembly Standard Turn Counter Encoder Mount 60-0001 Part 6-32 x 3/8” Hex Socket Head Set Screw Part Helical Flexible Encoder Shaft Coupling 60-0130N Part Internal Retainer Ring 1376-13 Part Bearing 1376-05 Part Encoder Housing 1392-104A Part Internal Retainer Ring 02-0436 Part Encoder Shaft 1392-103A-01 Part Encoder Gear 01-0320A-M Part 10-24 x 1-1/4” Hex Socket Head Set Screw 6.a.6: t...
Page 120 ” “ S ” T SL4500 4- oRque eaSuRemenT TROUBLESHOOTING Under normal operating conditions, and with proper maintenance, the torque gauge and load cell system are designed to give lasting trouble-free performance. Faulty indication on the gauge will very often define a fault within the gauge. IF TROUBLESHOOTING REVEALS THAT THERE IS INSUFFICIENT FLUID IN THE SYSTEM, BEFORE RECHARGING, CHECK THAT ALL SYSTEM COMPONENTS ARE FREE FROM DAMAGE. THIS WILL ENSURE THAT FLUID LOSS WILL NOT CONTINUE AFTER RELOADING Symptom: No indication on gauge. Possible Problem: Obstruction in hydraulic hose. Solutions: Check hydraulic hose for kinks.
Page 121 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 & COMPLETIONS HIGHLY RECOMMENDS PLACING YOUR LOAD CELL IN A CONTAINMENT BASIN BEFORE PROCEEDING WITH THE BLEEDING &...
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Page 123 ” “ S ” T SL4500 4- 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.
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Page 125 ANDARD RA IO ” “ S ” T SL4500 4- C O D DURING CRO O R RA IO POWER to be the Best! HYDRAULICS, INC. HYDRAULICS, INC. MOTOR SELECTION GUIDE I ING 15 Series Two Speed Weight = 51 lbs. All available displacements of standard motor.
Page 126 ” “ S ” T SL4500 4- yDRauLic oToR Technical Information - All Styles VANE CROSSING VANE FILTRATION The Rineer patented vane crossing vane design produces 25 micron minimum. much higher volumetric and mechanical efficiencies than is FLUID possible with a standard vane type design. This design provides a sealing vane between cavities to improve We suggest premium grade fluids containing high quality rust, mechanical and volumetric efficiencies.
Page 127 RA IO ” “ S ” T SL4500 4- yDRauLic oToR becomes a 4 CID motor. PILOT PRESSURE SHIFTING METHOD A minimum of 100 PSI over case drain pressure is required to shift the spool. The maximum allowable pressure to port "C" or Selecting between full and partial displacement is "D"...
Page 128 ” “ S ” T SL4500 4- yDRauLic oToR Performance Data - Selected Displacements 6 C.I.D. C.I.D. ACTUAL TORQUE AND POWER 6-CID ACTUAL TORQUE AND POWER 9.5-CID 2000 RPM 1700 RPM 100 RPM 100 RPM 2000 RPM 1700 RPM 1600 RPM 1300 RPM 1200 RPM 900 RPM...
Page 129 ” “ S ” T SL4500 4- yDRauLic oToR Model Code M015 - 61/62 -015 -000 Special Code Designator M015 - 61 = 015 Single Speed M015 - 62 = 015 Two Speed Seal - Package Selection Options: Bearing Package Selection 62 = Two Speed Single Pilot 30 = Keyed Shaft Open During Crossover...
Page 130 ” “ S ” T SL4500 4- yDRauLic oToR Repair Manual 15 Series HYDRAULICS, INC. HYDRAULICS, INC. Standard Motor Two Speed Motor 331 BREESPORT * SAN ANTONIO, TX 78216 * (210) 341-6333 FAX (210) 341-1231 ecTion onTenTS echnicaL anuaL...
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Page 132 ” “ S ” T SL4500 4- yDRauLic oToR WARNING: RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION. REMOVAL OF SHAFT SEAL 1) Two of the 3/8" bolt holes are provided with jack screw threads. 1) Remove snap ring 2) Insert a piece of 1/4"...
Page 133 ” “ S ” T SL4500 4- yDRauLic oToR WARNING: RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION. DISASSEMBLY OF FRONT DISASSEMBLY OF ROTOR/STATOR HOUSING AND SHAFT CARTRIDGE 1) Mark one side of the Lift up rotor/stator cartridge motor for proper assembly, and remove from the rear...
Page 134 ” “ S ” T SL4500 4- yDRauLic oToR WARNING: RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION. PLATES: Normal wear 1) Remove the rotor. results in marking of timing 2) Remove both the rotor plates which does not and stator vanes.
Page 135 ” “ S ” T SL4500 4- yDRauLic oToR WARNING: RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION. ASSEMBLY OF ROTOR/STATOR ASSEMBLY OF WHEEL MOTOR CARTRIDGE FRONT HOUSING 1) Reverse the procedures in 1) Reverse the procedures steps 8 thru 3.
Page 136 ” “ S ” T SL4500 4- yDRauLic oToR WARNING: RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION. 1) Rotate shaft in both 1) Install dowel pins into directions to assure that the rotor/stator cartridge. shaft turns smoothly.
Page 137 ” “ S ” T SL4500 4- yDRauLic oToR Information: B o lt To rq u e - S e a l K its: M a in B o lts (5 /8 -11 ): 1 9 0 ft. lb s. S ta n d a rd 1 5 se rie s se a l kit S e a l P la te (3 /8 -1 6 ) # 0 1 5 0 9 4 0...
Page 138 ” “ S ” T SL4500 4- yDRauLic aLVeS 7.16 ecTion onTenTS echnicaL anuaL...
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Page 151 ” “ S ” T SL4500 4- yDRauLic aLVeS Capacit y: Pilot - t o- ope n che ck va lve w it h st a nda r d pilot gpm ( 1 2 0 L/ m in .) Funct ional Gr oup: Model: Pr odu ct s : Ca r t r idge s : Pilot - t o- Ope n Che ck V a lve : 3 - Por t , N on - V e n t e d : St a n da r d CKEB...
Page 152 ” “ S ” T SL4500 4- yDRauLic aLVeS use counterbalance valves. cavities, same flow path for a given frame size). However, cartridge extension dimensions from the mounting surface may vary. Stainless steel cartridge options P or W Incorporates the Sun floating style ...
Page 153 ” “ S ” T SL4500 4- yDRauLic aLVeS Capacit y: Pilot - t o- ope n, spr in g bia se d close d, un ba la n ce d gpm ( 2 4 0 L/ m in .) poppe t logic e le m e n t Funct ional Gr oup: Model:...
Page 154 ” “ S ” T SL4500 4- yDRauLic aLVeS These valves have positive seals Stainless steel cartridge options P or W   between port 3 and port 2. are intended for use within corrosive environments with all external components manufactured in stainless steel or titanium.
Page 155 ” “ S ” T SL4500 4- yDRauLic aLVeS Capacit y: Pilot ope r a t e d, ba la nce d pist on r e lie f va lve 1 2 g p m ( 4 5 L/ m in .) Funct ional Group: Model: Pr od u ct s : Ca r t r id ge s : Re lie f : 2 Por t : Pilot Ope r a t e d , Ba la n ce d Pist on...
Page 156 ” “ S ” T SL4500 4- yDRauLic aLVeS RPCC- KAN Ex t e r n a l M a t e r ia l/ Se a l Con t r ol Ad j u st m e n t Ra n g e M a t e r ia l 75 - 3000 psi ( 5 - 210 K Handk nob...