DPT 100

SERVICE MANUAL NO PAGE
M-075
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DPT 100 DRILL PIPE TONG
REV DATE
FRANKS INTERNATIONAL, INC.
PIPEWRANGLER DPT-100 DRILL PIPE TONG Operation & Maintenance Manual
All materials contained herein, unless noted otherwise, are the copyrighted property of Franks International, Inc., its subsidiaries, affiliated companies and/ or licensors. To reproduce, republish broadcast, post transmit, modify, distribute or display this work or a portion of material from this work, you must first obtain written permission from an officer of Franks International, Inc.
2004 Franks International, Inc.
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FOREWORD
This manual is intended as a general guide for the installation, operation and servicing of the PIPEWRANGLER DPT-100 DRILL PIPE TONG. Before the equipment is put into use, it is recommended that the information contained within this manual be carefully studied. By following the suggested procedures, the equipment should give a long, trouble free service life. The equipment covered by this manual, and information disclosed within, includes features that are proprietary to FRANKS INTERNATIONAL and may be covered by one or more patents. Nothing within this document shall be construed to be a license or permission for the disclosure of such proprietary information to third parties nor the use of this information for purposes other than the installation, operation, maintenance, inspection and servicing of the covered equipment. Improvements may be made from time to time, therefore the text and illustrations may differ to some extent with respect to the subject unit of equipment. In any reference to the unit for which this manual is used, it is essential that the equipment serial number is noted. Applicability: This manual applies to equipment with Serial Numbers of the form __________________ beginning with S.N. __________________
Questions with regard to the covered equipment and/or requests for replacement parts should be directed to: FRANKS INTERNATIONAL DRILL PIPE TOOL DEPARTMENT 700 E. Verot School Road Lafayette, LA 70508 USA Phone: 337-233-0303 Fax: 337-572-2353
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SECTION ALL PAGE NO. ALL RELEASE DATE 12/14/2004
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REVISION TABLE REMARKS INITIAL RELEASE
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TABLE OF CONTENTS SECTION 1.0 TITLE INTRODUCTION 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 2.0 SPINNER WRENCH MOVING WRENCH 1.2.1 Moving Wrench Controls 1.2.2 Torque Cylinder BACK-UP WRENCH 1.3.1 Back-Up Wrench Controls WINCH 1.4.1 Winch Controls LIFT CYLINDER 1.5.1 Lift Cylinder Controls TILT FUNCTION 1.6.1 Tilt Controls EMERGENCY STOP DIE HOLDERS PAGE 8 8 9 10 10 11 11 11 11 12 12 12 12 12
SPECIFICATIONS 2.1 2.2 2.3 2.4 DRILL PIPE TONG DIMENSIONS DRILL PIPE SPINNER WRENCH RANGE TONG SIZE RANGE TONG PERFORMANCE 2.4.1 Hydraulic Requirements 2.4.2 Air Requirements 2.4.3 Make-Up Torque Rating 2.4.4 Break-Out Torque Rating 2.4.5 Tong Arm Length and Rotation LIFT CYLINDER
2.5 3.0
13 14 14 14 14 15 15
INSTALLATION & OPERATION 3.1 3.2 3.3 3.4 3.5 INTRODUCTION PRE-RIG-UP CHECK RIG-UP FUNCTION TEST CONNECTION MAKE-UP 3.5.1 Preparation
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SECTION TITLE 3.6 3.7 3.5.2 Make-Up Procedure CONNECTION BREAK-OUT 3.6.1 Preparation 3.6.2 Break-Out Procedure SAFETY 3.7.1 General 3.7.2 Operational Safety
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17 18
4.0
MAINTENANCE 4.1 4.2 4.3 INTRODUCTION BEFORE EACH JOB 4.2.1 Certification 4.2.2 Checks AFTER EACH JOB 4.3.1 Cleaning 4.3.2 Inspection 4.3.3 Lubrication PERIODIC MAINTENANCE 4.4.1 Spinner Wrench 4.4.2 Moving Wrench 4.4.3 Back-Up Wrench 4.4.4 Hanging Arm 4.4.5 Hydraulic Pneumatic System TORQUE GAUGE CHECKS 4.5.1 Torque Vs Pressure Table
19 19 19 19
4.4
21
4.5 5.0
23 24 24 24
SERVICING PROCEDURES 5.1 5.2 INTRODUCTION SPINNER WRENCH 5.2.1 Motors 5.2.2 Flange Bearings 5.2.3 Rollers 5.2.4 Grip Cylinder 5.2.5 Case / Spinner Wrench Assembly 5.2.6 Mount Pin 5.2.7 Mount Tube MOVING WRENCH 5.3.1 Dies and Die Holders
5.3
26
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SECTION TITLE
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5.4
5.5
5.6
5.7 5.8 5.9 6.0
5.3.2 Die Holder Backups and Top Grip Cylinders 5.3.3 Retainer Bolt 5.3.4 Cam Follower Bearings 5.3.5 Torque Arm 5.3.6 Torque Cylinder BACK-UP WRENCH 5.4.1 Dies and Die Holders 5.4.2 Die Holder Backups and Bottom Grip Cylinders 5.4.3 Pipe Stop HANGING ARM 5.5.1 Balance Screw and D-Ring 5.5.2 Hanging Arm Pivot Pin 5.5.3 Tilt Cylinder 5.5.4 Hose Hanger HYDRAULIC-PNEUMATIC SYSTEM 5.6.1 Main Manifold 5.6.2 Control Handles 5.6.3 Flow Divider Assembly TROUBLESHOOTING PORT OPERATION MAINTENANCE CHECKLIST
27
28
29
31 35 37 39 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
DRAWINGS AND PARTS LISTS 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 ASSEMBLY DRAWING 2698C-201 BILL OF MATERIALS 2698C-201 ASSEMBLY DRAWING 2698C-202 BILL OF MATERIALS 2698C-202 ASSEMBLY DRAWING 2698C-203 BILL OF MATERIALS 2698C-203 ASSEMBLY DRAWING 2698C-204 BILL OF MATERIALS 2698C-204 ASSEMBLY DRAWING 2698C-205 BILL OF MATERIALS 2698C-205 ASSEMBLY DRAWING 2698C-206 BILL OF MATERIALS 2698C-206 ASSEMBLY DRAWING 2698C-207 BILL OF MATERIALS 2698C-207 ASSEMBLY DRAWING 2698C-208 BILL OF MATERIALS 2698C-208
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SECTION TITLE 6.17 6.18 6.19 6.20 6.21 6.22 6.23 6.24 6.25 6.26 6.27 6.28 6.29 6.30 6.31 6.32 6.33 7.0
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ASSEMBLY DRAWING 2698C-209 BILL OF MATERIALS 2698C-209 ASSEMBLY DRAWING 2698C-210 BILL OF MATERIALS 2698C-210 SCHEMATIC DRAWING 2698C-211 SCHEMATIC DRAWING 2698C-212 BILL OF MATERIALS 2698C-212 SCHEMATIC DRAWING 2698C-213 SCHEMATIC DRAWING 2698C-214 MANIFOLD VALVE LOCATIONS 2698C-215 MANIFOLD VALVE LOCATIONS 2698C-216 MANIFOLD VALVE LOCATIONS 2698C-217 ASSEMBLY DRAWING 2698C-218 BILL OF MATERIALS 2698C-218 ASSEMBLY DRAWING 2698C-219 BILL OF MATERIALS 2698C-219 SCHEMATIC DRAWING 2698C-220
55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 72
RECOMMENDED SPARE AND REPLACEMENT PARTS LISTS 7.1 RECOMMENDED SPARE PARTS LIST
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1.0 INTRODUCTION
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The DPT-100 is a drill pipe tong designed to make-up and break-out drill pipe and drill collars on the rig floor. The combined system of Spinner Wrench, Moving Wrench and Back-up Wrench provides a fully integrated make-up/break-out tool. It eliminates the use of individual rig tongs together with associated hanging lines, snublines, etc. It therefore provides a safer rig floor environment as well as removing the torque measurement errors caused by incorrect snubline angles. The Spinner Wrench, attached to the top of the tong removes the need for a separate tool for spinning up drill pipe and accessories. The Back-Up Wrench backs up the Spinner when working. Controls to operate the tong are arranged in a control box mounted on the left-hand side above the Moving Wrench (Left Control Handle) whilst a Torque Gauge and Torque Limiter Valve are sited on the right hand side (Right Control Handle). Adjustment of hydraulic pressures and speed of all cylinder operations in both extension and retraction are regulated by individual pressure relief and flow control valves located in the Main Manifold. 1.1 SPINNER WRENCH The Spinner Wrench is a Franks Drill Pipe Spinner modified to mount onto and is controlled by the DPT-100 Drill Pipe Tong. Power is provided by three hydraulic motors. Each motor drives a composite roller whilst a grip cylinder maintains contact roller pressure onto the pipe. The process of first gripping and then spinning is controlled by an adjustable sequence valve located in the Main Manifold. The operation of the Spinner Wrench is activated by the Spin Button and direction of the Spinner motors controlled by a Make/Break button. Speed of the Spinner Wrench Motors is determined by the flow from the hydraulic power unit. There is no speed adjustment. Speed of the Spinner Grip Cylinder is controlled by an adjustable flow control valve for each of the closing and opening functions. The spring in the spinner mount allows for vertical movement of the Spinner Wrench during spin in or spin out of the drill pipe and accessories.
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1.2 MOVING WRENCH
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The Moving Wrench is located on top of the Back-Up Wrench. It is a welded assembly containing Top Grip Cylinders, Die Holder Backups, Die Holders and Dies and attached by a Torque Arm to the Torque cylinder. 1.2.1 Moving Wrench Controls Operation of the Top Grip Cylinders and Torque Cylinder is controlled by the Torque Button on the Left Control Handle. An adjustable sequence valve controls the closing of the Top Grip Cylinders and operation of the Torque Cylinder. Grip pressure is determined by adjustment of hydraulic pressure relief valves to the Top Grip Cylinders whilst adjustable flow control valves to the rod and piston of these cylinders determine speed of open/close operations. Maximum flow to these valves is 12 GPM. NOTE: The Top Grip Cylinders maintain a hold on the connection by a counterbalance valve, which keeps constant pressure on the piston. The valve will not allow the dies to release from the connection if there is a momentary drop in pressure, such as when the Torque Cylinder operates. 1.2.2 Torque Cylinder The required torque value is set by the Torque Limiter Valve in the Right Control Handle. This provides infinite adjustment of the hydraulic pressure limit of the Torque Cylinder from zero to maximum. Once set, the same torque can be repeated for each connection. NOTE: The speed of the Moving Wrench will be influenced by the Torque Limiter Valve adjustment - the lower the torque value setting, the slower the operation of the cylinder. Correct orientation of the Torque Cylinder is controlled by the Make/Break Button and Torque Arm Pin. The Torque Arm must be placed in the correct orientation prior to operation. 1.3 BACK-UP WRENCH The Back-Up Wrench is located under the Moving Wrench. It is a welded assembly, which includes the frame of the DPT-100. It contains the Bottom Grip Cylinders, Die Holder Backups, Die Holders and Dies. During operation, the
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Back-up Wrench provides the anchor for the Spinner Wrench and the Moving Wrench. 1.3.1 Back-Up Wrench Controls Operation of the Bottom Grip Cylinders is controlled by the Back-Up button. Grip pressure is determined by the adjustment of hydraulic pressure relief valves to the cylinders. Adjustable flow control valves to the rod and piston of the cylinders control speed of open/close operations. NOTE: Whilst the Spin button is depressed, the hydraulic pressure supplied to the Bottom Grip Cylinders is reduced to 65 PSI. This is needed to assure minimum interference between the box and pin threads of the connection whilst spinning the tubular. 1.4 WINCH The DPT-100 is fitted with a winch to pull the tool away from the rotary table when work is completed. The Winch is located on the back of the Cylinder under the Main Manifold mount. 1.4.1 Winch Controls Power is provided by a hydraulic motor and operation is controlled by a proportional Joystick No. 1. Hydraulic pressure is controlled by an adjustable pressure relief valve in the Main Manifold. Speed of the Winch Motor is controlled by two adjustable flow control valves for both the Winch In and Winch Out functions. 1.5 LIFT CYLINDER The DPT-100 is supplied with a double-acting Lift Cylinder to raise and lower the entire tong. 1.5.1 Lift Cylinder Controls The operation of the Lift Cylinder is controlled by a proportional control Joystick No. 2 on the Left Control Handle. Hydraulic pressure is controlled by an adjustable pressure relief valve in the Main Manifold.
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Speed of the Cylinder is controlled by two adjustable flow control valves in the Main Manifold for Lift Up and Lift Down functions. 1.6 TILT FUNCTION A double-acting Tilt Cylinder is provided to level the tool in relation to the connection being worked. The Cylinder is located on the back of the Hanging Arm and in front of the Main Manifold mount. 1.6.1 Tilt Controls The operation of the Tilt Cylinder is controlled by proportional control Joystick No. 2 on the Left Control Handle. Hydraulic pressure for the Cylinder is controlled by an adjustable pressurereducing, relief valve in the Main Manifold. Speed of the Tilt Forward and Tilt Back functions is adjusted by two flow control valves. 1.7 EMERGENCY STOP The DPT-100 is equipped with an Emergency Stop Function on the Left Control Handle. This button, except for those functions that are equipped with a pilot-operated check valve, diverts all hydraulic fluid back to the hydraulic power unit. 1.8 DIE HOLDERS The Die Holders for the DPT-100 are available in two different styles. Both styles fit on the same Die Holder Backup. It is recommended that the same style of Die Holder is used for the entire tool. Style I Accommodates a single contour die (FCC #80822). Size: 0.500 x 2.352 x 3.860 in. Style II Accommodates two standard, flat tong dies (FCC #60046). Size: 0.500 x 1.250 x 3.875 in.
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2.0 SPECIFICATIONS 2.1 DRILL PIPE TONG DIMENSIONS Length: Width: Overall height to top of D-ring: Weight: 2.2 DRILL PIPE SPINNER WRENCH RANGE
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69 64 97 5,400 lbs.
All drill pipe tubulars with actual OD of 2 7/8 to 11. 2.3 TONG SIZE RANGE All drill pipe tubulars and accessories with actual OD of 3 1/2 to 10 1/8. 2.4 TONG PERFORMANCE 2.4.1 Hydraulic Requirements Maximum Flow Recommended Flow Maximum Pressure Recommended Pressure 2.4.2 Air Requirements Maximum Flow Recommended Flow Maximum Pressure Recommended Pressure 2.4.3 Make-Up Torque Rating Maximum Torque at 2800 PSI Maximum Torque at 3000 PSI 2.4.4 Break-Out Torque Rating Maximum Torque at 2800 PSI Maximum Torque at 3000 PSI 133,000 ft-lbs 143,000 ft-lbs 92,000 ft-lbs 100,000 ft-lbs 4 CFM N/A 150 PSI 90 PSI 35 GPM 34 GPM 3000 PSI 2800 PSI
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2.4.5 Tong Arm Length and Rotation Tong Arm Length Maximum Rotation 2.5 LIFT CYLINDER Length-Retracted: Length-Extended: Weight: 86 158 95 lbs
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36 45 degrees
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3.0 INSTALLATION AND OPERATION 3.1 INTRODUCTION
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The combined DPT-100 system of Moving Wrench, Back-Up Wrench and Spinner Wrench provides a fully integrated make-up/break-out tool for drill pipe tubulars and accessories. This DPT-100 was designed to be attached by a hanging cable to the crown of the derrick. 3.2 PRE-RIG-UP CHECK Prior to installation of the DPT-100 drill pipe tong, the following should be checked and assembled: 1. Install a 3/4 hanging cable (eye to eye) to an appropriately sized (17-ton or larger) certified padeye in the crown of the derrick. The padeye needs to be located as close to the center of the crown as possible. The further the padeye is from the center, the more manpower will be needed to get the DPT-100 into position at the rotary table. The lower eye of the hanging cable needs to be approximately 20 ft. above the drill floor. 2. Install Air Filter Extractor (FCC #50461) and air hose to be used for the DPT100. Inspect air filter elements and replace as necessary. 3. Inspect hydraulic filter element on DPT-100. Replace as necessary. 4. Inspect the dies and the spinner rollers to guarantee that they are in good condition. Replace as necessary. 5. Inspect all hoses, fittings, bolts and nuts to be sure that none have come loose. Repair as necessary. 6. Inspect the condition of the winch hook and cable. Replace as necessary. 3.3 RIG-UP Once the Pre-Rig-Up Check is completed, move the DPT-100 to the drill floor. The DPT-100 should only be lifted by the D-ring on the hanger arm assembly. 1. Connect the Lift Cylinder piston-end clevis to the D-ring on the hanging arm assembly using suitable 3/4 bolt-type anchor shackles (4 3/4 ton SWL) (FCC #60146). The D-ring should be placed in the center of the balance screw in preparation of lifting the DPT-100 to be level. 2. Attach the Lift Cylinder rod-end clevis to the Swivel (5-ton SWL) (FCC #60216).
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3. Attach the Swivel to the lower eye of the hanging cable using suitable 3/4 bolt-type anchor shackle (4 3/4 ton SWL) (FCC #60146). 4. Connect the hydraulic lines from the DPT-100 to the Lift Cylinder. 5. Connect the pressure and return lines from the DPT-100 to the hydraulic power supply. For hydraulic requirements, see Section 2 of this manual. 6. Connect the DPT-100 air supply line to air hose to the rig air supply. For air requirements, see Section 2.0 of this manual. 7. Attach the Winch Hook and Cable to the derrick leg. 3.4 FUNCTION TEST Prior to dispatch of equipment for operational purposes, a full function check should be undertaken on the DPT-100 to verify satisfactory operation. Systems to check should include but not limited to: 1. 2. 3. 4. 5. 6. 7. Lift Cylinder operation Back-Up Wrench operation Spinner operation Moving Wrench operation Tilt operation Winch operation Torque Gauge operation a) Make-Up b) Break-Out
Should adjustments be necessary to the speed or sequence of the above operations, it is necessary to do this prior to dispatch. All of the settings can be adjusted in the field, make sure that the proper procedures are followed. See Troubleshooting section 5.7 of this manual for problems with function checks. 3.5 CONNECTION MAKE-UP 3.5.1 Preparation 1. Check for satisfactory installation of the Winch Hook and Cable on the derrick leg or other suitable support. 2. Start hydraulic power unit and check for leaks. 3. Check that all quick connectors are fully engaged to ensure full flow of the hydraulic fluid. 4. Check that system pressure and flow are at the correct settings. 5. Pull E-Stop Button on Left Control Handle. 6. Lift the tool off the drill floor.
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7. Move the tool in to the first connection. 8. Adjust the Lift Cylinder so the tool is in the proper vertical position. 9. Check that the tool is hanging level (side to side). Adjust D-ring on balance screw as necessary. 10. Check that the tool is hanging level (front to back). Use Tilt function to adjust level. 11. Remove pin from pipe stop handle and move to maximum size. 12. Move the tool so that the connection is centered on the dies. 13. Push Back-Up Button on Left Control Handle to grip on the connection. 14. Move pipe stop to connection until it stops and pin in place. If between holes, go back to first available hole. NOTE: If the size of the connections change follow steps 11 14 to reset the pipe stop to the correct size. 15. Pull out the Back-Up Button on the Left Hand Control Handle to release grip on the connection. If Torque Arm is not in the Make position, use the following steps: a) Completely remove Torque Arm Pin from the Break hole in the Moving Wrench. b) Put Make/Break Button on Left Control Handle in the Make position. c) Once the Torque Cylinder has stopped moving, install the Torque Arm Pin through the Make hole in the Moving Wrench. Check to be sure that the pin is fully inserted. 3.5.2 Make-Up Procedure For correct make-up of a connection, the following procedure must be adopted: 1. Check that the Moving Wrench and Make/Break Button are in the correct position for make-up. 2. Make any vertical adjustments to the tool in relation to the connection using the Lift Cylinder. 3. Activate the Back-Up Wrench by pushing in the Back-Up Button on the Left Control Handle. 4. Press and hold the Spin Button on the Left Control Handle to spin up the connection. Release the Spin Button. 5. Start with the Torque Limiter on the Right Control Handle screwed all the way out, and then increase torque (screw knob in) to correct setting.
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6. Press and hold the Torque Button 7. If Torque Cylinder strokes completely, release Torque Button and repeat Step 5 and 6 again. After achieving correct torque on connection, release Torque Button. 8. Release the Back-Up Wrench from the connection by pulling out the BackUp Button. 9. Set the tool back from the connection using the Winch. 10. Press E-Stop Button. 3.6 CONNECTION BREAK-OUT 3.6.1 Preparation Follow the same procedure as Section 3.5.1, steps 1 15. Then do the following: 16. If Torque Arm is not in the Break position, use the following steps: a) Completely remove Torque Arm Pin from the Make hole in the Moving Wrench. b) Put Make/Break Button on Left Control Handle in the Break position. c) Once the Torque Cylinder has stopped moving, install the Torque Arm Pin through the Break hole in the Moving Wrench. Check to be sure that the pin is fully inserted. 3.6.2 Break-Out Procedure For correct break-out of a connection, the following procedure must be adopted: 1. Check that the Moving Wrench and Make/Break Button is in the correct position for break-out. 2. Make any vertical adjustments to the tool in relation to the connection using the Lift Cylinder. 3. Activate the Back-Up Wrench by pushing in the Back-Up Button on the Left Control Handle. 4. Press and hold the Torque Button for one full stroke of the Torque Cylinder, then release. 5. Press and hold the Spin Button on the Left Control Handle to spin out the connection. If the connection does not spin, follow step 4 again. 6. Release the Spin Button.
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7. Release the Back-Up Wrench from the connection by pulling out the Back-Up Button. 8. Set the tool back from the connection using the Winch. 9. Press E-Stop Button. 3.7 SAFETY 3.7.1 General This equipment must be operated with utmost caution at all times. Precautions should be taken to protect rig personnel while the equipment is in use. Particular care should be exercised to keep limbs and hands away from moving parts of the equipment. 3.7.2 Operational Safety The following points must be observed prior to, during and after operation of this equipment: 1. Do not undertake any adjustments to the equipment while the tong is operating. 2. Check for adequacy and security of both hanging and winch lines for the equipment. Avoid mounting lines against sharp corners. 3. Check for integrity of hydraulic system and all flexible hoses. 4. Do not attempt to engage tool on tubulars and connections outside the stated limitations. 5. Check for security of all fasteners, hoses and fittings.
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4.0 MAINTENANCE 4.1 INTRODUCTION
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A full description of maintenance and repair of the Drill Pipe Spinner is provided in the Franks International operations and maintenance manual M-077. The relevant instructions covering routine maintenance in connection with the DPT-100 is included in this section of the manual. 4.2 BEFORE EACH JOB 4.2.1 Certification Check for validity of applicable certification for load bearing parts of the equipment package. Items to be considered but not limited to lifting points and slings for equipment transportation skid. 4.2.2 Checks In addition to the above item, the following should be checked for wear and damage and repaired/replaced as necessary: 1. 2. 3. 4. 5. 6. 7. 8. Overall visual inspection of the entire tool. Check all Buttons and Joysticks for function. Check Spinner Wrench Rollers. Check Dies. Check Die Holders. Check Pipe Stop. Inspect level of oil in Winch, replenish or replace as necessary. Check entire hydraulic and air system for leaks and loose hoses and fittings. 9. Check entire tool for loose fasteners, tighten as necessary.
4.3
AFTER EACH JOB 4.3.1 Cleaning The complete exterior of all the equipment should be thoroughly steam cleaned to remove all operational debris. The die holders and dies should be removed and cleaned separately.
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4.3.2 Inspection
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After a thorough cleaning of the equipment, the following inspections should be performed to assess wear and/or damage: 1. Hydraulic couplings for signs of damage or leaks. 2. Hydraulic pipe work for leaks. 3. Flexible hydraulic and air hoses for leaks and loose connections/fittings. 4. Spinner Wrench Rollers and Flange Bearings for wear and damage. 5. Spinner Mount and Spinner Spring for wear and damage. 6. All Buttons and Joysticks for function and damage. 7. Dies for wear and damage. 8. Die Holders and Die Holder Backups for wear and damage. 9. Torque Cylinder Tube and Mount for wear and damage. 10. Torque Cylinder Rod, Torque Cylinder Rod Pin and Safety Clip for wear and damage. 11. Pipe Stop, Pipe Stop Handle and Safety Pin for wear and damage. 12. Remove side covers and inspect Top and Bottom Grip Cylinders and Cylinder Mount Pins for wear. Reinstall side covers when complete. 13. Main Manifold Cover for deformation. 14. Frame Assembly for cracks and deformation. 15. Winch oil level. 16. Entire tool for loose fasteners. 4.3.3 Lubrication NOTE: Unless otherwise specified below, use good quality lithium-based bearing grease. 1. After inspection, the back of the Dies and slot of the Die Holders should be coated with a thin layer of Never-Seize or copper-based anti-seize compound. 2. The Back-up Wrench - Grip Cylinders should be extended and a generous amount of grease applied to the Die Holder Backups. 3. The Moving Wrench - Grip Cylinders should be extended and a generous amount of grease applied to the Die Holder Backups.
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4. The Die Holders should be removed from the Die Holder Backup and a generous amount of grease applied to the Die Holder Backup where they contact the Die Holder. 5. With air only to the tool, pull the E-Stop Button and put the Make/Break Button in the Make position. Apply a generous amount of grease around the shaft of the Spinner Mount and use a grease gun to load grease into the Spinner Mount Tube (vertical tube with slot). Push E-Stop when done. 6. Use a grease gun to lubricate the following grease zerks provided: a) b) c) d) e) f) Spinner Roller Flange Bearings Spinner Grip Cylinder Mounts Tilt Cylinder Mounts Hanging Arm Pin Torque Cylinder Mounts Make-Up Wrench Grip Cylinder Mounts (Remove side covers to access) g) Back-Up Wrench Grip Cylinder Mounts (Remove side covers to access) h) Winch Cable Guides
4.4
PERIODIC MAINTENANCE In addition to the between job cleaning and lubrication already detailed, it is necessary to maintain the equipment to greater depth periodically. The precise period at which these tasks should be performed is not possible to fully define owing to the varied usage and conditions to which the equipment is exposed. Experience and opportunity should provide the basis for establishing a timetable. Items to be checked for wear and/or damage should include but not be limited to the following, repair and/or replace as necessary: 4.4.1 Spinner Wrench 1. Inspect Spinner Wrench Rollers. 2. Inspect Spinner Wrench Flange Bearings. 3. Check contact between Spinner Wrench Rollers and Square Drive Shafts. 4. Inspect Spinner Wrench Grip Cylinder. 5. Check Spinner Wrench Case Halves for deformation.
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6. Check Spinner Wrench Pivot Pin for deformation. 7. Check Spinner Wrench Motors for leaks. 8. Check Spinner Wrench Motor Shaft Key. 9. Check Spinner Mount Pin for deformation. 10. Check Spinner Mount Base for deformation. 4.4.2 Moving Wrench 1. Check Moving Wrench Body and Side Covers for deformation. a. Inspect all holes for pins and bolts. b. Inspect guides for Die Holder Backups. 2. Inspect Dies. 3. Inspect Die Holders. 4. Inspect Die Holder Backups. 5. Inspect Top Grip Cylinders. 6. Inspect Torque Arm for deformation. 7. Inspect Moving Wrench retainer bolt. 8. Inspect Torque Arm pin. 9. Inspect Moving Wrench cam followers. 10. Inspect Torque Cylinder and Rod pin. 11. Inspect Torque Cylinder mount. 4.4.3 Back-Up Wrench 1. Check Back-Up Wrench and Side Covers for deformation. a. Inspect all holes for pins and bolts. b. Inspect guides for Die Holder Backups. 2. Inspect Dies. 3. Inspect Die Holders. 4. Inspect Die Holder Backups. 5. Inspect Bottom Grip Cylinders. 6. Inspect tube frame for deformation. 4.4.4 Hanging Arm 1. 2. 3. 4. Inspect entire Hanging Arm and Mount System for deformation. Inspect D-Ring. Inspect Balance Screw. Inspect Hose Hanger and hoses.
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4.4.5 Hydraulic Pneumatic System 1. 2. 3. 4. 5. 6. 7.
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Check overall system for leaks. Check the condition of all hoses and check for loose or worn hoses. Check all fittings and connectors are tight. Check Main Manifold for leaks (air and hydraulic) and damage. Check Control Handles for leaks (air and hydraulic). Check all valves, cylinders and motors for leaks. Check Buttons, Joysticks and Torque Limiter on Control Handle for functionality. 8. Check certification of Torque Gauge, if necessary, get certification.
4.5
TORQUE GAUGE CHECKS Should the torque gauge accuracy or function require checking while in the field, the following procedure can be adopted to determine accuracy: 1. 2. 3. 4. Check that the gauge damping screw is fully out. Connect a 3000 psi pressure gauge to the torque gauge connection. Activate the torque grip button. Use the table below to check the expected torque reading against pressure on the test gauge.
4.5.1 Torque vs Pressure Table Torque Ft/Lbs. (36 arm) 25,000 50,000 75,000 100,000 Convert to Inch/Lbs 300,000 600,000 90,000 1,200,000 Pressure Lbs. (11 sq.in.) 757.9 1,515.8 2,273.6 3,031.5
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5.0 SERVICING PROCEDURES 5.1 INTRODUCTION
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The procedures detailed in this section are designed to assist with the routine servicing of the DPT-100 drill pipe tong as specified in Section 4 of this manual. Appropriate information regarding servicing of the equipment is included in this section of the manual and should be read in conjunction with the drawings and parts lists located in Section 6. Important Note: Whenever fitting replacement parts to the equipment, always ensure that original Franks supplied components are fitted as the majority of items have been designed and selected to suit their specific duty requirements. 5.2 SPINNER WRENCH Periodically, dependent upon usage, inspect all areas for excessive wear, damage or free play. Pay particular attention to all pins and pivot positions. Section 6 of this manual contains all relevant assembly drawings and parts lists to assist with disassembly of equipment and identification of replacement parts. 5.2.1 Motors The Spinner Wrench Motors are located on the top of the case assembly and are bolted via adapter plates to the Top Flange Bearings. Whilst the motor is removed, the Top Flange bearings should be checked for wear and free play. A repair kit for the motors are available as a spare parts item. 5.2.2 Flange Bearings The Spinner Wrench Flange Bearings are located on the top and bottom of the case assembly. The Top Flange Bearings are located under the Spinner Wrench Motor adapter plate and the Bottom Flange Bearings bolted to the bottom of the case assembly. 5.2.3 Rollers The Spinner Wrench Rollers are located in the case assembly on a squaredrive shaft. To replace the rollers loosen the Allen screws that hold the Spinner Bottom Flange Bearings to the square-drive shaft. Remove the Spinner Wrench Motor, adapter plate and Top Flange Bearing. The
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square-drive shaft will then slide out the top of the case, leaving the roller loose inside the case assembly. When replacing the front roller on the double roller side, the drive shaft for the rear roller must be removed first to allow the front roller to come out of the case. 5.2.4 Grip Cylinder The Spinner Wrench Grip Cylinder is located inside the case assembly behind the rollers and is held in place by two pins and located on the top of the case assembly. Remove the hoses from both ends and inspect the cylinder rod for signs of damage or leaky seals. A repair kit for this cylinder is available as a spare parts item. 5.2.5 Spinner Wrench Case Assembly The Spinner Wrench Case Assembly is located on the top of the DPT-100 on a Spinner Wrench Mount Pin. To remove, pull the safety pin from the top of the Spinner Wrench Pivot Pin, located at the rear of the case assembly. Please note that hydraulic hoses should be disconnected / removed prior to lifting. Lift both cases up and off of the Spinner Wrench Pivot Pin together. Inspect case assembly for damage or deformation. Inspect all holes and threads for excessive wear or deformation. The entire Spinner Wrench Assembly can be removed down to the Spinner Wrench Mount Pin by removing the bolt through the Spinner Wrench Mount Pin and Spinner Wrench Mount Tube. Please note that hydraulic hoses should be disconnected / removed prior to lifting. Lift the whole assembly as one part. 5.2.6 Mount Pin The Spinner Wrench Mount Pin is located below the Spinner Wrench and travels inside the Spinner Wrench Mount Tube. After removal of the Spinner Wrench Case Assembly, remove the bolt through the Spinner Wrench Mount Pin and Spinner Wrench Mount Tube. Lift the Spinner Wrench Mount Pin out of the Tube. Inspect the pin for damage. 5.2.7 Mount Tube After removal of the Entire Spinner Wrench or Spinner Wrench Mount Pin, remove the Spinner Wrench Mount Tube from the welded frame by
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5.3
removing the bolt at the base of the tube. Inspect internal bore of the tube and slot for damage or excessive wear. MOVING WRENCH Periodically, dependent upon usage, inspect all areas for excessive wear, damage or free play. Pay particular attention to all pins and pivot positions. 5.3.1 Dies and Die Holders Dies and Die Holders are removed after completely extending the Top Grip Cylinder. Press the Torque Button while not on a connection and either push the E-Stop Button or shut down the hydraulic power unit to keep extended. Remove the Die from the Die Holder by removing either the top or bottom die retainer screw. Inspect the dies and die holders for damage or excessive wear. 5.3.2 Die Holder Backups and Top Grip Cylinders After removing the Die Holders, remove the Moving Wrench side covers and Top Grip Cylinder Pin. Disconnect the hydraulic hoses to the Top Grip Cylinder. Pull the Top Grip Cylinder and Die Holder Backup through the side cover opening. Remove the Die Holder Backup from the Top Grip Cylinder and inspect the cylinder rod for signs of damage or leaky seals. A repair kit for this cylinder is available as a spare parts item. Inspect Die Holder Backup for excessive wear or damage. 5.3.3 Retainer Bolt The moving Wrench Retainer Bolt is located inside the rear of the case of the Moving Wrench and Back-Up Wrench. To access the top of the bolt, remove the Moving Wrench front cover. To access the bottom of the bolt, remove the rear side covers on the Back-Up Wrench. Inspect the bolt and nut for excessive wear or damage. 5.3.4 Cam Follower Bearings The Moving Wrench cam follower bearings are located behind the Moving Wrench and ride on a cam on the Back-Up Wrench. Remove the nut from the top of the bearing. Inspect bearing for excessive wear and damage.
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5.3.5 Torque Arm
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The Torque Arm is attached to the rear of the Moving Wrench. Remove both pins and the Torque Cylinder Rod Pin. Inspect the Torque Arm for deformation or damage. Inspect all holes and pins for excessive wear or deformation. 5.3.6 Torque Cylinder The Torque Cylinder is located at the rear of the tool above the Winch and below the Main Manifold Mount. The Torque Cylinder is removed by first detaching the Torque Cylinder Mount. Disconnect the hydraulic hoses from the Torque Cylinder and inspect the cylinder rod for signs of damage or leaky seals. A repair kit for this cylinder is available as a spare parts item. 5.4 BACK-UP WRENCH Periodically, dependent upon usage, inspect all areas for excessive wear, damage or free play. Pay particular attention to all pins and pivot positions. 5.4.1 Dies and Die Holders Dies and Die Holders are removed after completely extending the Bottom Grip Cylinder. Press the Back-Up Button while not on a connection and either push the E-Stop Button or shut down the hydraulic power unit to keep extended. Remove the Die from the Die Holder by removing either the top or bottom die retainer screw. Inspect the Dies and Die Holders for damage or excessive wear. 5.4.2 Die Holder Backups and Bottom Grip Cylinders After removing the Die Holders, remove the Back-Up Wrench side covers and Bottom Grip Cylinder Pin. Disconnect the hydraulic hoses to the Bottom Grip Cylinder. Pull the Bottom Grip Cylinder and Die Holder Backup through the side cover opening. Remove the Die Holder Backup from the Bottom Grip Cylinder and inspect the cylinder rod for signs of damage or leaky seals. A repair kit for this cylinder is available as a spare parts item. Inspect Die Holder Backup for excessive wear or damage.
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5.4.3 Pipe Stop
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The Pipe Stop is located inside the case of the Back-Up Wrench assembly and is accessed through the front and rear Side Covers of the Back-Up Wrench. Remove bolts, Pipe Stop Safety Pin and Pipe Stop Handle, and then slide bars out. Inspect for excessive wear and deformation. 5.5 HANGING ARM Periodically, dependent upon usage, inspect all areas for excessive wear, damage or free play. Pay particular attention to all pins and pivot positions. 5.5.1 Balance Screw and D-Ring The Balance Screw and D-Ring are located at the top of the Hanging Arm. Remove by unfastening the bolt and nut that go through the Balance Screw. Inspect for excessive wear and damage. 5.5.2 Hanging Arm Pivot Pin The Hanging Arm Pivot Pin is located at the bottom of the Hanging Arm. Support the Hanging Arm prior to removing Pivot Pin. The Pivot Pin is removed by taking out the safety pin. Inspect for excessive wear and damage. 5.5.3 Tilt Cylinder The Tilt Cylinder is located at the bottom of the Hanging Arm at the rear. The Tilt Cylinder is removed by pulling the pins on both ends of the cylinder and removing the hydraulic lines. Inspect the cylinder rod for signs of damage and leaky seals. A repair kit for this cylinder is available as a spare parts item. 5.5.4 Hose Hanger The Hose Hanger is located three-quarters up the Hanging Arm. The Hanger is removed from the Hanging Arm by detaching the hydraulic hoses from the saddle and removing the U-bolt. Inspect the hanger and hoses for excessive wear and damage.
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5.6 HYDRAULIC PNEUMATIC SYSTEM
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Periodically, dependent upon usage, inspect all areas for leaks and loose valves, plugs, fittings and hoses. Pay particular attention to excessive wear on hydraulic hoses. NOTE: whenever disconnecting hydraulic and pneumatic lines, they should be tagged and marked, to ease installation. 5.6.1 Main Manifold Main Manifold is located at the rear of the tool above the Torque Cylinder. Access is given by removing the Main Manifold Cover. Remove the Manifold by first removing and tagging all hydraulic hoses and unfastening it from the frame of the tool. Inspect for leaks and loose valves, plugs, fittings and hoses. NOTE: When replacing cartridge valves in manifolds, a very thin coat of white lithium-based grease should be applied to all rubber seals and care should be exercised when beginning to insert the cartridge valve into the port in the manifold and starting the threads. 5.6.2 Control Handles Left and Right Control Handles are located at the front of the tool above the Moving Wrench. The Left Control Handle houses all the actuators for the different functions (such as Tilt, Winch, Lift, E-Stop, Make/Break, Back-up, Spin, Grip-Torque). The Right Control Handle houses the Torque Limiter and Torque Gauge. 1. Left and Right Control Boxes and Arms: to remove the control boxes and arms, first unfasten the front cover plate. Disconnect and tag all hydraulic and/or pneumatic lines for ease of installation. Remove the bolts to detach the arm from the frame of the tool. 2. Left Control Handle Controls: to access the rear of the controls, unfasten the front cover plate. 3. To remove air valves, first disconnect and tag the air lines from the valve. Remove the button from the actuator shaft and gland nut from the front of the cover plate. Inspect actuator shaft and valve for excessive wear and damage.
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4. To remove joysticks, first disconnect and tag the air lines from the joystick. Remove the mount bolts from the front of the cover plate. Inspect joystick handle and valve for excessive wear and damage. 5. Right Control Handle Controls: to access the Torque Control Block and Valves and Torque Gauge, unfasten the front cover plate. 6. To remove Torque Limiter Valve, remove the gland nut from the front of the valve and the Torque Control Block will come free of the front cover plate. Remove the Valve from the front of the Torque Control Block. 7. The Check Valve is located at the rear of the block and is accessible at this point. 8. To remove Torque Gauge, disconnect and tag the hydraulic line and remove from the front cover plate. Inspect the needle for straightness and damage. 5.6.3 Flow Divider Assembly Flow Divider Assembly is located inside the case of the Back-Up Wrench at the rear. The Assembly is accessed through the rear side covers. Inspect for leaks, and then remove and tag all hydraulic hoses to the Assembly.
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5.7 TROUBLESHOOTING
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The following items are listed to help finding potential problems on the DPT-100. This is not a complete list but should help with the troubleshooting process: Symptom After successful rig-up, try to operate tool and nothing happens. Remedy 1. Check hydraulic power supply is on and is delivering 32-34 GPM. 2. Check main hydraulic connections are completely seated to allow the check valves in the connectors to open. 3. Check main air line to tool is connected and has 90 PSI minimum. 4. Check E-Stop Button is operating properly - see next item. 5. Check system pressure at gauge port (location G3 on Main Manifold). 1. Check if air line is broken or leaking between the Left Control Handle and the air piloted valve (location AP1 on Main Manifold). 2. Check air piloted valve is shifting. 3. Check directional valve (location PD1 on the Main Manifold) is shifting. 1. Check Make/Break Selector Button is shifting and not leaking. 2. Check if air line is broken or leaking between the Left Control Handle and the air piloted valve (location AP4 on the Main Manifold). 3. Check air piloted valve is shifting. 4. Check directional valves (location PD3C and PD3D on the Main Manifold) are shifting. 1. Check that hydraulic connections to Lift Cylinder are completely seated to allow the check valves in the connectors to open. 2. Check the joystick is shifting and not leaking. 3. Check if air line is broken or leaking between the Left Control Handle and the DO3 pattern directional valve (location DO3, valve 3 on Main Manifold). 4. Check if DO3 pattern directional valve is shifting.
E-Stop is pulled out (engaged) and no controls operate.
Make/Break Selector Button is moved in (engaged) or out (disengaged) and Torque Cylinder does not extend / contract.
Lift Cylinder Joystick is operated and nothing happens.
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Symptom Tilt Cylinder Joystick is operated and nothing happens.
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Winch Joystick is operated and nothing happens.
Back-Up Button is in (engaged) and nothing happens.
Back-Up Button is in (engaged), Spin Button is pressed and nothing happens.
Spin Button is pressed and the door closes but the Spinner Motors do not turn OR Spinner Motors turn before door closes. Back-Up Button is in (engaged), Torque Button is pressed and nothing happens.
Remedy 1. Check the joystick is shifting and not leaking. 2. Check if air line is broken or leaking between the Left Control Handle and the DO3 pattern directional valve (location DO3, valve 4 on Main Manifold). 3. Check if DO3 pattern directional valve is shifting. 1. Check the joystick is shifting and not leaking. 2. Check if air line is broken or leaking between the Left Control Handle and the DO3 pattern directional valve (location DO3, valve 2 on Main Manifold). 3. Check if DO3 pattern directional valve is shifting. 1. Check Back-Up Button is shifting and not leaking. 2. Check if air line is broken or leaking between the Left Control Handle and the air piloted valve (location AP2 on Main Manifold). 3. Check air piloted valve is shifting. 4. Check directional valve (location PD3A on the Main Manifold) is shifting. 1. Check Spin Button is shifting and not leaking. 2. Check if air line is broken or leaking between the Left Control Handle and the air piloted valve (location AP5 on Main Manifold). 3. Check air piloted valve is shifting. 4. Check directional valves (location PD3E on Main Manifold) is shifting. 1. Check spinner sequence valve is properly adjusted. Adjust using procedure in Section 5.8 (under section covering Sequence Valves). 1. Check Torque Button is shifting and not leaking. 2. Check if air line is broken or leaking between the Left Control Handle and the air piloted valve (location AP3 on Main Manifold). 3. Check air piloted valve is shifting. 4. Check directional valve (location PD3B on Main Manifold) is shifting.
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Symptom Remedy Torque Button is pressed and 2. Check torque sequence valve is properly Top Grip Cylinders operate but adjusted. Adjust using procedure in Section 5.8 the Torque Cylinder does not OR (under section covering Sequence Valves). Torque Cylinder operates before pipe is gripped by Top Grip Cylinders. Movement at Start-Up, Bottom 1. Check that the Back-Up Button is out Grip Cylinders extend. (disengaged) and shifting. 2. Check air piloted valve (location AP2 on Main Manifold) is shifting. 3. Check directional valve (location PD3A on the Main Manifold) is shifting. Movement at Start-Up, Torque 1. Check position of the Make/Break Selector Cylinder moves. Button. 2. Check air piloted valve (location AP4 on Main Manifold) is shifting. 3. Check directional valve (location PD3C on the Main Manifold) is shifting. Movement at Start-Up, Top Grip 1. Check that the Torque Button is out (disengaged) Cylinders extend then Torque and shifting. Cylinder moves. 2. Check air piloted valve (location AP3 on Main Manifold) is shifting. 3. Check directional valve (location PD3B on the Main Manifold) is shifting. Movement at Start-Up, Spinner 1. Check that the Spin Button is out (disengaged) Wrench closes then Spinner and shifting. Wrench Motors turn. 2. Check air piloted valve (location AP5 on Main Manifold) is shifting. 3. Check directional valve (location PD3E on the Main Manifold) is shifting. Movement at Start-Up, Lift 1. Check Lift Joystick is shifting. Cylinder moves. 2. Check Lift Joystick spring return is operating properly. 3. Check Lift Joystick does not have garbage keeping it in one position. 4. Check DO3 pattern directional valve (location DO3, valve 3 on Main Manifold) is shifting.
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Symptom Movement at Start-Up, Tilt Cylinder moves.
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Movement at Start-Up, Winch moves.
Spinner Wrench slips on tubular.
Dies slip on connection.
Remedy 1. Check Tilt Joystick is shifting. 2. Check Tilt Joystick spring return is operating properly. 3. Check Tilt Joystick does not have garbage keeping it in one position. 4. Check DO3 pattern directional valve (location DO3, valve 4 on Main Manifold) is shifting. 1. Check Winch Joystick is shifting. 2. Check Winch Joystick spring return is operating properly. 3. Check Winch Joystick does not have garbage keeping it in one position. 4. Check DO3 pattern directional valve (location DO3, valve 2 on Main Manifold) is shifting. 1. Check alignment of tool with connection. The Spinner Wrench should be parallel to the Moving and Back-Up Wrenches and level. 2. Check Spinner Wrench Rollers for excessive wear or damage. 3. Check pressure on rod side of Spinner Wrench Grip Cylinder (location Port A3 on Main Manifold) is at the recommended setting (see Section 5.8). 1. Check alignment of tool with connection. The Moving and Back-Up Wrenches should be perpendicular to the connection and level. 2. Check the connection must be centered in the dies. See Section 3.5.1 Steps 11-14 to adjust the Pipe Stop properly. 3. Check Dies for excessive wear and damage. 4. Check hydraulic pressure on Top and Bottom Grip Cylinders at gauge ports (location G1 for Back-Up and G2 for Moving Wrench on Main Manifold) is at the recommended setting (see Section 5.8).
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Symptom Torque Button is pressed, Top Grip Cylinders are extended, Torque Cylinder is moving and no reading or incorrect reading on Torque Gauge.
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Remedy 1. Check torque gauge damper screw is completely open and screwed in 1/4 turn. 2. Check Torque Limiter Valve in Right Control Handle is operating properly, set to proper torque and not sticking or has trash. 3. Check air line from Make/Break signal in Left Control Handle to directional valve (location DV1 in Right Control Handle). 4. Check directional valve is shifting. 5. Follow procedure for testing Torque Gauge. Procedure is found in Section 4.5.
5.8
PORT A B G2 A1 B1 G1
PORT OPERATION
OPERATION Top Wrench Grip Cylinders Top Wrench Grip Cylinders Gauge Port For Top Wrench Grip Cylinders Bottom Wrench Grip Cylinders Bottom Wrench Grip Cylinders Gauge Port for Bottom Wrench Grip Cylinders NOTES NOT ADJUSTABLE
OUTPUTS
Set to System Pressure (Port PR1F)
Reg. Conn.: Set to System Pressure Prem. Conn.: Set to 1800 Psi (Port PR1E)
A2 B2 A3 B3 C1 C2 C3 C4 C5 C6 C7 C8
Torque Cylinder Torque Cylinder Spinner Wrench Grip Cylinder Spinner Wrench Grip Cylinder Auxiliary / Not Used Auxiliary / Not Used Winch Motor Winch Motor Lift Cylinder Lift Cylinder Tilt Cylinder Tilt Cylinder
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M1 M2 G3 Spinner Wrench Motors Spinner Wrench Motors Gauge Port for Main System Pressure
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Shows pressure from Power Pack ADJUSTABLE
SEQUENCE (CARTRIDGE) PS1 Extend Top Wrench Grip Cylinders then operate Torque Cylinder PS2
Set to (1) Close Grip Cylinder (2) Operate Torque Cylinder Retract Spinner Wrench Grip Cylinder then rotate Set to (1) Close Grip Cylinder Spinner Wrench Motors (2) Operate Spinner Wrench Motors ADJUSTABLE (SPEED) Port C1 - Auxiliary / Not Used Port C2 - Auxiliary / Not Used Port C3 - Winch Motor OPERATION Port C4 - Winch Motor Port C5 - Lift Cylinder Port C6 - Lift Cylinder Port C7 - Tilt Cylinder Port C8 - Tilt Cylinder Port A1 - Bottom Wrench Grip Cylinders Port B1 - Bottom Wrench Grip Cylinders Port A - Top Wrench Grip Cylinders Port B - Top Wrench Grip Cylinders Port A3 - Spinner Wrench Grip Cylinder Port B3 - Spinner Wrench Grip Cylinder Bottom Wrench Grip Cylinders Top Wrench Grip Cylinders Torque Cylinder Spinner Wrench Grip Cylinder Spinner Wrench Motors NOT ADJUSTABLE E-Stop Bottom Wrench Grip Cylinders Top Wrench Grip Cylinders and Torque Cylinder Make And Break Position of Torque Cylinder Spinner Wrench Grip Cylinders and Motors NOT ADJUSTABLE Bottom Wrench Grip Cylinder - Extend/Retract Top Wrench Grip Cylinder - Extend/Retract Torque Cylinder - Make/Break Position Spinner Wrench Motors - Make/Break Position
FLOW CONTROL (CARTRIDGE) FC1A FC1B FC1C PORT FC1D FC1E FC1F FC1G FC1H FC1I FC1J FC1K FC1L FC1M FC1N CV1A CV1B CV1C CV1D CV2 AP1 AP2 AP3 AP4 AP5 PD3A PD3B PD3C PD3D
NOTES
CHECK (CARTRIDGE)
NOT ADJUSTABLE
AIR PILOT (CARTRIDGE)
DIRECTIONAL CONTROL (CARTRIDGE)
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PD3E PR1A PR1B PR1C PR1D PR1E PR1F PR1G PR2 Spinner Wrench Grip Cylinder - Extend/Retract PRESSURE REDUCING (CARTRIDGE) Auxiliary / Not Used Winch Motor Lift Cylinder Tilt Cylinder Bottom Wrench Grip Cylinder Top Wrench Grip Cylinder Spinner Wrench Grip Cylinder Spinner Wrench Motors
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ADJUSTABLE
5.9
MAINTENANCE CHECKLIST See the following page for a maintenance checklist with Daily, Weekly, Monthly, Bi-Monthly, Annual and Bi-Annual items to be inspected. This is not a complete list and should be used as a guide. If more items or changes need to be made, the initiative should be taken by the customer and send a notice to the Franks International Drill Pipe Tool Department (contact information is located at the front of this manual).
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OPS-QR-0XX (RevX) Ref: OPS-P-4.1.13
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Page 1 of 1
PIPEWRANGLER MAINTENANCE CHECKLIST

TONG # : JOB # : FTGE RUN: TONG SIZE : RIG NAME PIPE SIZE MAINTENANCE CHECK DATE: STANDBY ONLY:
Place a tick in the appropriate box on the right to indicate the type of inspection being performed.
Da ily
IF A TICK IS SHOWN IN THE CLEAR CELLS, THIS WILL INDICATE THAT THE ITEM WAS FOUND TO BE ACCEPTABLE
COMMENTS
Certification Safety Inspections MPI, Hanging Arm Gussets (retest 24 mths) Exp date: MPI, Hanger Assy, Hex Bolt (retest 12 mths) Exp date: MPI, Moving Wrench Assy (retest 24 mths) Exp date: MPI, Back-Up Wrench Assy (retest 24 mths) Exp date: MPI, Spinner Wrench Case Halves (retest 24 mths) Exp date: Overall Visual Inspection CHECK EMERGENCY STOP BUTTONS IS OPERATIONAL Certified Winch Cable and Hook (retest 12 mths) Exp date: Long Term Rental Maintenance and Workshop Maintenance Check overall tool for loose fasteners Check overall tool for broken or damaged parts Check Spinner Wrench Rollers Check Spinner Wrench Flange Bearings Check contact between Spinner Wrench Rollers and Square Drive Shaft Check Spinner Wrench Grip Cylinder Check Spinner Wrench Case Halves Check Spinner Wrench Pivot and Back-Up Pin Check Spinner Wrench Motors Check Spinner Mount Pin Check Spinner Mount Base Check Moving Wrench Body Check Moving Wrench Side Covers Check Back-Up Wrench Body Check Back-Up Wrench Side and Rear Covers Check Dies Check Die Holders Grease Die Holders Check Die Holder Backups Grease Die Holder Backups Check Grip Cylinders and Pin Mounts Check Moving Wrench Retainer Bolt Check Moving Wrench Cam Follower Bearings Check Torque Arm and Torque Arm Pin Check Torque Cylinder and Torque Cylinder Rod Pin Check Torque Cylinder Mount Check Hanging Arm and Hanging Arm Pivot Pin Check "D"-Ring, Balance Screw and Bolt Check Hose Hanger Check hydraulic system for leaks Check pneumatic system for leaks Check all hydraulic and pneumatic hoses for wear Check all fittings and connectors are tight Check Main Manifold for leaks Check Control Handles for leaks (hydraulic and pneumatic) Check all valves, cylinders and motors for leaks Check all Buttons, Joysticks and Torque Limiter for operability Grease all zerk fittings Check level of Winch Gear Case Oil Periodic Workshop Inspections / Maintenance Change Winch Gear Case Oil Torque Gauge Calibration : Next Cal date: s/n:
We ek ly Mo nth ly 6M on ths 1Y ea r 2Y ea rs W /S ho p
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6.0 SERVICING PROCEDURES 6.1 ASSEMBLY DRAWING 2698C-201
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6.2 BILL OF MATERIALS 2698C-201
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6.3 ASSEMBLY DRAWING 2698C-202
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6.21 SCHEMATIC DRAWING 2698C-211
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6.26 MANIFOLD VALVE LOCATION DRAWING 2698C-215
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7.0 RECOMMENDED SPARE PARTS LIST 7.1 RECOMMENDED SPARE PARTS LIST
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DPT 100

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SERVICE MANUAL NO PAGE

DPT 100 DRILL PIPE TONG

FRANKS INTERNATIONAL, INC.

PIPEWRANGLER DPT-100 DRILL PIPE TONG Operation & Maintenance Manual

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REVISION TABLE REMARKS INITIAL RELEASE

2004 Franks International, Inc.

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