Beruflich Dokumente
Kultur Dokumente
Nicholas Morelli
CUSTOM PIPE GLOBAL CONSULTING INC.
Revision 2
CONFIDENTIAL AND PROPRIETY INFORMATION MAY BE CONTAINED HEREIN,
NOT TO BE RELEASED WITHOUT WRITTEN PERMISSION OF
CUSTOM PIPE GLOBAL CONSULTING INC.
HYDRAULIC CATWALK
OVERVIEW MANUAL
TABLE OF CONTENTS
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HYDRAULIC CATWALK
OVERVIEW MANUAL
GENERAL NOTICES
Custom Pipe makes every reasonable effort to ensure the accuracy of the information provided in this
Manual. However, as information, components, and procedures are continually improving, Custom Pipe
reserves the right to change at any time without notice, information contained in this Manual and makes
no warranties or representations as to its accuracy
COMPONENT DESCRIPTION
INTRODUCTION
This section outlines all the major components of the Custom Pipe Catwalk and its main purpose is to familiarize
you with the items and terms that will be used in the following sections. On the next page is a top-down view
of the Catwalk with labels showing the location of major components, as well as a legend for describing smaller
assemblies. After the main view pages, there are descriptions of all the items listed. For any information on
operating instructions or maintenance procedures, refer to the “Operations,” or “Maintenance,” sections of the
Manual, respectively.
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OVERVIEW MANUAL
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HYDRAULIC CATWALK
OVERVIEW MANUAL
FRAME
DESCRIPTION
The frame is mainly composed of Wide Flange and HSS Tubing and is the main structural member of the Catwalk.
It holds all of the running components, and is the location of the valve banks.
MAIN COMPONENTS
Leveling Jacks: These are to assist in leveling the Catwalk for proper operations. The front leveling jacks
have their own separate control valve, just above the main valve. The rear jacks are manually operated
to assist in detaching the trailer from the truck if power is unavailable
Main Feed Cable Storage: Located under the operators platform to provide protection for the main feed
power cable and plug
E-Stops: One ESD switch is located on the control panel of the Catwalk, and the other is located on the
wireless Remote
Toolbox: A lockable place to store smaller Catwalk items such as deck pins, Skate attachments and the
Wireless Remote. Can also be used to hold spare parts
Stairs w/Handrails (optional): This hinge on the Catwalk to provide a proper and safe way to access the
deck
Strobe Light: Provides a visual confirmation the Catwalk is running. Also folds down to reduce height for
transport
Stow Locations: Used to store the Gullwing center supports, center jack stand supports and foot pads for
jacks
WARNING: The Catwalk frame needs to be completely supported for proper and safe operation.
Also ensure that all pins and guards are in place and properly secured to prevent damages/injury.
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HYDRAULIC CATWALK
OVERVIEW MANUAL
There are three section that constitute the LCA, Stage 1, Stage 2, and the Main Lift Arms. Stage 2 contains the
Trough, Kickers and Skate System. Stage 1 contains the Extension Cylinder and is the connection point for the
Main Lifting Arms.
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MAIN COMPONENTS
Main Lift Arms: Are used to lift the carriage to a user programmable set point.
Main Extend Cylinder: Is located in between Stage 1 and Stage 2 it is used to pull Stage 2 up to the rig
floor. All the main cylinders have counter-balance valves installed on both ends as a safety measure, to
prevent any motion in the event of a hose failure.
Cam Followers: These rollers are installed in Stage 1; they provide a low-friction method of extending
and retracting the sections together. Greasing is not necessary as the bearings are sealed and pre—
lubricated from the factory for the life of the roller.
Kicker Safety Valve: They are mounted on Section 1 and prevent the Kickers from being actuated once
the LCA has been extended from inside the deck. Even if the function is accidentally activated, these
valves will physically prevent hydraulic pressure from reaching the Kicker Cylinders.
Hose Carrier: Used to protect and organize the hydraulic hoses that run between Stage 1 and Stage 2. It
is a vital part of the Catwalk and needs regular inspection for damage or worn links and cover plates
PLC: Is used to preset height and extension points for repetitive and safe operation.
*NOTE: Kickers and Skate are detailed in their own individual sections further on.
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OVERVIEW MANUAL
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OVERVIEW MANUAL
The Skate System and Kickers are located in Stage 2 or top section of the LCA. The purpose of the Skate is to
push the pipe up the trough to the position that is useful for picking up the pipe. This can be done with a winch
or elevator system. If necessary, the Skate can also pull the pipe back with an adapter (when equipped). Each
Kicker consists of cylinders on either side of the trough, and as a set of 3 works together to “Kick” the pipe out
of the trough, usually when lying down. There are two sets; one for each side of the Catwalk will need to be
used.
Skate Assembly: A two piece Skate runs down the middle of Stage 2. There are different attachments to
assist in the task at hand. The Skate travels almost the entire length of the trough to accommodate even
the shortest lengths of pipe
Skate Motor/CB Valve: The Skate System is driven by a hydraulic motor with a counter balance valve.
The motor is of a case drain type design and requires no vent. The brake is pressure-released and
automatically applies as soon as the Skate stops moving. There is a dual counterbalance valve installed
to add redundancy to the braking system
Chain: The main drive chains are two continuous loops that run almost the entire length of Stage 2. They
ride in UHMW guides to help reduce friction and wear. It is very important to keep the guides free of
debris, as well as regularly inspect the chains and components for wear or damage. There is also a shorter
loop of chain in the front of Stage 2 that transfer’s power from the Skate Motor to the Main Drive Chains
Tensioning System: The chain tensioner consists of non-adjustable idler and a shaft that is mounted in
two adjustable spherical bearings. These are located in the very back of Stage 2. The tension bolts have
jam nuts on them to help ensure that tension is maintained
WARNING: The Skate MUST be in contact with the Tubular as much as possible. Shock loading of
the drive chains is unsafe and will severely reduce their service life.
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OVERVIEW MANUAL
Kicker Safety System: as a standard feature the Kickers will by default automatically return. This is in
combination with valves that close whenever the LCA lifted out of the frame. This is to ensure that a Tubular
cannot be kicked out accidentally above the deck, and to keep the Kickers fully retracted and out of the way of
the Skate.
WARNING: The Kickers must NEVER be actuated when the Skate is directly on top of them. Severe
damage to the Skate assembly WILL result.
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GULLWING INDEXERS
DECRIPTION
The Gullwing Indexers are used to load pipe to the carriage from the Gullwings. They are used with alignment
pins to assure one pipe is loaded at a time.
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OVERVIEW MANUAL
GULLWINGS
DESCIPTION
The Gullwings are an integrated set of pipe racks that are mounted to the Catwalk, and are most often
used in conjunction with the Indexers. They are hydraulically adjustable to either feed Tubulars in to the
Catwalk, or collect Tubulars when lying down. The end pin can be removed to easily work in conjunction
with existing pipe racks. Since they are mounted to the frame, they swing in to stow for easy transport.
Hinge Assembly: Used to Pivot the Gullwings in and out for transport when pin is in.
WARNING: The Gullwing Legs MUST maintain contact with solid ground when loaded with pipe.
The hinges are designed to support ONLY the weight of the Gullwings when free-standing.
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HYDRAULIC CATWALK
OVERVIEW MANUAL
CONTROL PANEL
DESCRIPTION
The Main Control Panel is located on the Driller Side. The purpose of the panel is to provide a place to control
the HPU, as well as indicating any ESD conditions that may exist. The main disconnect switch is a circuit breaker
style, and the handle has the means to be locked out with a standard pad lock.
MAIN PANEL
Main Disconnect: Can be locked in the “OFF” position, as well as indicating if the breaker has been
tripped.
Hand-Off-Auto Switch: Is used to either start the motor manually (Hand), or to start with the Wireless
Remote (auto).
Start Button: Is used to start the motor when H-O-A Switch is in Hand.
Run Indicator: Shows when the Catwalk motor is running.
E-Stop Indicator: Shows when an ESD switch has been pushed, the safety barrier has been tripped, the
Catwalk is low on oil, or the oil temperature is too high.
High Temp Indicator: The oil in the reservoir is too hot to run (limit set at 80° C).
Low Oil Indicator: The oil level in the reservoir is too low to run.
PLC PANEL
There is a PLC error indictor located on the door of the panel, if there is an error a series of flashes will occur.
FLASHES
1. Main Lift Sensor Error
2. Extend Cylinder Sensor Error
3. Main Lift Past Set Point
4. Extend Cylinder Past Set Point 5- Radio Error/Off
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CONTROL PANEL
WARNING: High Voltages are present in all of these panels. Work to be performed by Qualified
Personnel only.
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HERCULES
HYDRAULIC CATWALK – OPERATION & MAINTENANCE MANUAL
Nicholas Morelli
CUSTOM PIPE GLOBAL CONSULTING INC.
Revision 2
CONFIDENTIAL AND PROPRIETY INFORMATION MAY BE CONTAINED HEREIN,
NOT TO BE RELEASED WITHOUT WRITTEN PERMISSION OF
CUSTOM PIPE GLOBAL CONSULTING INC.
HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
TABLE OF CONTENTS
MANUAL INTRODUCTION...........................................................................................3
OPERATOR REQUIREMENTS AND RESPONSIBILITIES ................................................... 3
CATWALK GENERAL SAFETY .......................................................................................4
SPECIFIC COMPONENT AND EQUIPMENT OVERVIEW................................................. 5
BASIC HERCULES FRAME ....................................................................................................................... 5
HERCULES MAJOR COMPONENTS........................................................................................................ 6
HYDRAULIC LEVELING JACKS................................................................................................................. 7
FRONT ARMS ........................................................................................................................................ 8
TROUGH CARRIAGE .............................................................................................................................. 9
MAIN TROUGH ................................................................................................................................... 10
TROUGH KICKERS................................................................................................................................ 11
HYDRAULIC GULLWINGS ..................................................................................................................... 12
TUBULAR PIPE RUNS ........................................................................................................................... 13
PIPE RACK INDEXERS ........................................................................................................................... 14
SKATE SYSTEM .................................................................................................................................... 15
REAR ARMS ......................................................................................................................................... 16
“LED” WORK LIGHTS ........................................................................................................................... 17
HYDRAULIC TANK ............................................................................................................................... 18
CATWALK CONTROL SYSTEMS ........................................................................................................... 19
PLC CONTROL BOX & SENSORS .......................................................................................................... 20
MAIN VALVE BANK ............................................................................................................................. 21
AUXILIARY VALVE BANK ..................................................................................................................... 22
EMERGENCY STOPS ............................................................................................................................ 23
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OPERATION & MAINTENANCE MANUAL
SPOTTING AND INITIAL POWER UP OF THE CATWALK & LEVELING SYSTEM ............. 24
SPOTTING THE CATWALK ................................................................................................................... 24
ENERGIZING THE CATWALK ............................................................................................................... 24
INITIAL INSPECTION ............................................................................................................................ 25
FILLING THE HYDRAULIC TANK ........................................................................................................... 26
INITIAL CATWALK START UP ............................................................................................................... 27
MOTOR ROTATION ............................................................................................................................. 27
MANUAL CATWALK START UP ............................................................................................................ 28
LEVELING OUT THE CATWALK ............................................................................................................ 29
SETTING UP THE CATWALK FOR OPERATION ........................................................... 30
PIPE RACK INDEXERS .......................................................................................................................... 30
PIPE RACK CASING RUNS .................................................................................................................... 31
HYDRAULIC GULLWINGS .................................................................................................................... 32
SKATE SYSTEM .................................................................................................................................... 33
OPERATING THE CATWALK WITH THE WIRELESS REMOTE SYSTEM .......................... 34
REMOTE OVERVIEW ........................................................................................................................... 34
REMOTE CONTROL CATWALK START UP ............................................................................................ 35
PROGRAMMING NEW HEIGHTS USING THE REMOTE CONTROL ....................................................... 36
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
MANUAL INTRODUCTION
This Manual was created and should be used to obtain knowledge and assistance for the upkeep and safe
operation of the Hercules Hydraulic Catwalk. If any further instruction and or assistance is required please
contact a “Custom Pipe Handlers Representative”.
WARNING: This Catwalk must always be operated by a Certified Catwalk Operator with a Card of
Certification issued by a Custom Pipe Handler Representative.
WARNING: Any personnel who may negligently misuse this Catwalk in any unsafe manner or form could
result in serious injury or death.
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
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OPERATION & MAINTENANCE MANUAL
D
OFF DRILLER SIDE
C
DRILLER SIDE
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OPERATION & MAINTENANCE MANUAL
F
OFF DRILLER SIDE
D
E
G
B
H
A
DRILLER SIDE
A. Front Arms
B. Rear Arms
C. Main Trough
D. Trough Carriage
E. Skate
F. HPU & Valve Bank
G. Gullwings
H. Indexers
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OPERATION & MAINTENANCE MANUAL
CAUTION: Before moving the Catwalk always make sure that all 4 Leveling Jacks have been retracted to their
“Home” position.
WARNING: NEVER operate Catwalk with only Leveling Jacks as support for Catwalk, serious injury and
equipment failure may result.
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OPERATION & MAINTENANCE MANUAL
FRONT ARMS
CAUTION: Front Arms are a major pinch point, while operating stay back to ensure safety.
A. PLC Sensor
B. Main Lift Cylinder
C. Spherical Bearings
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OPERATION & MAINTENANCE MANUAL
TROUGH CARRIAGE
• This is a ridged structure that connects the Front and Rear Arms
• The Carriage is lined with Cam Followers in which the Trough moves backwards and forwards
• The Carriage is “Home” for the Trough Extension Motor and the Dual 100R Chain that connects the trough
to the Hydraulic Gear Motor
• The Trough Carriage is also “Home” for the Cable Encoder for the Trough Extension function when using
the PLC
Cam Followers
Hydraulic Drive Motor
FRONT REAR
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OPERATION & MAINTENANCE MANUAL
MAIN TROUGH
• Another rigid structure of the Catwalk that is designed to control and contain all Tubulars and Tubular
products to and from the rig floor
• Equipped with 3 sets of Kickers that eject the Tubulars from the Trough to either DS or ODS of the Catwalk
• The Trough houses the Skate and the Skate Drive System along with the Tubular Kickers built into the
Trough
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OPERATION & MAINTENANCE MANUAL
TROUGH KICKERS
CAUTION: Test Plunger Valves before operating Catwalk to ensure the Kickers will activate properly.
• They will only activate when Trough and Trough Carriage is in the “Home” position and the Plunger Valves
have been compressed
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HYDRAULIC GULLWINGS
WARNING: DO NOT over load Gullwings with Pipe. Doing so may cause failure, collapse and cause serious
injury or death.
• The Hydraulic Gullwings generally were designed to hold Drill Pipe, Drill Collar, Tubing or Casing on
the ODS of the Catwalk
• There is a built-in Indexer in the Gullwing that dispenses Tubulars one at a time when
commanded either from the Valve Bank or from the Remote Control
• All Tubulars are held back by the Gullwing Stopper Pin, which can be adjusted for different sizes of
Tubulars
Built in Indexer
Gullwing Leveling Jack
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OPERATION & MAINTENANCE MANUAL
• Designed to create a bridge between the Casing Pipe Racks and the Catwalk so that the
Operator is further away from the critical area
• They can be adjusted to suite multiple different heights of Pipe Racks and can be extended to reach
further away
Height Adjustment
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CAUTION: Ensure all connecting pins have Safety Pins in place so the Indexer Arm(s) DO NOT slide out during
operation.
• The Indexers are generally located on the DS of the Catwalk and are used to pick up Tubulars from the
existing Pipe Racks next to the Catwalk
• The longer Indexer Arms (A) can pick up Tubulars on racks as low as 18” and work with the Tubular Pipe
Runs
• The shorter Indexer Arms (B) can be used if the Pipe Racks are set up close to the Catwalk and, like the
longer Indexer Arms they will only pick up one Tubular at a time
WARNING: Always have Deck Pins in the opposite side of where you are picking up Tubulars.
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OPERATION & MAINTENANCE MANUAL
SKATE SYSTEM
• The driven Skate System Chain Devise is designed to push and retrieve to and from the rig floor
• It is connected to the Motor by 80R Chain that runs down both sides of the Main Trough giving the Skate
two connection points
WARNING: Always visually check the chain for tightness before operating the Skate, not doing so could result
in the chain to snap or jump links.
CAUTION: Always use correct size of Hood for the Pipe the Catwalk is running. Using the wrong Head may
allow the Tubulars to slip out of the Trough when latched by the Elevators.
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OPERATION & MAINTENANCE MANUAL
REAR ARMS
• The Rear Arms are always activated after the Front Arms have reached their programmed height
• They push the Main Trough & Trough Carriage towards the rig floor reducing the overall angle of
presentation of the Main Trough on the rig floor
• They house one Cylinder each; However only one arm houses the PLC Sensor
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OPERATION & MAINTENANCE MANUAL
HYDRAULIC TANK
CAUTION: For proper Catwalk Operation ensure the Hydraulic Tank is filled when needed and always fill to
the top of the Sight Glass. Failing to do so may result in severe damage to the Catwalks Hydraulic System.
• The 190 Gallon Hydraulic Tank supplies Hydraulic Oil to the Valve Bank as well as the entire Catwalk
Hydraulic System
• NEVER let Hydraulic Oil get to the Bottom Sight Glass, it may B
cause the Main Pump to run dry
• This Sight Glass is equipped with a Low Oil Sensor and is triggered
when Hydraulic Oil is reaching dangerously low levels
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OPERATION & MAINTENANCE MANUAL
DESCRIPTIONS
A. Main Power Switch & Lock Out: This allows power to the Catwalk, always make sure that the handle is
turned to the OFF position when hooking up power to the Catwalk
B. Catwalk Running Indicator & Button: When the Main Power Handle is turned ON and the selector switch
is turned to the HAND position the Catwalk can be started by pressing the top button, the GREEN Indicator
will illuminate once Catwalk is running
C. Catwalk Stop Indicator & Button: This button will shut the Catwalk down. When the Catwalk is shut down
the RED Indicator will illuminate
D. PLC & Manual Selector Switch: This switch allows the Operator to switch between running the Catwalk
manually and the PLC Remote System; the Catwalk will only start manually if the switch is turned to the
HAND position, if it is turned to the AUTO position the Catwalk can only be started from the Remote Control
E. Low Oil Indicator: The Low Oil Sensor Light will illuminate when triggered. At this time the Catwalk should
be shut down, checked for leaks and then the Oil Tank properly filled before work continues
F. High Temperature Indicator: Will illuminate when the Hydraulic Oil has exceeded 80 °C, in this case turn
the Catwalk off to prevent damage to the Hydraulic System. Ensure the Hydraulic Cooling Fan is operating
properly
G. Hour Meter: This will inform the Operator how many hours the Catwalk has been operating
H. LED Light Switch: This switch controls the LED Lights on the rear of the Catwalk, always turn OFF the Lights
when not in use
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OPERATION & MAINTENANCE MANUAL
• RED Indicator will flash when there is a PLC Error (A) please see Error
Codes below
WARNING: Tampering with the PLC Panel may cause PLC System Failure which may damage equipment
and cause injury.
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
• The Main Valve Bank controls all the main functions of the Catwalk
• Valve Handles should only be used to operate the Catwalk and should NEVER be used as a hanger
A B C D E F G H
A. Driller Side Indexer: This handle controls the DS Pipe Rack Indexer and is used to pick Tubulars off of the
Pipe Racks and transfer them to the Main Trough, then back to the Pipe Racks when pulling the Tubulars
out of the hole
B. Driller Side Trough Kicker: This handle controls the DS Trough Kicker and kicks the Tubulars out towards
the DS of the Catwalk
C. Off Driller Side Trough Kicker: This handle controls the ODS Trough Kicker and Kicks the Tubular out
towards the ODS of the Catwalk
D. Off Driller Side Indexer: This controls the Indexer inside of the Hydraulic Gullwing and will pick up one
Tubular at a time off the Gullwing and transfer it to the Main Trough
E. Skate Control: This handle controls the Skate on the Main Trough, holding it up will move the Skate
forward and holding it down will pull the Skate back
F. Main Trough Extension: This handle controls the Main Trough Extension, holding the handle up will
extend the Trough and holding the handle down will retract the Trough to its “Home” position
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
G. Rear Arm Control: This handle controls the Rear Arms on the Catwalk, both handles need to be lifted
equally to activate the Rear Arms, NEVER lift Rear Arms if the Front Arms are not lifted
H. Front Arm Control: These handles control the Front Arms on the Catwalk, again both handles need to be
lifted to activate the Front Arms equally
I. Main Valve Bank Pressure Gauge: Indicates what the pressure is when any of the Main Valve controls are
activated, pressure should NEVER exceed 3000 PSI
WARNING: Lifting the Rear Arms before the Front Arms will cause severe damage to the Catwalk.
A. Front Driller Side Leveling Jack: Controls the Leveling Jack on the Front Driller Side of the Catwalk
B. Rear Driller Side Leveling Jack: Controls the Leveling Jack on the Rear Driller Side of the Catwalk
C. Front Of Driller Side Leveling Jack: Controls the Leveling Jack on the Front Of Driller Side of the Catwalk
D. Rear Of Driller Side Leveling Jack: Controls the Leveling Jack on the Rear Of The Driller Side of the Catwalk
E. Front Driller Side Gullwing Leveling Jack (if equipped): Controls the Front Driller Side Leveling Jack on the
Gullwing
F. Rear Driller Side Gullwing Leveling Jack (if equipped): Controls the Rear Driller Side Leveling Jack on the
Gullwing
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
G. Front Of Driller Side Gullwing Leveling Jack (on conventional units): Controls the Front Of Driller Side
Gullwing Leveling Jack
H. Rear Of Driller Side Gullwing Leveling Jack (on conventional units): Controls the Rear Of Driller Side
Gullwing Leveling Jack
I. Winch Control: Controls the Hydraulic Winch attached to the rear of the Catwalk; Pulling the handle up
will let out cable and pulling the handle down will retract the cable if installed
EMERGENCY STOPS
There are three (3) Emergency Stops for the Catwalk located on the rear (A) and the front of the Catwalk (B).
There is also an Emergency Stop on the Remote Control System (C).
The E-Stop can be triggered by pressing the RED button firmly.
CAUTION: Only use Emergency Stops in an emergency situation. Using the Stops as a conventional way to
kill power to the Catwalk may cause damage to the system.
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
When spotting the Catwalk visually check the area where the Catwalk will be placed and ensure it is free of
debris, that may cause damage to the Catwalk.
Before folding over the V-Door into position check to ensure the bolts on the Trunion Mounts are tight and in
place.
After hooking up the Catwalk to the rigs power source, a Qualified Electrician, should first ensure that the proper
voltage is being supplied to the Catwalks Main Panel (A).
• Before starting the Catwalk all initial inspections must be done and documented
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
INITIAL INSPECTION
• Check tightness of all Drive Chains, if loose refer to “Tightening Chains” in the Manuals Contents page
• Ensure all grease points have been properly lubricated as per the “Greasing” portion of this Manual
• Ensure all pins are in place and all Safety Pins are present
WARNING: Anything found during the Inspection should be properly fixed and documented before Catwalk
is operated. Not doing so could result in damage to the equipment and or injury to rig personnel.
• Check the Remote Control Antenna for any damage after a rig move and make sure it is securely fastened
• Check Hydraulic Tank and make sure it is filled, see filling Hydraulic Tank (Page 26)
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
• Before starting the Catwalk the Hydraulic Tank must be filled with the proper Hydraulic Oil depending on
the climate the Catwalk is operating at
• Filling the Catwalk with the incorrect oil may result in slow operation and damage to the Main Pump
• Fill fluid from the Main Fluid Cap located on the top of the DS of the Hydraulic Tank (A)
• Fill the tank until the oil has filled the top Sight Glass on the side of the Hydraulic Tank
Fill to Here
CAUTION: Only use clean Hydraulic Fluid to fill the Hydraulic Tank. Using contaminated oil will cause
Hydraulic System Failure and cause severe damage to the Catwalk.
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
OFF ON H
MOTOR ROTATION
• To check Motor Rotation follow steps above and then press the GREEN power button (1) on the panel and
quickly press the RED button (2) to kill the power
• Motor should be turning towards the Operator, if not wiring will need to be adjusted at the rigs power
source
1 2
CAUTION: If Catwalk is left ON with the motor rotating in the wrong direction, severe damage will be caused
to the Catwalk.
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
• Allow the Hydraulic Pressure to rise to 1500 psi, this is the Catwalks stationary pressure
A B C
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
A B
• Once Catwalk is lifted by the Leveling Jacks use wood or rig matting to support the Catwalk
CAUTION: It is critical that the Catwalk is very level both side to side and length ways. If Catwalk is not level
damages may occur during operation. Components that may be damaged include Front Arms, Rear Arms,
Skate System and Trough.
WARNING: Leveling Jacks MUST be fully retracted before the Catwalk can be moved. Failing to do so will
cause severe damage to the Leveling Jacks.
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
• The height of Pipe Racks that the Indexers will be picking the Tubulars from will determine which type of
Indexer Arms to use
• If the Indexer Arms are picking up Tubulars off of 18” Pipe Racks then the long Hockey Stick Style Indexer
Arms should be used; if the Pipe Racks are 48” tall and close to the Catwalk then the shorter Indexer Arms
may work better
• Once the Operator has chosen what Indexer Arm to use, he then must remove them from their transport
positions into the Indexer Arm Receivers located on the Driller Side of the Catwalk
• Remove the bottom pin on the Receiver and slide the Indexer Arm into place; once the arm is in place slide
the pin back through the Receiver and through the Indexer Arm locking it into position
• This is a two person job… always have help
A. The transport storage for the long Hockey Stick Style Indexer Arms
B. The long Indexer Arm once properly set up
C. Short Indexer Arm once properly set up
CAUTION: Not properly pinning the Indexer Arms may cause them to slip out causing damage to the Catwalk
and/or injury to the Operator and/or Tubulars. Always ensure the “Safety Pins” are in place.
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
• The Pipe Rack Casing Runs are generally located on the Driller Side of the Catwalk
• Depending on what height the Pipe Racks are the Operator may need to adjust the pin location of the arm
• The arms swing out and can extend towards the Pipe Rack
• The arms should be placed below the first row of Tubulars so that the Tubulars do not drop onto the arms
but gently roll towards the awaiting Indexer Arms
Reach Adjustment
CAUTION: Casing Runs must be securely positioned in between rows of Tubulars so that they do not fall out
when Pipe is being rolled across them causing damage to the equipment and or injury to personnel.
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
HYDRAULIC GULLWINGS
• The Hydraulic Gullwings are typically found on the Off Driller Side of the Catwalk
• Once un-pinned in the center they will swing out until they create a 90º angle between the Catwalk and
the Gullwings Arm (A)
• Once in that position the Gullwing Stopper Bars must be installed so that the Gullwing cannot swing back
towards the Catwalk (B)
• From the Auxiliary Valve Bank the Gullwing Leveling Jacks can be lowered, only lower the Leveling Jacks
until they touch the ground
• Now that the Gullwings are properly set up the Gullwing Stopper Pins must be installed as well as the End
Stopper Pins before any Tubulars are loaded
End Stopper
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
SKATE SYSTEM
1. Attaching the Pull Back Arm; this is used when pulling back Tubulars from the rig and laying them down
2. Attaching the Casing Hood; this is used when the Catwalk is picking up Tubulars so that the Tail End of
the Tubular does not jump out of the Trough when the Elevators are latched
When setting up the Retrieval Head, the Operator must check the following things:
NOTE: Once all components have been properly set up, the Operator should test the Catwalk to ensure all
functions are working properly. If issues are found the Catwalk should be shut down, locked-out and
evaluated before operating any further.
CAUTION: When operating the Catwalk for the first time, move all functions slowly until the Operator
knows where each function starts and stops and how it reacts to the movement from the Valve Bank.
Operating at full speed for the first time may result in equipment damage and or injury to the worker.
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
H
I G
A B C D E F
A. Main Lift Toggle: This controls the Front Arms, Rear Arms, and the Trough Extension. Moving it upwards will
command the Front and Rear Arms to lift. Once they have reached their programed height, the Trough will
extend from the base carriage
B. Skate Toggle: Controls the movement of the Skate inside the Trough
C. Driller Side Pipe Rack Indexer Toggle: Pick up Tubulars on the DS of the Catwalk
D. Driller Side Trough Kicker Toggle: Remove/Kickout Tubulars from the Trough to the Driller Side of the
Catwalk
E. Off Driller Side Trough Kicker Toggle: Remove/Kickout Tubulars from the Trough to the Off Driller Side of
the Catwalk
F. Off Driller Side Indexer Toggle: This controls the indexer inside of the Gullwing to load one Tubular at a time
G. Emergency Stop: This should only be used in an Emergency situation
H. Remote ON Indicator Light: When this light is illuminated it means the Remote Control is turned ON. When
this light blinks vigorously it may mean that the battery is getting low and needs to be changed
I. These two switches are used when the Operator chooses to program a new height for the Catwalk to ascend
to or adjust the trough presentation on the rig floor
J. The GREEN button is used to arm the Remote,
turn the Catwalk on, and also save the desired
programmed height into the Catwalks PLC J
System
L
K. Key to turn the Remote Control ON
K
L. These two buttons are used to turn the Catwalk
ON from the Remote
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
Before starting the Catwalk always make sure that the Catwalk is being supplied with the proper amount of
power.
NOTE: Remote System will only work when Selector Switch is turned to AUTO.
STEPS:
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
When programing the Catwalk to reach a new height or a rig floor presentation, the Operator must always use
the RED key. The Catwalk re-programing will not work with the BLACK key.
• The Operator will start the Catwalk with the RED key
only turning it 90º
• Once the Catwalk is started the Operator must “HOME” Program
the Catwalks PLC System Key
Now that the Catwalk has been “HOMED” the Operator can now start the process of programming a new height
for the Catwalk.
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
WRITTEN STEPS
1. With the Remote on, turn the RED key from 90º to 180º (the Remote will now be in program mode)
2. Press and hold the Front Lift & Rear Lift Selector to the Front Lift (1)
3. While holding the Selector to Front Lift use your other hand and push the Trough Lift Toggle upwards to
raise the Trough until it is at your desired height then release both the Front & Rear Selector and Trough
Lift Toggle Together
4. Press and hold the Front Lift & Rear Lift selector to the Rear Lift (2)
5. While holding the selector over to Rear Lift use your other hand and push the Trough Lift Toggle upwards
to raise the Rear Arms until they are at the desired height; then let go of both the Front & Rear Selector
and Trough Lift Toggle together
6. Press and hold the Extend Selector over to the Extend (3)
7. While holding the selector over to the extend, use your other hand to push the Trough Lift Toggle upwards
until the Trough has been extended to the desired distance. Once the distance has been achieved let go of
both the Extend Selector and the Trough Lift Toggle together (6)
8. The Catwalk should now be in the Operators newly set desired position
9. To save the position press and hold the GREEN button on the side of the Remote Control and move either
the Front Lift/Rear Lift or the Extend Selectors back and forth three times. The Catwalk should now be
programed to the desired height. (4)
10.Turn the RED key back to the 90º position and run the Catwalk down to the “Home” position. The Operator
should run a full cycle up and down with the Catwalk to ensure the program was set properly (5)
11.Once the Operator is satisfied with the program, he then must turn the Remote OFF and insert the BLACK
Operating Key
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
VISUAL STEPS
1 2
• Press and hold Front Lift Selector (1)
1 2
• Press and hold the Rear Lift Selector (1)
• While holding the selector press Trough
Lift Upwards until the Rear Arms are at
desired height (2)
• Once at the desired height let go of both
selectors together
Extending Trough
1 2
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HYDRAULIC CATWALK
OPERATION & MAINTENANCE MANUAL
Save Program
• Press the Trough Lift Toggle downwards to run the Catwalk back to its “Home” position
• Once in the “Home” position run the Catwalk back up to ensure the Catwalk is set to where the Operator
has programed it to
Operation
Program
• If the Operator is satisfied with the program of the new position, he must turn the Catwalk OFF, remove
the RED key and replace it with the BLACK Operating Key
• The Catwalk is now ready to run in regular operations
WARNING: When programing the Catwalk no one should be near the Catwalk and proper hand signals
should be visual while the Catwalk is ascending to the rig floor. If Operator cannot see hand signals then
radio contact should be present. Not doing so can result in damage to the rig and the Catwalk and may
cause severe injury or death.
CAUTION: When programing the Catwalk always move slowly to ensure Catwalk is at correct height so it
does not make contact with the rig floor. DO NOT program Catwalk if it is loaded with a Tubular or Tubular
product.
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CATWALK – INSPECTION & MAINTENANCE GUIDE
Nicholas Morelli
CUSTOM PIPE GLOBAL CONSULTING INC.
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CATWALK
INSPECTION & MAINTENANCE GUIDE
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CATWALK
INSPECTION & MAINTENANCE GUIDE
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CATWALK
INSPECTION & MAINTENANCE GUIDE
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CATWALK
INSPECTION & MAINTENANCE GUIDE
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HERCULES
HYDRAULIC CATWALK – PLC/HMI Troubleshooting Instructions
Nicholas Morelli
CUSTOM PIPE GLOBAL CONSULTING INC.
Revision 1
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HYDRAULIC CATWALK
PLC/HMI TROUBLESHOOTING INSTRUCTIONS
TABLE OF CONTENTS
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HYDRAULIC CATWALK
PLC/HMI TROUBLESHOOTING INSTRUCTIONS
HOME SCREEN
The Home Screen is the first screen one sees on the HMI. The current reading of the Position for each sensor is
displayed, as well as the commanded Speed. The position percentage is based on a full range of 4-20 mA, and
therefore not necessarily the fully in to fully out span.
There in an indicator on the right showing if the Emergency Stop is active, as well as error indicators showing if
an axis has gone too fast or too slow (FF = Front Scissor Fast, RS = Rear Scissor Slow, etc.). If one or more of
these are lit up, they need to be pushed to reset.
The “Auto_Man” switch controls how the catwalk will respond to the Remote Control “Main”. When switched
to “ON”, the “MAIN LIFT” paddle on the remote will control all configured axis (Front Scissor, Rear Scissor, and
Extend). Holding up on the paddle will first ramp the Front Scissor up to the High position, then ramp the Rear
Scissor, then the Extend. Holding down on the paddle will reverse the operation back to Home (Extend, then
Rear, then Front). With this switch “ON”, the paddle can be held at full.
ENSURE THAT THE CATWALK IS CONFIGURED TO PROPER HOME AND HIGH POSITIONS BEFORE USING AUTO
“ON”.
The buttons at the top of the screen will switch screens to a visual of the remote control, or the Position Settings
screen.
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HYDRAULIC CATWALK
PLC/HMI TROUBLESHOOTING INSTRUCTIONS
REMOTE CONTROLLER
The Remote Controller screen is a visual display of the remote. When a toggle or button is engaged on the
remote, the corresponding visual will go brighter. The value shown on the MAIN LIFT paddle is the voltage
output, showing the proportional control from that paddle. This is configured in the ranges of 1.5-4.5 V down,
and 5.5-8.5 V up. 1.5V is max down, and 8.5 is max up.
The proportional control from the remote is combined with the set speed for a particular zone to give the final
output speed.
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HYDRAULIC CATWALK
PLC/HMI TROUBLESHOOTING INSTRUCTIONS
POSITION SETTINGS
The Position Settings screen is where the Home and High values are generally set in the field. Move the catwalk
manually to the Home position, then press “Set Current Position as HOME”. Similarly, move the catwalk
manually to the desired final position, then press “Set Current Position as HIGH”.
The values displayed are based on a full range of 4-20 mA. They show the Home and High position settings, as
well as the current reading from the sensors.
The buttons at the top of the screen switch to the “Home Screen” or “Administrator Settings Start Screen”. The
Commissioning Settings button is Username and Password protected.
Some displays have a limit for incorrect entries. Ensure the username and password are correct.
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HYDRAULIC CATWALK
PLC/HMI TROUBLESHOOTING INSTRUCTIONS
The Administrator Settings Start Screen is an access point for further configurations.
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HYDRAULIC CATWALK
PLC/HMI TROUBLESHOOTING INSTRUCTIONS
SET TIME
The Set Time screen is where the PLC Date and Time is set. Enter the Date and Time in the format shown, then
press “Set” to send to the PLC.
The “Background Graphic” switch allows the background picture to be turned off on this screen and the Home
Screen.
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HYDRAULIC CATWALK
PLC/HMI TROUBLESHOOTING INSTRUCTIONS
The First Commission Screen allows initial testing of speed and direction for each axis. Enter a speed in to the
left of “Speed Setting %” text. Select which axis to move on the lower buttons, and then press UP or DOWN.
Start slow (eg. 15 -20) and move up from there. There is a minimum value typically in this range that will move
the axis, due to the value controller. Do not enter more than 100.
The current positions and actual commanded speed outputs are shown.
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HYDRAULIC CATWALK
PLC/HMI TROUBLESHOOTING INSTRUCTIONS
AUTORANGE SETTINGS
The AutoRange Setting screen sets the values for the Speed Zones based on the set Home and High values.
The calculated ranges are shown on the Speed Range Setting screens.
Always confirm the ranges on the individual Speed Ranges Settings screens to double check the adjustments
are appropriate.
Note the negative and positive values for the proper progression of ranges.
The values on this page can be entered manually by pressing on the I/O box showing the current value.
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HYDRAULIC CATWALK
PLC/HMI TROUBLESHOOTING INSTRUCTIONS
SPEED RANGES
The individual Speed Ranges are used with the settings on the Speed Settings screen for each Range. When an
axis is a range shown on this screen, it will use the corresponding speed setting to allow smooth transitions.
Several options are available for populating these values. Currently the lower left button shows “Disable Auto
Calculation”, which denotes that it is currently auto – calculating the values using the values set for Home and
High, and adding the values in the AutoRanging Screen. (i.e. The Home value was set to 2.34, either on this
screen or the Position Settings screen, and the High value was set to 56.52. The Low Limit is then auto calculated
as 2.34 + (-2.00) = 0.34. The Very Slow To High value is auto calculated to 56.52 + (-7.00) = 49.52. Other values
calculated accordingly.)
If the “Disable Auto Calculation” is selected it disables the auto calculation for all axes and will change the
button text to “Enable Auto Calculation”.
The ranges can be set in sequence by selecting “Initialize Setting Procedure”. The text box will request to move
axis to Low Limit. Move axis as requested, then select “Set Current Selection”; or enter a value next to “Manual
Entry” if current position is not as desired, then select “Manual Entry”. The value for the specific set point will
change and the text box will request the next range point. Continue until all ranges are complete, or select “Exit
Setup” at any point.
Each value can be entered manually as well. If auto calculation is enabled, only changes to Home or High will
be accepted.
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HYDRAULIC CATWALK
PLC/HMI TROUBLESHOOTING INSTRUCTIONS
SPEED SETTINGS
The Speed Settings screen allows adjustments for UP and DOWN speeds, separately for each range. The speeds
entered above are for the corresponding range in text between the UP and DOWN values.
Also on this screen is an entry for “Max Measured Speed Limit”, which reads if there is a runaway. It is a
representation of the Percentage Change in Axis per Second. This should be set high enough to avoid any
nuisance errors.
In the bottom right of the screen, the “Ramp” value allows adjustments to the rate of change in speed when
entering a new zone. A higher value changes quicker, a lower value changes slower. If the ramp is too slow, the
axis may not reach the set speed by the end of the current zone. This would be most important to watch for at
the Home and High positions.
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HYDRAULIC CATWALK
PLC/HMI TROUBLESHOOTING INSTRUCTIONS
ALARMS
The Alarm screen will pop up when any alarm appears, with a time stamp based off the HMI time (set in the
Control Panel of the HMI before the program runs). It shows a description of the alarm, as well as the Status.
The Status will show an “I” for Incoming alarms when an alarm occurs. If the alarm condition is removed the
Status will add an “O” for the Outgoing indication, showing “IO”. If the alarm is then acknowledged by the
selecting the Green Check Mark icon at the bottom right of the pop up, the alarm will disappear from the list.
If an alarm is acknowledged while the condition is still active the Status will show “IA” for Incoming
Acknowledged, and will disappear when the condition is removed.
A small icon appears showing a warning sign and the number of currently active unacknowledged alarm
conditions. It can be moved with drag ‘n’ drop to anywhere on the screen, and will disappear when all alarms
are outgoing and acknowledged.
The main alarm pop up can be moved on the screen, or closed with X in the top right corner. To reopen the pop
up, select the alarm indication warning icon. If the icon is not present, there are no alarms to acknowledge.
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HYDRAULIC CATWALK
PLC/HMI TROUBLESHOOTING INSTRUCTIONS
The Output Trend screen shows a 100 second snap shot of the current PLC output command of each axis, and
was used in testing.
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HYDRAULIC CATWALK
PLC/HMI TROUBLESHOOTING INSTRUCTIONS
GENERAL REVIEW
BASIC CUSTOMER SETUP
When setting to a new height: Set the Auto_Man to off go to the Position Setting screen, move all axes manually
to desired Home then “Set Current Position as Home”, then move all axes manually to High position and “Set
Current Position as High”. Return all axes to Home manually before switching to auto.
The High position can also be set by holding the ARM/SET button on the Remote for 10 seconds.
ADMINISTRATOR SETUP
The Administrator Setup will initially be done at the factory during commissioning.
Ensure the “Auto_Man” switch on the HMI is “OFF” for manual control.
Use the manual hydraulics to move the catwalk into a middle range area. Go to the First Commission screen
and test all axes for direction and speed control.
Move the catwalk manually to a temporary Home position above the hard limit down, to give room for
overshoot while configuring speeds. Set position to Home.
Move catwalk manually to a temporary High position below the hard limit up, to give room for overshoot while
configuring speeds. Set position to High.
Ensure there is a wide enough range between Home and High so that all Speed Ranges can be used.
Check all Speed Ranges and Speeds for proper values. The ranges should not overlap and the speeds should be
lowest near the limits and highest in “Fast” range, similar to the example shown on the Speed Settings
screenshot.
Enable the Front toggle on the Remote and push the MAIN LIFT paddle all the way up. The Front Scissor should
ramp up and down through the speeds and ranges, and stop just past the temporary High position. Be ready to
let go of paddle and stop the hydraulic paddles or E-Stop. Adjust speeds and/or ranges as necessary. Push the
MAIN LIFT paddle all the way down and watch the ramping on the way down. The Front Scissor should stop just
past the temporary Home position.
Start with ranges large enough so that the speed visibly finishes ramping to the new speed, and the overshoot
of Home and High is as small as possible (~0.5%). The ranges and speeds can then be fine-tuned for smooth
motion.
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HYDRAULIC CATWALK
PLC/HMI TROUBLESHOOTING INSTRUCTIONS
The axes will have a minimum value for the Speed Setting that will move the axes. This value will be higher
when moving from a standstill.
Repeat the above individual testing for the Rear Scissor, then the Extend, as was done with the Front Scissor.
When finished, manually return the axes to the temporary Home.
Hold the MAIN LIFT paddle on the Remote all the way up and watch the Front Scissor ramp to High position.
Keep holding the paddle all the way up and the as the Front Scissor enters its Very Slow to High range the Rear
Scissor will start to ramp up. When the Rear Scissor enters its Very Slow to High range, the Extend will start to
ramp up and proceed to its High Position.
Hold the MAIN LIFT paddle all the way down and the catwalk will return to home with ramping and overlapping.
Once operation is satisfactory, set the actual Home and High positions desired and test the speeds into the hard
stops.
Return to the Home Screen to exit commissioning. The login will last 1 hour from the time the Username and
Password are entered, but will only need to be re-entered if entering the Administrator Settings screen from
the Position Settings screen after the time expires.
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