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AC Gear Driven Drawworks

Operation and Maintenance Manual

Model: LDW1000K1003 Serial Number: 141

Cosco Shipyard Energy Drilling - N490

PO 49012E001752 SO 2404947

Disclaimer

The information in this publication is subject to change without notice.

Improvements in design, engineering, materials, production methods, etc. may necessitate changes to the product and may result in inconsistencies between the numeric values, figures, and descriptions in this publication and the physical equipment. Cameron reserves the right to make any and all changes deemed necessary.

Although the author and publisher have made every effort to ensure that the information in this publication was correct prior to release, the author and publisher do not assume and hereby disclaim any liability to any party for any loss, damage, or disruption caused by errors or omissions, whether such errors or omissions result from negligence, accident, or any other cause.

Copyright

© 2013 Cameron. All Rights Reserved.

This document contains material protected under International and Federal Copyright Laws and Treaties. Any unauthorized reprint or use of this material is prohibited.

No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without express written permission from Cameron.

Trademarks

The following are registered trademarks or trademarks of Cameron, and/or its subsidiaries and/or affiliates in the USA and other countries:

LEWCO™ OEM™

All other brand names, product names or trademarks belong to their respective holders.

Published By

Cameron Drilling Systems 6401 W. Sam Houston Parkway N. Houston, TX 77041 Tel: 832.782.6500, Tel: 713.983.4700

Revision History

Document No.: DS-DW-OMM

Revision Level Date Description of Change

04 05/07 Style and Formatting

05 12/10 Modified Document Layout

06 12/10 Style and Formatting

07 07/11 Branding and Formatting Update, Changed Grease Specifications

08 04/12 LeTourneau to Cameron Branding Change, removed procedures for Johnson brakes, added performance curves, performance and equipment specifications

09 07/12 Corrected result of sample calculation and removed “per inch of length or diameter” from definition of coefficient of steel expansion in the Hub Replacement section. Updated Contact Information section.

10 09/12 Added loss of electrical power and block calibration to the emergency lowering procedure. Added lube oil capacities to the Lubrication and Utility Requirements sections. Updated table formatting.

11 04/13 Added Annual Maintenance Section with brake holding test instructions. Added brake holding test item to the Maintenance After Moving section. Minor formatting changes.

AC Gear Driven (K-Series) Drawworks DS-DW-OMM-11

iii

Table of Contents

Introduction ....................................................................................................................................................... 1

Conventions ....................................................................................................................................................... 1

Contact Information ........................................................................................................................................... 1

Warranty and Liability Information ...................................................................................................................... 2

Equipment Overview ........................................................................................................................................... 2

Safety Provisions ................................................................................................................................................. 4

Functional Description ......................................................................................................................................... 5

Equipment Specifications .................................................................................................................................... 6

Performance Curves ............................................................................................................................................ 7

Utility Requirements .......................................................................................................................................... 10

Shipping and Handling ...................................................................................................................................... 15

Lifting .............................................................................................................................................................. 15

Installation ........................................................................................................................................................ 17

Inspection ......................................................................................................................................................... 17

Mounting ......................................................................................................................................................... 18

Assembly .......................................................................................................................................................... 19

Lubrication ....................................................................................................................................................... 22

Commissioning ................................................................................................................................................. 24

Operation ......................................................................................................................................................... 25

Safe Operating Practices ................................................................................................................................... 25

Control System ................................................................................................................................................. 25

Braking System ................................................................................................................................................. 26

Operating Pressures .......................................................................................................................................... 27

Operating Temperatures ................................................................................................................................... 28

Emergency Lowering Procedure ........................................................................................................................ 30

Maintenance .................................................................................................................................................... 33

Initial Maintenance ........................................................................................................................................... 34

Daily Maintenance ............................................................................................................................................ 34

Weekly Maintenance ........................................................................................................................................ 35

Monthly Maintenance ....................................................................................................................................... 36

Annual Maintenance ........................................................................................................................................ 37

Maintenance After Moving ............................................................................................................................... 38

Overhaul ........................................................................................................................................................... 38

Replacement of Parts ........................................................................................................................................ 39

Preservation and Storage .................................................................................................................................. 43

Preservation Procedure ..................................................................................................................................... 43

Storage Recommendations ............................................................................................................................... 44

Torque Specifications ........................................................................................................................................ 45


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Introduction

This manual provides general instructions to install, repair, maintain, and adjust the LEWCO™ K-Series Drawworks. The information is intended for operators and service personnel who are familiar with drilling equipment. It will not cover every situation that may be encountered.

This manual provides information pertaining to the basic Drawworks design. Each Drawworks is a combination of a basic design and optional features and accessories. Information on optional features and accessories can be found in the Accessory Manuals in the final documentation package for each Drawworks.

Conventions

WARNING, CAUTION, and NOTE statements are used throughout this document to emphasize important and critical information relating to the handling, installation, operation, and maintenance of the equipment. These statements must be read any time they appear, in order to ensure personal safety and prevent equipment damage.

WARNING

Warnings indicate the potential for catastrophic damage to equipment or the environment and severe personal injury, including

loss of life.

CAUTION

Cautions indicate the potential for damage to equipment or the environment.

NOTE

Notes provide additional information for reliable and efficient handling, installation, operation, and maintenance of equipment.

Contact Information

Mailing Address: Cameron Drilling Systems

6401 West Sam Houston Parkway North

Houston, Texas, USA 77041

Phone Resources: 1-713-983-4700 (Main)

1-866-972-6742 (24 Hours Toll-Free)

1-832-782-6742 (24 Hour Local)

Web Resources: [email protected] (Part Sales Email)

[email protected] (Customer Service Email)

mailto:[email protected]

mailto:[email protected]


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Warranty and Liability Information

Equipment warranties are specified in the purchase contract. Failure to follow operation and maintenance instructions or making aftermarket modifications may invalidate third party certifications and void the equipment warranty.

Equipment Overview

Specifications are in accordance with engineering design and should be followed in all repairs. Operation and maintenance information for equipment other than Cameron products is taken, in part, from the various manufacturers’ service manuals. In the event of conflict between this manual and component manufacturer’s information, the manufacturer’s information will take precedence over this manual unless specifically stated otherwise.

Cameron reserves the right to change, discontinue, or modify Drawworks models at any time without notice and without incurring any obligation.

Prior to shipment, Cameron personnel perform a functional test on the Drawworks, and all related mechanical components, for an extended period to verify that the Drawworks and components operate in accordance with the following requirements:

• The complete Drawworks is aligned and all locating pins, or chocks, are secured.

• All mechanical and air or hydraulic control systems are operable and functionally checked.

• The lubrication system, air system, and brake pressures are checked and inspected.

• The brake discs and pads are burnished and the brake torque checked to ensure full braking capability.

• Guards, covers, and inspection openings are checked to ensure that the proper safety measures are in place.

WARNING

Guards, covers, and doors serve as enclosures for the gearbox, provide safety protection for personnel, and prevent foreign

material from entering the working parts. They should be closed and in place when the Drawworks is operating and should only be

opened for Drawworks service.

Use sound mechanical practices and proper safety precautions at all times. It is the owner/operator’s responsibility to obtain proper instruction and to train personnel in the safe operation and maintenance of the Drawworks, motors, control, and accessory components.

WARNING

Use of inadequately trained or unprepared personnel could result in damage to equipment and serious personal injury or loss of life.


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Drawworks operation can require more than 80 gallons of oil for servicing and maintenance. Emphasis should be placed on environmental protection and practical resource conservation with a minimization of wastes, emissions, and releases.

The Drawworks should not be operated with any suspected failure. If damage is suspected, have it inspected by qualified service personnel. Additionally, dangerous voltages or currents may exist in the main motors, lube pump, heater, and cooling fan motor. Power should always be disconnected before any maintenance or servicing.

Prior to performing maintenance or service on the LEWCO™ Drawworks:

1. Read this manual in its entirety.

2. Shut down or disengage the equipment’s power source.

WARNING

Failure to shut down power before servicing can result in damage to equipment and serious injury or loss of life to personnel.

3. Ensure personnel are adequately trained and have all updated documentation.

WARNING

Use of inadequately trained or unprepared personnel could result in damage to equipment and serious personal injury or loss of life.

4. Ensure the control system is properly integrated with the Drawworks and its component systems. Proper control system integration is critical to the safe and efficient operation of the Drawworks in accordance with the equipment specifications. Control system integration is the responsibility of the owner/operator and the manufacturer of the chosen control system. Cameron is neither responsible nor liable for any damage or injuries that may result from the use of the Drawworks without proper control system integration.

WARNING

Failure to properly integrate the chosen control system with the Drawworks can result in damage to the equipment, severe personal

injury, or loss of life.

5. Ensure equipment operators are properly trained in the use of the chosen control system. Even if the Drawworks is properly integrated with the chosen control system and the control system functions properly, errors in operation or operating in a manner other than in strict conformance with the control system manufacturer’s instructions, unpredictable operation or failure of the Drawworks can occur. Cameron is not responsible for any damage or injuries resulting from malfunctions or errors in the operation of the control system.


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Safety Provisions

The following safety provisions, as well as all applicable local, regional, or national health, environmental, and safety regulations, should be adhered to at all times. When there is a discrepancy between regulations and the information presented in the manual, the applicable regulations should always override.

In addition to the following provisions, proper training, precaution, and good judgment should always be followed when operating, maintaining, or repairing equipment.

1. NEVER start any task without being completely familiar with the safety techniques that apply to it.

2. ALWAYS obey WARNING signs. WARNING signs and provisions help to prevent accidents. Remind others to obey WARNING signs as well.

3. NEVER disable guards, safety systems, or switches to any equipment for any reason.

4. Wear proper eye protection, such as safety glasses or goggles.

5. Remove jewelry, such as rings, watches, necklaces, etc.

6. Personnel should always wear Personal Protective Equipment (PPE) such as steel toe footwear, hard hat, etc. Ensure PPE clothing is available if the task requires such protection.

7. ALWAYS wear and properly secure a safety harness when working at an elevated level.

8. Turn off and lock-out any electrical power prior to performing any task on electrical equipment.

9. Turn off and bleed down any hydraulic pressure prior to performing any task on any hydraulic equipment.

10. Avoid working with loose tools or components directly above any other people.

11. ALWAYS ensure heavy and/or overhead components being removed or installed are moved and lifted with the proper equipment and the equipment is properly secured.

12. ALWAYS use the appropriate tools. NEVER use a tool for a purpose it is not designed for. NEVER modify any tool.

13. NEVER allow personnel to “ride” the hoisting equipment.

14. NEVER exceed the lifting capacity of the Drawworks.

15. ALWAYS use the correct reeving for the load.

16. NEVER use the motor to leave or suspend the traveling block for an extended period of time. Set the emergency brake on the Drawworks if it is not operating.

17. ALWAYS ensure that the brake is holding the load before releasing the motor power.

18. NEVER leave the Drawworks controls unattended with a suspended load.

19. Properly service and inspect the brakes, hoist, hoisting gear, and controls at the beginning of each tour and before starting each trip.

20. Move loads smoothly without sudden starts or stops. Know the position of the traveling block in the derrick at all times.

21. Service and check the hoist when a load approaching the rated load is anticipated, as well as after the load is removed.

22. Place the load on a firm support, such as a casing spider or slips in the rotary table.


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Functional Description

The exact version of the Drawworks being provided can be determined by reviewing the Unitization drawing in the Parts Catalog. Each Drawworks has a unique serial number assigned. The serial number is placed on the nameplate located on the Driller’s Side (DS) of the Drawworks frame. All inquiries concerning the Drawworks should include this serial number.

Recommendations for rig up, operation, and maintenance of Cameron drilling equipment are based on the knowledge and experience of Cameron engineers and operating personnel. Following these recommendations will result in better overall equipment performance and increased operating life.

The LEWCO™ K-Series Drawworks is a gear driven, single speed, skid mounted unit, powered by AC drive motor(s), and includes the following:

• A hoisting drum mounted on a heavy duty shaft with two brake discs

• A shaft that supported by two large self-aligning spherical roller bearings with provisions for a splined coupling (hub) to connect an optional auxiliary brake

• Variable Frequency Drive (VFD) motors coupled to a constant engagement gearbox

• The motors are capable of raising and lowering the load when operated by the proper control system and connected to sufficient power dissipation equipment

• A transmission shaft, coupling the gearbox to the drum shaft

• Spring applied, air or hydraulic released, caliper brakes

• The spring brakes are applied by actuating the emergency shutdown button, by loss of electric power, or by various functions of the operating system (refer to purchase specifications for details)

• An optional auxiliary brake, coupled to the drum shaft through a manually shifted splined coupling

• All necessary hydraulics, lubrication, cooling, and instrumentation

This product is supplied in accordance with the buyer’s specifications and does not necessarily include all accessories and safety devices required to put this product into operation. Power equipment and safety devices such as, but not limited to, motors and controls, rotating equipment guards, cables, and wrenches are available from other suppliers.


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Equipment Specifications

Table 1: Performance Specifications*

Model LDW550K LDW750K LDW1000K LDW1500K LDW2000K

Hook Load (lbs) 550,000 750,000 1,000,000 1,500,000 2,000,000

Drum Diameter x Length (Inches) 25 X 49 27 X 56-1/4 30 X 56-1/4 36 X 72/82** 42 X 82

Wire Rope Diameter (Inches) EE IP 1-1/8 1-1/4 1-3/8 1-5/8 1-7/8

Wire Rope Diameter (Inches) E IP 1-1/4 1-3/8 1-1/2 1-3/4 2

No. Lines Strung / Hook Load (lbs)

10/550K 12/750K 12/1000K 14/1500K 16/2000K

8/455K 10/648K 10/860K 12/1330K 14/1810K

6/356K 8/538K 8/715K 10/1150K 12/1610K

Layer for Max. Hook Load 2 2 2 2 3

Maximum Torque on Drum (ft.-lbs) 82,900 105,600 155,400 247,600 347,500

Motor HP/Size 1500 1150 1500 1500 1500

No. of Motors 1 2 2 3 4

No. Gearboxes/Ratio 1/7.51 1/7.51 1/7.51 1/7.51 2/9.1

Rated HP 1500 2300 3000 4500 6000

Alternate Motors HP/Size 1150 1500 1150 1150 1150

No. of Alternate Motors 2 1 3 4 6

No. of Alternate Gearboxes/Ratio 1/7.51 1/9.1 1/7.51 2/7.51 2/7.51

Brake Caliper Model 60HHA 60HHA 60HHA 60HHA 60HHA

No. of Brake Calipers 2 4 4 6 8

Brake Disc Dia. (inch) 68 68 71 80 90

Optional Auxiliary Brake

Eaton Brake Model WCB336 WCB336 WCB436 WCB336 WCB348

No. of Auxiliary Brakes / Air Pressure (PSI) 1/85 1/102 1/115 2/115 2/78

Alternate Eaton Brake Model WCB248 WCB248 WCB4248 WCB348 WCB448

No. of Auxiliary Brakes / Air Pressure (PSI) 1/55 1/66 1/99 1/99 116

* All specifications are subject to change. Information important to a particular application should be verified by Cameron. ** Drawworks model LDW1500K is offered with two available options for drum size, 36" x 72" and 36" x 82".


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Performance Curves

The following performance curves are based on standard equipment configurations. If components or equipment specifications deviate from the standard configurations indicated, differences in performance may result.

Figure 1: LDW550K Performance Curves


0

100

200

300

400

500

600

0 50 100 150 200 250 300 350 400

Hoo

k Pu

ll (1

000

lbs)

Hook Speed (ft/min)

LDW550K AC Gear Driven Drawworks 25" Bare Drum, 1-1/8" Wire Rope, Second Layer,

One 1500HP OEM™ AC Motor

10 Lines8 Lines6 Lines

0

100

200

300

400

500

600

700

800

0 50 100 150 200 250 300 350

Hoo

k Pu

ll (1

000

lbs)

Hook Speed (ft/min)

LDW750K AC Gear Driven Drawworks 27" Bare Drum, 1-1/4" Wire Rope, Second Layer

Two 1150HP OEM™ AC Motor

12 Lines10 Lines8 Lines


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0

200

400

600

800

1000

1200

0 50 100 150 200 250 300 350 400

Hoo

k Pu

ll (1

000

lbs)

Hook Speed (ft/min)


Two 1500HP OEM™ AC Motors

12 Lines

10 Lines

8 Lines

0

200

400

600

800

1000

1200

1400

1600

0 50 100 150 200 250 300 350

Hoo

k Pu

ll (1

000

lbs)

Hook Speed (ft/min)


Three 1500HP OEM™ AC Motors

14 Lines

12 Lines

10 Lines


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0

500

1000

1500

2000

2500

0 50 100 150 200 250 300

Hoo

k Pu

ll (1

000

lbs)

Hook Speed (ft/min)

LDW2000K AC Gear Driven Drawworks 42" Bare Drum, 2" Wire Rope, Third Layer

Four 1500HP OEM™ AC Motors

16 Lines

14 Lines

12 Lines


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Utility Requirements

Specific requirements for water, air, oil, and electricity depend on the type and model of the Drawworks and its accessories. Water and air or hydraulic connections, marked with appropriate name plates, are located on the Drawworks skid. Refer to the drawings included in the Parts Catalog and the component information included in the Accessory Manuals for additional details.

Table 2: LDW550K Utility Requirements

Model LDW550K

Rig Air Requirements

Minimum Air Pressure 120 PSI

Minimum Air Flow 100 CFM

Gearbox Requirements

Gearbox Heat Exchanger Fan Motor 3 HP, 460 VAC, 3 Phase, 60 Hz Standard

Gearbox Lubrication Oil ANSI/AGMA 9005-EO2

ISO VG 220 EP FZG>12

Lube Oil Sump Capacity 69 US Gallons (261 L)

Gearbox Lubrication Oil Temperature 100°F to 130°F (38°C to 54°C)

Electrical Requirements

Lube Oil Pump Motor 7.5 HP, 460 VAC, 3 Phase, 60 Hz

Lube Oil Heaters 460 VAC, 1 kW, 3 Phase, Type 5 DPST Thermostat

Drive Motor One OEM 1500 HP AC Motor

Drive Motor Blower 20 HP, 460 VAC


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Model LDW750K





Gearbox Heat Exchanger Coolant Flow 70 GPM

Gearbox Heat Exchanger Coolant Fresh Water or Fresh Water/Glycol Mixture

Maximum Coolant Inlet Pressure 150 PSI

Maximum Coolant Inlet Temperature 100°F (38°C)



Single Motor Gearbox Lube Oil Sump Capacity 69 US Gallons (261 L)

Double Motor Gearbox Lube Oil Sump Capacity 80 US Gallons (303 L)



Lube Oil Pump Motor 10 HP, 460 VAC, 3 Phase, 60 Hz

Lube Oil Heaters (Qty 4) 460 VAC, 1 kW, 3 Phase, Type 5 DPST Thermostat

Drive Motor Two OEM 1150 HP AC Motors

Drive Motor Blower 460 VAC, 15 HP


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Model LDW1000K





Gearbox Heat Exchanger Coolant Fresh Water or SAE 40 Oil

Gearbox Heat Exchanger Coolant Flow 50 GPM with Fresh Water

36 GPM with SAE 40 Oil


Maximum Coolant Inlet Temperature 100°F (38°C) with Fresh Water

150°F (66°C) with SAE 40 Oil



Gearbox Lubrication Oil Viscosity Index 160



Lube Oil Pump Motor 10 HP, 230-460 VAC, 3 Phase, 60 Hz



Drive Motor OEM 1500 HP AC Motors, 575 VAC, 40 Hz

Lube Oil Pump Motor 230-460VAC, 40 Hz

Heaters Four Heaters with Type 5 DPST Thermostat, 460 VAC, 1 kW

Auxiliary Brake Requirements

Eaton Brake Coolant Fresh Water or Fresh Water/Glycol Mixture

Eaton Brake Minimum Coolant Flow

260 GPM with 100% Water

304 GPM with 70/30 Water/Glycol Mixture


Maximum Internal Coolant Pressure 40 PSI

Minimum Coolant Inlet Temperature 45°F (7°C)

Maximum Coolant Outlet Temperature

150°F (66°C) with 100% Water

165°F (74°C) with 70/30 Water/Glycol Mixture


Inlet to Outlet Temperature Difference < 50°F (10°C)

Maximum Heat Rejection 3900 HP


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Model LDW1500K











Maximum Gearbox Heat Exchanger Heat Rejection 113 HP









Drive Motor Three OEM 1500 HP AC Motors, 575 VAC, 40 Hz

Drive Motor Blowers 20 HP, 460V

Lube Oil Pump Motor 230-460VAC, 60 Hz

Heaters Four Heaters with Type 5 DPST Thermostat, 460 VAC, 1 kW

Auxiliary Brake Requirements









150°F (66°C) with 100% Water






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Model LDW2000K



Minimum Air Flow 200 CFM per Gearbox

Gearbox Requirements*







Gearbox Heat Exchanger Motor 3 HP, 460VAC, 3 Phase, 60 Hz









Drive Motor OEM 1500 HP AC Motors, 600 VAC, 60 Hz

Lube Oil Pump Motor Two Lube Oil Pumps per Gearbox 10 HP, 230-460VAC, 3 Phase, 60 Hz

Gearbox Heat Exchanger Motor One Heat Exchanger per Gearbox 3 HP, 460VAC, 3 Phase, 60 Hz

Heaters Four Heaters per Gearbox with Type 5 DPST Thermostat,

460 VAC, 1 kW

Auxiliary Brake Requirements**









150°F (66°C) with 100% Water





* Utilities listed are for one gearbox. The LDW2000K Drawworks includes two separate gearboxes. ** Utilities listed are for one brake. The LDW2000K Drawworks includes two brakes. Each brake has its own inlet and outlet.


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Shipping and Handling

During transport the equipment should not be submerged in water, exposed to excessive vibration, or allowed to collide with other equipment or property. This may cause severe damage to the equipment making it unsuitable for use at the site of commissioning.

The specific procedures for the transport of this equipment are dependent upon the freight forwarding service contracted for each customer order. Freight forwarders have specific procedures deemed appropriate for transportation of the items they are contracted to deliver. The freight forwarder should be contacted for specific information on securing and transporting the equipment.

Each Drawworks is secured to a master shipping skid that is designed for the lifting, handling, and transport requirements of the equipment. All openings, vents, and connection points are covered or heat shrunk. All covers, levers, and loose components are banded to the master shipping skid. The packaging of the equipment should not be altered or removed before the equipment is to be commissioned.

Packing or crating of equipment is prepared according to the customer purchase specifications. If no specifications are provided, the Drawworks will be prepared for shipment according to Cameron shipping and preservation guidelines.

Upon receipt of the equipment, the equipment should be identified and inspected for damage, taking care to ensure that the packaging is not disrupted. Disruption of the packaging may result in exposure of the equipment and its components which may cause damage and result in impairment of equipment operation upon commissioning. If any damage to the equipment is found, contact Cameron personnel immediately for further assistance.

CAUTION

Disruption of the packaging may result in exposure of the equipment and its components which may cause damage and result in impairment of

equipment operation upon commissioning.

Lifting

All operations must be compliant with international standards. The lifting capacity of the machinery used for lifting this equipment must exceed the weight of the equipment as specified on the freight documents. Failure to use adequately rated machinery or improper lifting procedures may result in damage to property and severe personal injury.

Equipment should be lifted according to the general lifting arrangement shown in Figure 6. Any ship-loose items should be handled with a forklift of appropriate load capacity according to the weight of the ship-loose crate on the freight documents.


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WARNING

All bolted connections on the equipment must be properly secured. Failure to properly secure the equipment and all associated

components can result in property damage and severe personal injury, including loss of life.

WARNING

Lifting capacity of all lifting gear must accommodate the actual weights given on the freight documents. The preliminary weights

given in this and other project documents may not match the exact weight of the equipment upon delivery. Failure to use adequately

rated lifting gear can result in damage to property and severe personal injury, including loss of life.

Figure 6: Lifting Arrangement


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WARNING

Ensure sufficient clearance to other items and structures when lifting to avoid damage to property and severe personal injury, including loss

of life.

WARNING

Always wear approved personal protective equipment, such as safety glasses, steel toe footwear, and hard hat when lifting or handling any

equipment to avoid severe personal injury or loss of life.

Installation

Recommendations for rig-up, operation, and maintenance of the LEWCO™ Drawworks are based on the knowledge and experience of Cameron engineers and operating personnel. Following these recommendations will result in better overall rig performance and increased equipment operating life.

Inspection

Inspect the Drawworks at each rig-up or rig-down, using the following instructions:

1. Inspect the Drawworks to ensure that all components are in place and check for wear or damage. Replace worn or damaged components as necessary.

2. Inspect the Drawworks skid for signs of damage, particularly bending of the skid. This can cause misalignment resulting in serious wear or damage to the operating parts. Failure to repair damage to the skid can lead to dangerous operating conditions unless corrected.

3. Verify that all securing bolts are tight. Tighten as needed.

4. Make sure that all covers are in place and secured.

5. Inspect the brake system for corrosion that might prevent or obstruct the movement of the brake parts.

6. Check the oil level of the HPU reservoir. See the Johnson User’s Manual in the Accessory Manuals for additional information on HPU inspection.

7. Open the air tank release valve, shown in Figure 7, located on the outside of the skid or under the rig floor (depending on the installation requirements). Hold the valve open for at least five seconds to drain any water that may have accumulated in the tank.

8. Release the bleed valves in the air filter, as shown in Figure 8, to drain any water that may have accumulated in the line.

Figure 7: Air Tank Release Valve


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Mounting

The Drawworks relies on the support structure to provide the rigidity required to prevent deflection during operation. The support structure must be flat and correctly sized to provide the necessary cross section and rigidity. Contact Cameron for assistance.

The weight and operating loads of the Drawworks are distributed in the skid mounting points under the Drawworks, the gearbox, the drive motors, and the auxiliary brake. See the Drawworks Tie-Down information in the Parts Catalog for details.

Mount the Drawworks using the following instructions as a guide:

1. Align the Drawworks with the centerline of the well in accordance with the Unitization drawing in the Parts Catalog.

Secure the Drawworks to the substructure, either with bolts or clamp plates, on the front and rear skid beams of the Drawworks frame at the following locations:

• Under each Drawworks side plate • Under the auxiliary brake • Under the gearbox • At the skid ends

Use stops and location blocks to help relocate the Drawworks after each move.

See the Drawworks Tie-Down or Drawworks Frame and Skid drawing in the Parts Catalog for specific tie-down locations.

CAUTION

The Drawworks cannot be aligned until it is properly attached to the substructure. If an alignment is attempted before it is attached to

the substructure, the Drawworks’ components can be pulled out of alignment, which could cause an unsafe condition, erratic operation, premature wear, and damage to equipment.

Figure 8: Air Filter Bleed Valves


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If substructure support beams are not flat and true, shim the contact areas between the Drawworks skid beams and the substructure beams.

NOTE

Take care not to distort the Drawworks frame during tie-down. The Drawworks was manufactured and aligned while resting on a true

flat surface.

If the Drawworks is built as a split skid design, both skids have to be aligned, shimmed, and dowel pinned together, and the tie bolts must be properly tightened according to the Torque Specifications section.

NOTE

On permanent installations (offshore rigs), the Drawworks beams may be welded to the substructure at the same locations. Contact

Cameron before performing any welding.

Assembly

Ensure that the block is strung properly, and then finish the Drawworks installation by using the following assembly instructions:

1. Remove the brake cover from the side of the main drum containing the wireline dead end slot.

2. Slide the end of the line through the slot provided in the drum flange.

3. Slip the main drum wireline clamp over the end of the line, and secure the bolts attaching the clamp. (See the Torque Specification table for recommended torque specification)

4. Make sure that a length of line equivalent to 2- or 3-line diameters extends beyond the clamp.

5. Slide the line back though the drum flange until the clamp is properly seated in the socket of the drum flange.

6. Install a line clamp retainer on each side of the line clamp.

7. Replace the brake cover.

8. When setting the deadline anchor, 12 to 14 wraps (coils) of wire line should be left on the drum when the block is in the lowest operating position.

9. If the Drawworks is installed on an offshore drilling rig with a heave compensator, leave extra line on the drum to allow for the heave compensator requirement.

10. Remove the caps protecting the control and service line connection points.

11. Inspect the ends of the lines, and remove any debris that may have entered.


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NOTE

The Drawworks is shipped with all connection points for control and service lines capped or plugged to protect them

from damage, dirt, or other debris. These lines should be capped or plugged whenever the Drawworks is moved.

12. Make sure that these connections are properly made up to prevent leaks and to provide proper control. The rig system will compensate for a moderate leakage of air or water, but the leakage will cause an unnecessary demand on the rig supply.

WARNING

Improper utility connections can cause a serious or deadly operating condition that could result in damage to equipment, serious personal


13. Connect the Drawworks to the driller’s console and to other rig systems as required.

14. Be sure the air or hydraulic and electrical connections are properly made-up and sealed to ensure proper and safe operation.

15. Connect the electrical service in accordance with the appropriate codes. Loose or improperly made electrical connections could cause improper signal transmission, fire, or explosion.

WARNING

Improper utility connections can cause a serious or deadly operating condition that could result in damage to equipment, serious personal


16. Verify that all connections are properly made, the covers are in place, and all bolts are tight with proper torque.

17. If the Drawworks is a split skid design, connect the skids together using the dowel pins and bolts provided as outlined in the following instructions:

17.1. Inspect the end of the skids and remove any debris.

17.2. Slide the skids together using the dowel pins for alignment.

17.3. Use shims to ensure that the Drawworks skid is flat and level with the substructure. Use shims to take up any gap between the Drawworks skid and the substructure. NEVER pull the Drawworks beams down to the substructure.


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CAUTION

The Drawworks frame can be distorted if pulled down to the substructure, causing the Drawworks’ components to be pulled out

of alignment, resulting in a potentially unsafe condition, erratic operation, premature wear, and damage to equipment.

17.4. Tighten the bolts to the proper torque as indicated in the Torque Specifications section.

17.5. Install the coupling shaft between the main drum and the gear box output shaft.

17.6. Make sure that the coupling shaft is aligned properly as shown on the Gear Drive drawing in the Parts Catalog.

17.7. Before reusing nuts and bolts, inspect them to make sure that they are in good condition and suitable for use. Those that are found to be unsuitable should be replaced. Torque the bolts to the values shown for the particular brand of coupling, as indicated on the Gear Drive drawing in the Parts Catalog.

18. Spool the wire rope on the drum

19. Verify that all covers, guards, etc. are in place and there is no loose equipment or tools around the Drawworks.

20. Align the auxiliary brake using a dial indicator. Make sure the two spline hubs are concentric and axially aligned as shown in Figure 9.

Figure 9: Auxiliary Brake Alignment

Drum Shaft - ODS

Drum Shaft Splined Hub

Use This Surface for Concentricity Reading to be within 0.38" TIR

Use This Surface for Axial Alignment Reading to be within 0.04" TIR

Auxiliary Brake Hub

Auxiliary Brake


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21. Tighten the mounting bolts after the auxiliary brake has been aligned.

22. Verify that the splined hub shifting mechanism operates smoothly and that the locking feature works in both the engaged and retracted positions.

23. Improper operation indicates a problem with alignment. Recheck the hub-to-hub total indicator run out (TIR) readings.

Lubrication

The lubrication system is made up of an oil pressure and cooling system for the gearbox and a manual grease system for the remaining components. The oil filter is located on the Well Side (WS) of the skid beneath a main drive motor, and it is positioned above the lube oil level for easy replacement. The pressure pumps and motors are located under removable floor plates adjacent to the Drawworks side plates on the Driller Side (DS). See the assembly drawings in the Parts Catalog for more information on lubrication system component locations.

Lubricating Oil

After the Drawworks has been assembled, lubricate the equipment according to the following instructions:

1. Fill the gearbox sump with ANSI/AGMA 9005-E02, ISO VG 220 EP (VZG>12) lubricating oil. The viscosity index of the oil should be 160 or greater (refer to the Utility Requirements section). See the Utility Requirements section or the Gear Drive drawing in the Parts Catalog for the amount of oil needed.

2. If applicable, fill the HPU reservoir with proper oil as recommended by Johnson HPU User’s Manual in the Accessory Manuals.

3. After the sump has been filled, start the first lubrication pump.

4. Allow the pump to run for a few minutes and then check the sump oil level. The dipstick is located at the DS end.

5. If required, add oil through the dipstick pipe to maintain the correct level.

6. Observe the pressure gage on the DS of the gear case while the first lube pump is running; it should read a pressure of at least 20 PSI.

7. Stop the first pump, and start the second pump.

8. Observe the pressure gage on the DS of the gear case while the second lube pump is running; it should read a pressure of at least 20 PSI.

9. Verify that the operating pump is functioning within acceptable limits each day and that both pumps are functioning within acceptable limits each week.

NOTE

Do not run both lube oil pumps simultaneously.


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Grease

1. On initial startup, the drum shaft bearings, auxiliary brake shaft bearings, and auxiliary brake shifter grease points should receive three to four shots from a standard manually operated grease gun.

2. Check the splines of the auxiliary brake coupling. Apply EP #4 grease by hand as necessary.

3. Grease all moving and exposed parts on the Johnson brakes on a monthly basis. If any of the brake components are corroded, apply grease more frequently.

4. Do not get any grease on the brake pads. Do not over grease. Wipe off any excess grease to prevent contamination of the brakes. This is particularly important in saltwater environments.

WARNING

Do not over grease the brake components. Wipe off any excess grease. Excess grease can cause contamination of the brakes and

compromise braking capability.

5. In non-saltwater environments, operators should base the lubrication schedule on usage to maintain the brakes in good working order. Also refer to the manufacturer’s instructions in the Accessory Manuals.

Lubrication Schedule

Table 7: Greasing Schedule

Frequency Lubrication Point Lubrication Comments

Daily

Shaft Bearings NLGI #2 Premium Lithium Grease

Two or three shots from a standard manually operated grease gun

Auxiliary Brake Shaft and Shifter

NLGI #2 Premium Lithium Grease

Two or three shots from a standard manually operated grease gun

Gear Box ANSI/AGMA 9005-EO2


If contamination is found, drain oil and replace.

If no contamination is found, drain the oil and replace annually.

Monthly

Auxiliary Brake Connection Splines EP #4 Grease Apply by hand as necessary.

Disc Brake Calipers* NLGI #2 EP Premium Lithium Grease

Do not over grease. Wipe off any excess.

Do not get any grease on the brake pads.

Excess grease can contaminate the brakes.

Semiannually Flexible Couplings NLGI #2 Premium Lithium Grease Remove and replace old grease.

* This is particularly important in saltwater environments. In non-saltwater environments, operators should base the lubrication schedule on usage to maintain brakes in proper working order.


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Commissioning

1. Verify that the gearbox oil sump and the HPU reservoir have been properly filled with oil and the Drawworks has been lubricated (refer to the Lubrication section).

2. Verify that all of the necessary utilities are available, as outlined in the Utility Requirements section and indicated in the component manufacturer’s information in the Accessory Manuals.

2.1. Verify that there is a minimum rig air pressure of 105 PSI available.

2.2. For the hydraulic service brake, verify the HPU oil pressure is 1,300 to 1,800 PSI.

3. Verify the proper operation of the lube oil pump(s), and a minimum pressure of 20 PSI is being met (refer to the Lubrication section).

4. Verify the proper operation of the service brakes.

5. Verify proper operation of the auxiliary brakes.

NOTE

Determine if the auxiliary brake will or will not be engaged for startup. Take appropriate action with the coupling shifter, and lock the shifter.

WARNING

Do not attempt to operate the Drawworks unless all brakes are operating properly. Brakes should move smoothly and without hesitation. Service the brakes if they fail to operate correctly.

Operating the Drawworks with faulty brakes could cause serious injury to personnel and damage to equipment.

6. Verify proper operation of the emergency shutdown function.

WARNING

Care should be taken when verifying the Emergency Stop function. Applying the brakes will quickly generate strong shock loads that

could cause serious injury to personnel and equipment.

WARNING

Always make sure that motor power is available before releasing the emergency brakes. Failure to do so can cause the loss of load control,

major equipment damage, severe personal injury, or loss of life.

7. Verify operation of the drive motors and the associated motor cooling systems.

8. Verify the proper operation of the hoist and lower functions of the Drawworks.


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Operation

Safe Operating Practices

• Know the load being lifted.

• Do not exceed the lifting capacity of the Drawworks.

• Use the correct reeving for the load.

• Be sure that the brakes, hoist, hoisting gear, and controls are properly serviced and inspected at the beginning of each tour and before starting each trip.

• Move loads smoothly without sudden starts or stops.

• Know the position of the traveling block in the derrick at all times.

• DO NOT allow personnel to ride the hoisting equipment.

• Check and service the hoist when a load approaching the rated load is anticipated as well as after the load is removed.

• Verify that the emergency stop function and interlocks are functional both before a trip and on a weekly basis.

• Do not leave the Drawworks controls unattended with a suspended load. Set the load on a firm support (e.g., a casing spider or slips in the rotary table).

• Do not use the motor to leave, or suspend, the traveling block for an extended period of time. Instead, set the emergency brake on the Drawworks.

• Make sure that the brake is holding the load before releasing the motor power.

WARNING

Qualified and trained personnel must control this equipment for safe operation. Insufficient training and failure to read and understand the operation and maintenance instructions can cause major equipment

damage, serious personal injury, or death.

Control System

The Drawworks control system is specified by the buyer and is not necessarily manufactured by Cameron. See the control system operations manual or the manufacturer’s operating instructions for details on the system control of the Drawworks.


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Braking System

The caliper brakes are released by air or hydraulic pressure. A clean, dry air or oil supply at the correct pressure is essential to the operation of the Drawworks. Monitor the Drawworks air or oil pressure gage regularly, at the beginning of each shift, or at least once a day.

A reduction in the air or oil pressure will adversely affect the braking system and can cause partial engagement of the brake. Operation with the brake partially engaged will seriously overheat the brake and will damage the calipers and the discs.

WARNING

Do not operate the Drawworks with reduced air or hydraulic pressure. This can cause the brakes to be partially engaged. Operation with the brakes partially engaged will overheat the brakes and will damage the

calipers and the discs.

Water that accumulates in the air system will also adversely affect the braking system. Water should be purged from the Drawworks air tank and air lines at the beginning of each shift or at least once a day (see Figure 7 and Figure 8 in the Installation section).

WARNING

Exercise caution and the appropriate safety measures when purging accumulated moisture from the air system. Water that accumulates in

the air tank and the air system will be released at high pressure, which could cause severe personal injury.

WARNING

Always make sure that motor power is available before releasing the emergency brakes. Failure to do so can cause the loss of load control,

major equipment damage, severe personal injury, or loss of life.


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Operating Pressures

The following operating parameters are recommended for safe and efficient operation of the Drawworks. A summary of this information is shown in Table 9 at the end of this section. If any questions arise, refer the situation to Cameron personnel.

Air Pressure

Emergency and Service Caliper Brakes: 105 to 120 PSI

Auxiliary Brakes: 105 to 120 PSI

WARNING

Do not operate the Drawworks with reduced air or hydraulic pressure. This can cause the brakes to be partially engaged. Operation with the brakes partially engaged will overheat the brakes and will damage the

calipers and the discs.

Water Pressure

Auxiliary Brake Cooling System: This provides the cooling water pressure to the optional auxiliary brake. The inlet water pressure should range from 30 to 45 PSI. If the pressure falls below 30 PSI, the coolant flow through the auxiliary brake will be reduced, and the braking load must be reduced, or the brake will overheat and cause damage to the brake discs.

WARNING

Do not operate the auxiliary brake while the inlet water pressure is below 30 PSI. If the pressure falls below 30 PSI, the coolant flow through the auxiliary brake will be reduced, and the brake may

overheat and cause damage to the brake discs.

Gearbox Cooling System: This provides the cooling water pressure to the gearbox heat exchangers. This pressure should range from 30 to 100 PSI. If the pressure falls below 30 PSI, the cooling capability of the heat exchanger will be reduced, and the gearbox may overheat.

CAUTION

Do not operate the Drawworks while the gearbox heat exchanger cooling water pressure is below 30 PSI. If the pressure falls below 30 PSI, the cooling capability of the heat exchanger will be reduced, and

the gearbox may overheat.


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Oil Pressure

Gearbox Lube Oil Pump: The gearbox lube oil pump provides the gearbox lubrication oil pressure. The lube oil pressure at the gearbox should be 20 to 40 PSI. If the pressure falls below 20 PSI, the cooling and lubrication capabilities of the lubrication system will be compromised. Continued use of the Drawworks could damage the gearbox.

CAUTION

Do not operate the Drawworks while the gearbox lube oil pressure is below 20 PSI. If the pressure falls below 20 PSI, the lubrication

capabilities of the lubrication system will be compromised and damage to the gearbox may occur.

Hydraulic Power Unit (HPU): If Drawworks is equipped with hydraulic emergency caliper brake, the oil pressure should be 1,300 to 1,800 PSI. See Johnson User’s Manual in the Accessory Manuals for the correct operating oil pressure.

Operating Temperatures

Water Temperature

Auxiliary Brake (Eaton): Inlet water temperature for the optional auxiliary brake (Eaton) should be 50°F to 90°F (10°C to 23°C). If the temperature rises above 90° F (32°C), the braking load must be reduced or the brake will overheat and cause damage to the brake discs. Maximum fresh water outlet temperature should be 150°F (66°C). See the manufacturer’s instructions in the Accessory Manuals to verify the correct fluid cooling temperature range.

WARNING

Do not operate the auxiliary brake while the inlet water temperature is above 90°F (32°C). If the temperature rises above 90°F (32°C), the braking load must be reduced, or the brake will overheat and cause

damage to the brake discs.

Gearbox: Maximum inlet water temperature for the gearbox oil cooler should be 90°F (32°C). If the temperature rises above 90°F (32°C), the cooling and lubrication capabilities of the lubrication system will be compromised. Continued use of the Drawworks could damage the gearbox.

CAUTION

Do not operate the Drawworks while the gearbox lube oil temperature is above 90°F (32°C). If the temperature rises above 90°F (32°C), the lubrication capabilities of the lubrication system will be compromised

and damage to the gearbox may occur.


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Oil Temperature

Gearbox: Oil temperature should be maintained in the 100°F to 150°F (38°C to 66°C) range. If the temperature rises above 150°F (66°C), the cooling and lubrication capabilities of the lubrication system will be compromised. Continued use of the Drawworks could damage the gearbox.

CAUTION

The auxiliary brake inlet water temperature and the gearbox oil temperature should be monitored and a warning or alarm should be

issued if the temperatures exceed the levels indicated above.

Table 8: Operating Temperatures and Pressures Summary

Utility Description Pressure Temperature

Rig Air Supply 105 to 120 PSI N/A

Auxiliary Brake Cooling Water Inlet 30 to 45 PSI 50°F to 90°F

(10°C to 23°C)

Auxiliary Brake Cooling Water Outlet N/A 150°F (66°C)

Gearbox Heat Exchangers Cooling Water 30 to 100 PSI ≤ 90°F

(≤ 23°C)

Gearbox Lubrication Oil ≥ 20 PSI 100°F to 150°F (38°C to 66°C)


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Emergency Lowering Procedure

Emergency Lowering with Air Released Brakes

In the event of a loss of electrical power or rig air supply failure, the emergency brake calipers will set and lock the hoisting drum. If the load needs to be lowered to a safe position, the emergency brakes can be released with air pressure stored in the Drawworks air tanks.

Air storage tanks, usually located under the hoisting drum in the Drawworks skid, provide auxiliary pressure for emergency release of the spring brakes. The tanks are charged by the rig air system and the charge is retained by two gate valves in the charge line (see Figure 10), located on both sides of the Drawworks.

The air storage tanks are capable of actuating the brake system at least three times without additional air volume from the rig air supply. Make sure there is at least 105 PSI of rig air pressure during normal operation to properly charge these tanks.

To release the emergency brakes in the event of a loss of electrical power or rig air supply failure, use the following instructions:

1. Turn the handle of both of the 3-way gate valves 90° to release the emergency air supply. The 3-way gate valves (Figure 10) are located under the floor on both sides of the Drawworks.

2. Pull the handle of the manual emergency lowering valve. This operation should be performed carefully, because there is a limited amount of stored air. Refer to the image in Figure 11 showing the emergency lowering valve. Also refer to the Skid Piping drawing in the Parts Catalog for more information on the location of the emergency lowering valve.

3. After the load has been lowered to a safe position, push the handle of the emergency lowering valve back to its original position.

4. Turn the handle of both of the 3-way gate valves back to their original positions.

5. If emergency lowering was necessary because of a loss of electrical power, the encoders will not register changes in the position of the block during the power outage. To account for this, reset the encoders and perform a block calibration as soon as power is restored. Refer to the operations manual for the rig’s control system for specific instructions on performing a block calibration.

CAUTION

If electrical power is intact and emergency lowering was necessary because of a loss of air pressure, the encoders and control system

should not be affected. If there is a fault with the encoders or control system during air pressure loss, it is indicative of a separate issue,

outside the scope of emergency lowering.

Figure 10: 3-Way Gate Valve


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NOTE

K-Series Drawworks manufactured prior to 2008 may be equipped with a solenoid control valve and 2-way ball valves for emergency lowering, instead of a mechanical control valve and 3-way gate

valves.

If present, the solenoid control valve can be controlled remotely from the drilling control system, but it can only be used during a loss of air

pressure, not during a loss of electrical power.

NOTE

K-Series Drawworks that were retrofitted or manufactured after January 2008 are equipped with a mechanical control valve that can

be used during a loss of air pressure or a loss of electrical power. However, this control valve cannot be controlled remotely and must

be operated manually.

The type of air control valve and air storage tank valves are indicated on the Skid Piping and Air Schematic drawings in the Parts Catalog. If the Drawworks is equipped with a solenoid valve for emergency lowering and 2-way ball valves on the air storage tanks, use the following instructions in the event of a loss of rig air supply.

1. Locate the ball valves for the air storage tanks.

2. One ball valve should be open and the other should be closed. Open the closed ball valve and close the open ball valve.

3. Use the rig control system to actuate the solenoid control valve.

4. After the load has been lowered to a safe position, deenergize the solenoid control valve using the rig control system in order to reapply the Drawworks brakes.

5. Close the ball valve that was opened in Step 2.

6. Open the ball valve that was closed in Step 2.

Figure 11: Emergency Lowering Valve


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Emergency Lowering with Hydraulically Released Brakes

In the event of a loss of electrical power or hydraulic supply failure, the emergency brake calipers will set and lock the hoisting drum. If the load needs to be lowered to a safe position, emergency lowering is possible using the manual HPU control panel. Refer to the Johnson User’s Manual in the Accessory Manuals for additional details on the HPU control panel.

It is recommended that two qualified members of rig personnel perform the emergency lowering procedure according to the Manual Lowering procedure in the manufacturer’s instructions included in the Accessory Manuals.

If emergency lowering was necessary because of a loss of electrical power, the encoders will not register changes in the position of the block during the power outage. To account for this, reset the encoders and perform a block calibration as soon as power is restored. Refer to the operations manual for the rig’s control system for specific instructions on performing a block calibration.

CAUTION

If electrical power is intact and emergency lowering was necessary because of a loss of hydraulic pressure, the encoders and control

system should not be affected. If there is a fault with the encoders or control system during hydraulic pressure loss, it is indicative of a

separate issue, outside the scope of emergency lowering.


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Maintenance

This product and many of its parts may be heavy or difficult to handle. Plan lifts carefully and use proper lifting gear to avoid damage to equipment and severe personal injury. Provide safe supports for all components and service the equipment in an area with adequate space and ventilation.

Consult the manufacturer’s instructions for additional maintenance recommendations for the drive motors, control system, caliper brakes, and auxiliary brake. If a discrepancy arises between this manual and the manufacturer’s instructions, the manufacturer’s instructions should always override unless specifically stated otherwise.

WARNING

Shut down equipment and disconnect electric and air or hydraulic power before performing maintenance or inspection in order to

prevent severe personal injury. The spring-operated brake calipers should be engaged. If the calipers must be released during

maintenance, they must be caged prior to service. Use sound mechanical practices when making maintenance repairs and

adjustments.

WARNING

Always secure the Drawworks and the load before performing maintenance on the brakes. Set the load on the slips and support the

traveling block.

WARNING

The braking system must be correctly adjusted and maintained. Failure to perform regular maintenance and proper adjustments will

affect the reliability of the braking system and cause an unsafe operating condition.

WARNING

The cylinders of the braking system have a limited amount of travel. Lack of proper adjustment can cause the cylinders to stroke more

than intended, which will cause the brakes to provide less than the rated braking force.


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Initial Maintenance

1. Fill the gearbox sump and the HPU reservoir with oil according to the Lubrication section before beginning operation. Note that all fluids are drained from the equipment prior to shipping.

2. Make sure that the oil pressure, the air pressure, the cooling water pressure, and the cooling water volume are satisfactory according to the Utility Requirements and Operating Pressures sections.

3. Lubricate each grease fitting on the unit. Refer to the Lubrication section for grease specifications.

4. Open the valve on the air tank for at least five seconds to drain any water that may have accumulated in the tank. Refer to the Installation Inspection section and Figure 7.

5. Release the bleed valves in the air filter to drain any water that may have accumulated in the lines. Refer to the Installation Inspection section and Figure 8.

Daily Maintenance

1. To ensure proper and safe operation, inspect the brake system daily to make sure it is clean and free of contamination, dirt, or corrosion. If the daily inspection reveals any contamination, dirt, or corrosion, clean the brake immediately.

1.1. If the brake pads are contaminated with oil, grease, or line dope, locate and remove the cause of contamination. Once the cause of contamination is removed, clean and replace the pads.

1.2. If oxidation or corrosion is found on the brake discs, burnish the discs by rotating the drum a few turns with the calipers slightly engaged. Reduce the Drawworks air pressure to 1/3 of the operating pressure to partially engage the brake calipers. After burnishing, inspect the brake discs and shoes, and check the holding capability of the brakes (see Step 5).

1.3. If moisture contamination occurs:

1.3.1. Open the valve on the air tank for at least five seconds to drain any water that may have accumulated in the tank. Refer to the Installation Inspection section and Figure 7.

1.3.2. Release the bleed valves in the air filter to drain any water that may have accumulated in the lines. Refer to the Installation Inspection section and Figure 8.

2. Use the Johnson caliper brakes to park a load for a short period of time to verify proper operation of the brakes.

3. Test the emergency brake function using the following steps:

4.1. Actuate the hoisting control lever to rotate the drum very slowly.

4.2. Push the emergency stop button. The drum should stop immediately.

4.3. Pull the emergency stop button. The drum should start to rotate smoothly.

4. Open the valve on the air tank for at least five seconds to drain any water that may have accumulated in the tank. Refer to the Installation Inspection section and Figure 7.

5. Release the bleed valves in the air filter to drain any water that may have accumulated in the lines. Refer to the Installation Inspection section and Figure 8.


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Weekly Maintenance

1. Inspect and adjust the brakes at least on a weekly basis, or more frequently as indicated by experience.

2. Check the brakes for contamination. Contamination can occur from oil, grease, line dope, oxidation, corrosion, or moisture.

2.1. If the brake pads are contaminated with oil, grease, or line dope, locate and remove the cause of contamination. Once the cause of contamination is removed, clean and replace the pads.

2.2. If oxidation or corrosion is found on the brake discs, burnish the discs by rotating the drum a few turns with the calipers slightly engaged. Reduce the Drawworks air pressure to 1/3 of the operating pressure to partially engage the brake calipers. After burnishing, inspect the brake discs and shoes, and check the holding capability of the brakes (see Step 5).

2.3. If moisture contamination occurs:

2.3.1. Open the valve on the air tank for at least five seconds to drain any water that may have accumulated in the tank. Refer to the Installation Inspection section and Figure 7.

2.3.2. Release the bleed valves in the air filter to drain any water that may have accumulated in the lines. Refer to the Installation Inspection section and Figure 8.

3. Inspect the thickness of each brake pad. Brake pads must be replaced when they are 1/4" thick. Allowing further wear will result in attachment rivets touching and scoring the disc. Loose debris can become packed in the grooves of the scored disc and cause compromise braking capability.

4. The brake pad clearance should be checked and adjusted weekly. During periods of heavy usage, it should be checked more frequently. The operating clearance between each brake pad and the brake disc should be between 1/8" and 3/16". Operating clearance should not exceed these dimensions. A beveled edge indicates improper clearance between the pad and the disc. Adjust the pad as needed to maintain proper running clearance, using the following instructions:

4.4. Apply air or hydraulic pressure to release the brakes and cage the actuators.

4.5. Remove the pin attaching the pad holder to the caliper lever.

4.6. Slide the pad holder toward the center of the disc and remove the pad holder from the caliper arm.

4.7. Remove the rivets holding the pad to the pad holder and remove the pad.

4.8. Clean the pad holder with a wire brush. DO NOT use petroleum solvent.

4.9. Make sure the pad is properly placed on the pad holder and doesn’t hang over the edge.

4.10. Rivet the pad to the pad holder. Make sure that the rivets pull up properly against the pad and the pad holder. Do not crush the pad under the rivet head.

4.11. Follow the Air Gap Adjustment Instructions in the Johnson Caliper Brake User Manual in the Accessory Manuals to increase the air gap and allow for the new caliper. Be sure that there is sufficient clearance.

4.12. Place the pad holder next to the caliper arm toward the center of the disc. Slide the pad holder outward until the pinholes in the holder align with the pinholes in the caliper arm.

4.13. Lubricate and replace the pins.


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4.14. Adjust the air gap in accordance with the Air Gap Adjustment Instructions in the Johnson Caliper Brake User Manual in the Accessory Manuals.

WARNING

Excessive air gap will reduce braking capability and could cause complete loss of brake power that could result in damage to

equipment, serious personal injury, or loss of life.

4.15. Burnish the pads in accordance with the Johnson Caliper Brake User Manual in the Accessory Manuals.

5. Check the holding capability of the brakes using the following procedure:

5.1. Place the traveling block near the lower travel limit before starting the test.

5.2. Actuate the calipers on one brake disc and attempt to turn the drum with the motors.

5.3. Repeat this procedure for each disc.

5.4. The brake passes the test if the drum cannot be rotated at full-rated torque.

Monthly Maintenance

Inspect the intake filters on the blowers once a month and remove any obstructions or debris. Blocked intakes will cause the motor to overheat under high-load conditions and possibly damage the blower impellers.

CAUTION

Blocked intakes will cause the motor to overheat under high-load conditions and possibly damage the blower impellers.


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Annual Maintenance

Perform an annual brake holding test on each individual caliper, to ensure that the brakes are capable of holding in the event of an emergency. Use the following instructions to perform the brake holding test on each caliper:

1. The caliper brakes are spring applied, air released. Use one of the following methods to ensure that the caliper being tested is the only one that is being applied to the disc:

A. Prevent air from entering the brake caliper by disconnecting the respective air hose and plugging it.

B. Install ball valves on the air line to each brake caliper, and close the ball valve for the caliper being tested. If using this method, be sure to change the valves to the open position before resuming normal operation. It is recommended to install valves that can be locked to ensure that they are open during normal operation. Ensure that the valves do not leak when closed if using this method. Leaks will cause the calipers to partially release and make the holding capacity appear less than what it actually is.

C. Release the calipers not being tested by using a caging bolt in each of the cylinders. This bolt will pull the piston back, compressing the springs, releasing the brake calipers.

2. Increase the Drawworks throttle until the brake caliper begins to slip.

3. Record the total current required to cause the caliper to begin to slip.

4. Repeat Steps 1 through 3 for each caliper.

5. Analyze the recorded currents according to the following acceptance criteria:

A. There should not be more than a 10% reduction in the average current required to cause the calipers to start slipping when compared with the average values from the FAT or commissioning records.

B. There should not be more than a 20% difference between the highest current value and the lowest current value.

6. If either of the above acceptance criteria are not met, burnishing of the brake pads is required in order to increase the holding capacity of the calipers. Refer to the Johnson User’s Manual in the Accessory Manuals for instructions on how to burnish the brake pads.

7. After burnishing the brake pads, retest each respective caliper.

8. If the calipers still do not meet the acceptance criteria, refer to the Troubleshooting section of the Johnson User’s Manual in the Accessory Manuals.

WARNING

Be sure to perform the brake holding test annually, after moving the Drawworks, after an emergency stop, and after any other major

event.


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Maintenance After Moving

When the Drawworks is moved between locations, the following maintenance procedures should be performed. Repair or replacement of worn or damaged items will increase the life and efficiency of the unit and improve safety for personnel.

1. Check for missing or loose bolts, and tighten or replace as necessary.

2. Check, repair, and adjust the brake discs and pads as necessary.

3. Check the air system filter element, the lube oil system filter, and the HPU oil filter (if applicable). Replace filters as necessary.

4. Check, clean, and repair the mechanical shifter on the auxiliary brake to ensure it is operating properly (if applicable).

5. Check the alignment of the auxiliary brake. Adjust the alignment as necessary. Refer to the Assembly instructions in the Installation section for details on auxiliary brake alignment.

CAUTION

The auxiliary brake is a disc brake connected to the end of the drum shaft by a manually operated splined coupling. To operate properly, the

brake system must be adjusted correctly and free of contamination.

6. Inspect all hoses for wear, fraying, flattening, or kinking. Replace damaged hoses as necessary.

7. Check the water supply system for the gearbox heat exchanger and auxiliary brake. Make sure that sufficient water is flowing and that all connections are leak free. Repair as necessary.

8. Check the main drum bearing housing bolts for looseness/movement. Tighten/replace as necessary.

9. Check each grease lines for flow and leakage. Make sure that grease is reaching the proper bearings. Repair as necessary.

10. Inspect the lube oil pumps and the motor couplings. Repair as necessary.

11. Clean the gearbox breather.

12. Perform a brake caliper holding test on each caliper. See the Annual Maintenance section.

Overhaul

When undertaking a major overhaul, it is cost effective to replace aging parts that are still working in addition to those that need repair. While no one wants to incur extra expense, it is easier to replace parts close to the end of their life when the unit is already down rather than waiting for the part to fail after the unit has been overhauled and put back into service.

During a Drawworks overhaul, many operators will have repair facilities replace the roller bearings throughout the Drawworks because it is more cost-effective than leaving a bearing in service and having it fail after the overhaul. The costs of the downtime and emergency repairs will be more than the cost of replacement during a regular overhaul.

It is recommended that Cameron field service personnel assist in an equipment overhaul. Contact Cameron for additional details on field service and equipment overhauls.


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Replacement of Parts

For assembly or removal of parts that fit from 0.000" to 0.004" tight, heat them to approximately 350°F (177°C). For parts that fit from 0.005" to 0.015" tight, heat them to approximately 600°F (316°C).

Hub Replacement

When replacing parts on a shaft assembly, be sure that the new part fits within the tolerances shown. The general rule for the interference used in cylindrical fits is as follows:

• Press Fit: 0.0005" × Shaft Diameter • Shrink fit: 0.001" × Shaft Diameter

Tolerance will affect the overall fit, depending on the precision of the allowance.

Use the following equation to determine the temperature required to expand the hub and facilitate an easy interference fit.

T = Required Heated Temperature (°F)

E = Expansion of Bore Diameter Required (inches)

B = Bore Diameter (inches)

TR = Room Temperature (°F)

0.0000061 = Approximate Coefficient of Expansion of Steel per Degree Fahrenheit

Sample Calculation

A hub with an 8.500" diameter bore hub has a 0.008" interference fit with the shaft. There should be 0.010" clearance while assembling the hub over the shaft. The total bore expansion needs to be 0.018".

E = 0.018"

B = 8.500"

TR = 70°F

T = 417°F

E

(0.0000061 × B)

TR + T =

0.018

(0.0000061 × 8.500)

70 + T =


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Shaft Replacement

When possible, a shaft that has been stripped for repair should be inspected for cracks using Magnaflux or other nondestructive testing. Cracks are most likely to appear at the corners or ends of keyways and at major changes in shaft diameter. Cracked shafts should be replaced immediately. A cracked shaft is dangerous and could result in a catastrophic failure.

WARNING

Replace cracked shafts. A cracked shaft will cause a catastrophic failure and result in damage to equipment and severe personal injury.

Check shafts to make sure they are straight. If shafts in a Drawworks are not straight, they can cause vibration, whipping of chains, and a generally poor running rig.

Support the shaft at the normal bearing locations and rotate the shaft on a steady, low-friction support.

Use a dial indicator to check for run-out at the ends and the middle of the shaft. The Total Indicator Reading (TIR) should not exceed 0.010". Excessive TIR will cause vibration. Lack of straightness is an indicator of other problems, such as cracking or overstressing.

Generally, the shafts require little or no maintenance other than periodic greasing of the bearings. The exception to this rule is the auxiliary brake shaft. The splined shifter connecting the auxiliary brake shaft to the drum shaft uses a bronze follower to move the spline sleeve. The follower will wear over time. Difficulties in shifting and/or excessive clearance in the shift mechanism are good indicators of a wear problem that must be addressed.

NOTE

When a shaft assembly is disassembled for any reason, be sure that all air, grease, and water lines are thoroughly cleaned.


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Bearing Replacement

Bearings are usually lightly tight on the shaft and slip fit in the housing. If a bearing is to be reused, it must not be heated with a torch as this may damage the bearing. Use an oven or oil bath to heat a bearing for installation. Do not use a torch because bearing material is very high-carbon steel that is subject to micro-cracking when a torch is used. However, if a bearing is to be discarded, it may be heated with a torch to ease the removal.

Do not overheat the bearing; 400°F to 450°F (204°C to 232°C) is sufficient. Higher temperatures will damage the bearing.

CAUTION

Hardened parts such as bearing races should not be heated above 400°F to 450°F (204°C to 232°C) because the hardness may be affected. Heat should be applied carefully and evenly to prevent

distortion. Use a bearing heater to heat reusable bearings.

Discard roller bearings if they show any of the following:

• Pitting • Rusting or corrosion • Chipping or spalling • Excessive internal looseness (which indicates extreme wear) • Cracking in either the rollers or the races

To Remove a Bearing or Inner Race:

The inner race must usually be heated to be removed from the shaft. For reassembly, the inner race should always be heated and mounted on an unheated shaft.

1. Place a U-shaped puller behind the bearing or the inner race.

2. Balance the pulling mechanism and remove all the slack by tightening.

3. While evenly applying heat to the bearing or inner race, increase the tension on the pulling mechanism until the part is free.

To Remove an Outer Race:

The tolerances for fitting outer races to the bearing housings range from 0.005" tight to 0.004" loose. If the outer race is a tight fit, the housing must be heated for it to be removed.

1. Arrange the puller mechanism to apply pressure toward the open end of the housing.

2. Apply heat to the housing and at the same time increase the pressure on the puller mechanism.

NOTE

The bearing must be cool before it can be reassembled.


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Spacer Replacement

Spacers that are used between bearings to maintain the centerlines of bearings or between bearings and other parts are usually 0.002" to 0.006" loose. Spacers used to hold a bearing in position, which is not adjacent to another part that is securely fixed to the shaft, are usually 0.001" to 0.003" tight.

To remove a spacer that has a shrink fit, follow the same procedure used to remove a bearing. To replace a spacer, heat the spacer evenly and install the heated spacer on a cool shaft.

Coupling Hub Replacement

Keyed or unkeyed hubs are always tight on the shaft. Do not pull on the outer rim of a hub when removing it from the shaft.

If the hub has puller holes, screw the puller bolts into the tapped holes; otherwise, use a U-shaped puller behind the part. Heat may be used to assist the removal. Apply the heat evenly around and on, or as near, the hub as possible. Do not overheat.

CAUTION

DO NOT heat flexible coupling hubs beyond the maximum temperature of 400°F (204°C) to prevent hub damage.

Prior to installation, the parts must be pre-fitted. Remove any burrs or raised metal on both the shaft and the hub. Replace the key if it contains grooves or burred edges. Measure the hub or sprocket bore and the shaft diameter to determine the interference of the fit.

CAUTION

To prevent hub damage, DO NOT heat flexible coupling hubs beyond the maximum temperature of 400°F (204°C) or the sprocket hubs

beyond the maximum temperature of 600°F (316°C).


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Preservation and Storage

Preservation Procedure

1. Clean the Drawworks with a power cleaning system (steam or pressurized water is preferred). Protect the motors and controls from water intrusion during cleaning.

2. Remove any loose paint, clean rusted surfaces to bright metal, and repaint.

3. Repaint any areas where the paint is thin.

4. Make sure that dirt, grease, and other accumulated materials are removed from the Drawworks before storage.

5. Consult the manufacturer’s instructions for cleaning motors and controls, located in the Accessory Manuals included in the final documentation package.

6. Flush and drain the oil system.

7. Refill the oil sump with clean oil.

8. Circulate clean oil through the system to coat all parts with an oil film. See the Lubrication section for lube oil specifications.

9. Drain the oil sump after circulating the oil.

10. Make sure that all grease-lubricated parts are completely greased (filled) with the usual operating grease. Use preservative oil on areas where grease is not applicable.

11. Cover the exposed parts (shaft, drum, etc.) with a dry, film-type rust preventative. Do not coat the braking surface of the brake discs.

WARNING

Do not coat the surface of the brake discs with rust preventative. If the disc brakes are covered by a film of rust preventative compound, it will

compromise the capability of the braking system upon resuming operation of the Drawworks.

12. See the Accessory Manuals in the final documentation package for preservation of the motors and controls.


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Storage Recommendations

1. The Drawworks should be stored in a location with good drainage to prevent the accumulation of standing water.

2. If possible, store the Drawworks indoors at a moderate temperature and low humidity. Storing the Drawworks outdoors is not recommended.

3. If outdoor storage cannot be avoided, the Drawworks should be in a location that provides overhead shelter and the packaging should be checked on a regular basis to ensure it is intact.

4. Support the Drawworks in a manner similar to the working support.

5. Make sure the temporary supports are high enough to allow free circulation of air below the Drawworks to prevent condensation and accumulated water.

6. The preferred method of gearbox storage includes forming an air-tight environment within the gearbox and using a heater to prevent condensation. This method is outlined in the following steps:

6.1. Ensure all openings to the gearbox are plugged and sealed air-tight, including the breather opening and drain.

6.2. Use a small heater (100 to 200 W) in the gearbox. This is the preferred preservation method. If a heater is not available, use a 100 to 200 W light bulb inside the gearbox. All electrical wiring for the heater or light bulb should be lined with silicone at the point of entry into the gearbox to ensure an air-tight seal.

6.3. Check the heater or light bulb on a weekly basis to ensure they are still operating properly. Replace the heater or light bulb as necessary, being sure to follow the instructions in Step 6.2.

NOTE

If using a light bulb, sealing the point of entry with clear silicone allows the light bulb to be checked visually without opening the gearbox.

7. If unable to follow the methods outlined in Step 6, the following points should be adhered to at a minimum:

7.1. Cover the drain with wire mesh to prevent the entrance of insects.

7.2. Elevate the Drawworks on the side of the gearbox that is opposite the drain. This will help to avoid the accumulation of standing water in the gearbox.

CAUTION

Condensation in the gearbox is a main concern during storage. Adherence to the preservation methods outlined above will help prevent accumulation of moisture and subsequent damage to

equipment.

8. Consult the Accessory Manuals in the final documentation package for long-term storage of the motors and controls.


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Torque Specifications

Table 9: Torque Specifications

Steel Fastener Torque Specifications (Lubed*)

Fastener Size (Fraction/ Decimal)

Thread Series

SAE Grade 5 Fasteners SAE Grade 8 Fasteners ASTM A193 Grade B7

Fasteners

USA Units (ft-lb)

Metric Units (N-m)

USA Units (ft-lb)

Metric Units (ft-lb)

USA Units (ft-lb)

Metric Units (N-m)

1/4 20 UNC 6 9 9 12 7 10

0.250 28 UNF 7 10 10 14 8 11

5/16 18 UNC 13 18 18 25 15 20

0.3125 24 UNF 14 20 20 28 16 22

3/8 16 UNC 23 31 33 44 26 36

0.375 24 UNF 26 35 37 50 30 40

7/16 14 UNC 37 50 52 71 42 57

0.4375 20 UNF 41 56 58 79 47 64

1/2 13 UNC 56 76 80 108 64 87

0.500 20 UNF 63 86 90 122 72 98

9/16 12 UNC 81 110 115 156 93 126

0.5625 18 UNF 91 123 128 174 103 140

5/8 11 UNC 112 152 158 215 128 173

0.625 18 UNF 127 172 179 243 145 196

3/4 10 UNC 199 270 281 381 227 308

0.750 16 UNF 222 301 314 425 253 343

7/8 9 UNC 321 435 453 614 366 496

0.875 14 UNF 354 480 500 678 404 547

1 8 UNC 481 652 679 921 549 744

1.000 14 UNF 539 731 762 1034 616 835

1-1/8 7 UNC 600 813 963 1305 778 1054

1.125 8 UN 621 842 997 1352 805 1092

12 UNF 673 912 1079 1463 872 1182

1-1/4 7 UNC 846 1147 1358 1842 1097 1487

1.250 8 UN 873 1184 1401 1900 1132 1534

12 UNF 937 1270 1504 2039 1215 1647

1-3/8 6 UNC 1109 1504 1781 2414 1438 1950

1.375 8 UN 1185 1607 1902 2578 1536 2083

— 12 UNF 1263 1712 2027 2748 1637 2220

1-1/2 6 UNC 1473 1997 2363 3204 1909 2588

1.500 8 UN 1563 2120 2509 3402 2027 2748

— 12 UNF 1657 2246 2659 3605 2148 2912

1-3/4 — — — — — — — —

1.750 8 UN — — — — 3300 4474

2 — — — — — —

2.000 8 UN — — — — 5018 6804

Bolt And Cap Screw Markings On Head

B7 Studs

* All torque values given are for fasteners lubricated with 30 weight motor oil.

HSE Policy StatementAt Cameron, we are committed ethically, financially, and personally to a working environment where no one gets hurt, nothing gets harmed.

© 2012 Cameron I LEWCO and OEM are trademarks of Cameron

Cameron

Drilling Systems6401 W Sam Houston Parkway NHouston, TX 77041, USATel: 713.983.4700Tel: 832.782.650024/7 Toll Free: 1.866.972.674224/7 Local: 1.832.782.6742

[email protected]@c-a-m.com

PO Box 1212Houston, TX 77251-1212, USATel: 713.983.2211Fax: 713.983.2611

www.c-a-m.com

Cameron

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