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Varco Technical Education Center
PS-21/PS-30 TrainingPS-21/30 Version 1
1
Course ObjectivesVarco Technical Education Center
Upon completion of this course the student should:One Day Course Fully understand the importance of safety and how it relates to the operation/maintenance of the PS 21/30 Understand why the PS 21/30 was developed and the design criteria behind its development Understand the system hook-up Show competency in the safe and correct operation of the PS 21/30 Know how to troubleshoot the operation of the PS 21/30 Be able to do all the above Show a high level of competency in the maintenance procedures associated with the PS 21/30
Two Day Course
PS-21/30
Version 1
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Program ContentsDay 1 General OverviewSafety General Safety Review PS 21/30 SafetyVarco Technical Education Center
General Information Background to PS 21/30 Development
General Description System Configurations Major Components System Requirements
PS-21/30
Version 1
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Program ContentsDay 1 OperationInstalling the PS 21/30 Installation process Hooking up the PS 21/30 Installation check list Equipment set-up Calculating crushing loads Selecting slips/inserts Installing the slips in the PS 21/30 Dressing & installing the insert carriers System operation Operating the PS 21/30 Routine maintenance ExaminationPS-21/30 Version 1Varco Technical Education Center
4
Program ContentsDay 2 MaintenanceSafety Analysis Dropped Pipe AnalysisVarco Technical Education Center
PS Releasing from RST
Hydraulic Systems Applying Electrical Power Applying Hydraulic Power
Setting the Slips Raising the Slips
PS-21/30
Version 1
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Program ContentsDay 2 MaintenanceAutomated Lubrication General DiscussionVarco Technical Education Center
Controls & Programming
Part Replacement Changing the Centring-Device Ram Inserts Changing the Centring-Device Ram Guides
Troubleshooting PC-POL Rules Troubleshooting Flowcharts
PS-21/30
Version 1
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Program ContentsDay 2 MaintenanceInspection Hinge Pin WearVarco Technical Education Center
Bore Wear (The Paper Test)
Repair Disassembling the Main Cylinders Replacing the Piston
Replacing the Seals Reinstalling the Main Cylinders Hoisting Rings Hydraulic Manifold Block
Cover Hinge Pins Centring Device Cylinders
ExaminationPS-21/30 Version 1
7
Varco Technical Education Center
Day 1 Operation
PS-21/30
Version 1
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PS Specific SafetyVarco Technical Education Center
The L-bars are for opening the top cover ONLY! DO NOT lift the Power Slip by the L-bars Handle with care (hydraulic hinge pins)
PS-21/30
Version 1
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PS Specific SafetyVarco Technical Education Center
The PS should be lifted ONLY with the dedicated lifting eyes
PS-21/30
Version 1
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PS Specific SafetyVarco Technical Education Center
After assembly, always lock the ram-insert in the universal guide assembly with the lynch pin
PS-21/30
Version 1
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PS Specific SafetyVarco Technical Education Center
The plate shown warns personnel against risks and dangers The plate must ALWAYS be present on the PS 21/30 The plate is a free-item and available on request at your nearest authorized Varco repair facility The best advice - Do Not touch the PS!
PS-21/30
Version 1
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Varco Technical Education Center
General InformationPS-21/30 Version 1
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Background to DevelopmentVarco Technical Education Center
The rig floor can be a dangerous place Especially with new racking systems, it is not safe to have personnel moving around on the rig floor In these cases the use of hand and foot-operated slips is not recommended
PS-21/30
Version 1
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FunctionVarco Technical Education Center
The PS 21/30 is designed to clamp and suspend tubular goodsPS-21/30 Version 1
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General DescriptionVarco Technical Education Center
The PS 21/30 is a hydraulically operated power slip which is equipped with replaceable slip assemblies and insert carriers to handle various styles and sizes of tubular The PS 21/30 can handle casing, drill pipe and drill collars and is used in combination with the Rotary Support Table
PS-21/30
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PS21/30 OperationVarco Technical Education Center
PS-21/30
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RatingsVarco Technical Education Center
PS 21 = 2-3/8 14 up to 500T
PS 30 = 2-3/8 20 up to 750T
PS-21/30
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System ConfigurationsVarco Technical Education Center
The PS 21/30 is Operated in Combination with the Rotary Table
Like the FMS, it eliminates the need for work platforms during casing operationsPS-21/30 Version 1
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System ConfigurationsVarco Technical Education Center
The PS 21/30 can be installed in a number of different rotary tables including Varcos RST
Example of PS30 in Emsco 49 Rotary Configuration
PS-21/30
Version 1
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Connection and OperationVarco Technical Education Center
Through incorporation of a hydraulic slip ring in the Varco RST, hoses do not need to be disconnected The PS 21/30 slips will set or raise when a remote command is given by the driller The status of the slips (set or up) is determined by the signal-line pressure
PS-21/30
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Rotary TablesVarco Technical Education Center
PS 21 = 37 PS 30 = 49
PS-21/30
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Back-Up TorqueVarco Technical Education Center
90,00080,000 70,000 60,000 50,000 40,000 30,000 20,000 10,000 0
13.375 10.75
Maximum Back-Up Torque (ft.lbs)
45,000ft.lbs PS21 Operational Limit
6.625 5
0
10
20
30
40
50
60
PS-21/30
Additional Pipe Weight (short tons) Version 1
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Back-Up TorqueVarco Technical Education Center
The PS 21 can generate a back-up torque up to 45,000ft.lbs - depending on weight and type of string The PS 30 can generate a back-up torque up to 55,000ft.lbs - depending on weight and type of string
PS-21/30
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Slip ArrangementVarco Technical Education Center
The PS 21/30 allows handling of all pipe sizes and types The slips have a rapidchange system with no loose parts Two handles on the middle slip retract and lock the spring-loaded retaining pin
PS-21/30
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Insert CarriersVarco Technical Education Center
Insert carriers can be changed in less than 5 minutes even with pipe in the hole A special locking mechanism eliminates the use of bolts/pins
PS-21/30
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Load RingsVarco Technical Education Center
Depending on the size of the insert carrier, one or two load rings have been added
PS-21/30
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Tubular SizesVarco Technical Education Center
PS 21
Universal Slip with Insert Carriers to Handle Pipe up to 10 Universal Ram with Ram Inserts to Centre Pipe up to 10 Size Specific Slips to Handle Pipe from 10 - 14 Size Specific Rams to Centre Pipe from 10 - 14
PS 30
Universal Slip with Insert Carriers to Handle Pipe up to 16 Universal Ram with Ram Inserts to Centre Pipe up to 16 Size Specific Slips to Handle Pipe from 16 - 20 Size Specific Rams to Centre Pipe from 16 - 20
PS-21/30
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Centering DeviceVarco Technical Education Center
When the pipe is hard to one side (due to rig movement or heavy directional drilling) a centring device centres the pipe prior to setting the slips The PS 21 always requires a centring device on floating rigs The PS 30 requires a centring device on all rigtypes
PS-21/30
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Centering DeviceVarco Technical Education Center
When a centering device is provided, a ram guide in each top cover half pushes the pipe to the centre
This happens in an automatic sequence before the slip cylinders are actuated to push the slips down No modifications to the controls is needed to operate a PS with a centring device
The ram inserts are pipe size specific and must be changed with each slip/insert carrier changePS-21/30 Version 1
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Stainless Steel Ram InsertVarco Technical Education Center
Available for drill pipe sizes 7-5/8 and smaller The guides use a steeper top and bottom lead-in chamfer to better guide the tool joint through the top guides The contact area between pipe and ram insert is enlarged A machined groove is included to maximum allowable wearPS-21/30 Version 1
indicate
31
Reliable Slips Set SignalVarco Technical Education Center
By the side-slips an indicator pin is activated which operates an indicator valve. The valves on left- and right-hand side are set in series with the barrel port signal from the right hand actuator to give a reliable slips set signal on the driller console.
PS-21/30
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Hand Slip BowlsVarco Technical Education Center
The PS 21/30 can be fitted with insert bowls for use with hand slips Extended hand slip handles are fitted between the handle and body of the hand-slip to eliminate clearance problems with the top cover
PS-21/30
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Hand Slip BowlsVarco Technical Education Center
Number#1 PN:202362 #2 PN:202363 #3 PN:202364 #3 PN:202361
PS PS 30 PS 30
Rating 150 tons 150 tons
Size Range13-3/8 11 10 9-5/8
Slip Size 16 16
PS 30PS 21/30
150 tons100 tons
8-5/8 2-3/88-5/8 2-3/8
1610
PS-21/30
Version 1
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Pipe WipersVarco Technical Education Center
When tripping out drillpipe, Varco recommends that a 19" spiral (helical) wiper be placed below the tool This wiper can be installed with the tool still in the rotary by pulling the insert carriers and lowering the wiper through the slips Position the wiper UNDERNEATH the tool to keep mud away from the moving parts of the PSPS-21/30 Version 1
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General RequirementsGeneralTubing & HosesVarco Technical Education Center
All hoses connecting the PS to the power unit/ring main must be minimum 2,300psi (with centring device) 3,000psi A closed centre power unit or ring line with a minimum of 2,500psi working pressure and 5gpm is required A flow rate of 10gpm is recommended 180F (82C)
Minimum Working Pressure Maximum Working Pressure Power Unit
Maximum Oil Temperature Application Filter
An in-line pressure filter in the hydraulic supply line between the power unit and the hookup kit An in-line 50 filter in the hydraulic signal line on the hook-up kit manifoldVersion 1
PS-21/30
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Pressure RequirementsPressure RequirementsVarco Technical Education Center
Optimum pressure is 2,500psi Pressure must not be less than 2,000psi for a PS without a centring device Pressure must not be less than 2,300psi for a PS with a centring device Back-pressure must not exceed 200psi for a PS with a centring device
PS-21/30
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Pressure RequirementsSpecial NoteVarco Technical Education Center
The sequence of the ram-guide and slip-cylinders is automatically controlled by the manifold on the PS The sequence valve is activated by a pressure difference between the slips up hose and the slips down hose The PS will function best when the activate pressure is 2,300psi and the back-pressure is no more than 200psi With these pressure settings, a centring force of tons is obtained at the ram-guides 10
PS-21/30
Version 1
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Hydraulic Fluid RequirementVarco Technical Education Center
Petroleum based hydraulic fluid with properties which provide inhibition, anti-rust, anti-foam de-aerating and anti-wear properties Fluid viscosity 150-225 SSU (SEA 10W) at 100F (38C) and with a viscosity index of 90F minimum
Do NOT use non-petroleum base or fire-resistant fluids
PS-21/30
Version 1
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Grease RequirementsVarco Technical Education Center
A high quality, multi-purpose, water-resistant, extreme pressure (EP1 or EP2) grease, with a minimum dripping point of 300F (150C) should be used
The use of grease with a dripping point of at least 480F (250C) is recommended
PS-21/30
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Grease RequirementsVarco Technical Education Center
ApplicationBowl (North Sea) Bowl (GOM)
BrandTRIBOL TRIBOL
TypeMOLUB ALLOY 968 SF Heavy MOLUB ALLOY 936 SF Heavy
QuantityN/A N/A
Cylinder Housing
TRIBOL
MOLUB ALLOY 968 SF Heavy
50cc (3.2in)
PS-21/30
Version 1
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Varco Technical Education Center
Installing the PS 21/30PS-21/30 Version 1
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Power Slip IdentificationVarco Technical Education Center
The identification stamp individually identifies the toolIt is therefore very important that, when contacting Varco for service purposes, to have this information availablePS-21/30 Version 1
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Installing the PS in the RotaryVarco Technical Education Center
3. Lift the PS with the special lifting sling
PS-21/30
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Installing the PS in the RotaryVarco Technical Education Center
4. Rotate the locking pins to the retracted position
PS-21/30
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Installing the PS in the RotaryVarco Technical Education Center
5.
Ensure that the manifold block on the PS 21/30 is on the same side as the hoses/connections and the drive-lugs (lugs, pockets or pins) are in position with those of the rotary Lower the PS 21/30 into the rotary table
6.
7. Engage the locks
PS-21/30
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Hooking Up the PSFlushing/Filtering SystemVarco Technical Education Center
An in-line filter is placed between the rigs pressure ring and the pressure line to the PS hook up system A flushing manifold ensures that all return oil flows directly into the rigs return ring line and does not re-enter the hook up kit manifold
The indicator gives information about the condition of the filter: Green = OK Red = Exchange filterPS-21/30 Version 1
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Hooking Up the PSVarco Technical Education Center
Mounting Plate
Top Plate = HUK
Bottom Plate = flushing + greasing
PS-21/30
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Hooking Up the PSAutomatic slip greasing and hydraulics flushing cabinetVarco Technical Education Center
PS-21/30
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Hooking Up the PSMounting plate hydraulic hook up manifoldVarco Technical Education Center
PS-21/30
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Hooking Up the PSVarco Technical Education Center
Grease pump + bucket
PS-21/30
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Hooking Up the PSVarco Technical Education Center
Drillers Control Panel
Hook Up Manifold Slips Up Switch (1600psi) Slips Set Switch (1800psi) Low Pressure Switch (2000psi)
JB
Accumulator
Manifold Block
Hydraulic Controls
Pressure Control (2500psi)
PS 21/30
Pressure Filter
PS-21/30
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Hooking Up the PSPS21 with centering device and automatic slip greasing system 5 hoses to be connected;Varco Technical Education Center
GREASE SIDE-SLIPS
SLIPS DOWN
SIGNAL
SLIPS UP
GREASE CENTER SLIPPS-21/30 Version 1
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Hooking Up the PSStandard PS-21 3 hoses to be connected;Hydraulic hose for slips down Hydraulic hose for slips up Hydraulic signal hoseVarco Technical Education Center
SLIPS UP SIGNALVersion 1
SLIPS DOWNPS-21/30
56
Hooking Up the PSPS 30 in RST configuration, without automatic slip greasing systemVarco Technical Education Center
Grease nipple
Grease nipple
SLIPS UPPS-21/30
SLIPS DOWNVersion 1
SIGNAL
57
Hooking Up the PSPS 30 in any configuration but RST, with automatic slip greasing system 5 hoses to be connectedVarco Technical Education Center
SLIPS UP GREASE CENTER_SLIP
GREASE SIDE SLIPS
SLIPS DOWN
SIGNAL
PS-21/30
Version 1
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Installation ChecklistVarco Technical Education Center
Arrange the hoses on the rig floor in such a position that the hazard of cutting or dragging is minimised Before operating, remove air from the hydraulic circuit by fully cycling the slips 10 times (or flush with flushing kit) Varco recommends that only OEM controls be used to operate the PS use of other controls may result in hydraulic circuit damage
PS-21/30
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Varco Technical Education Center
Equipment Set-UpPS-21/30 Version 1
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Pipe Crushing LoadsVarco Technical Education Center
F = Qyp x A x
1
1+
RK + L
RK L
2
F Qyp A
= = =
Crushing Load (lbs) Yield Stress of Pipe (psi) Sectional Area of Pipe (in2)
R L A
= = =
Outside Radius of Pipe (in) Length of Slip Contact (in) Crushing Factor (Nominally 2.6)
PS-21/30
Version 1
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Varco Technical Education Center
Opening
Maximum Throat Opening (Slips-Up)
Ram Guides
P/N for Ram Guides for PS21 with CD
202346-663
P/N for Fixed Guide for PS21 Without CD
202302-913
Selecting Slips & Inserts
Fixed Guides
Fixed Guide Diameter (in) for PS21 without CD
Insert p/n
2632
Slips & Inserts
Insert Carrier Assembly Less Inserts p/n
202273-1
Insert Carrier Assembly p/n
202273-663
Slip Body p/n
202250-1 500T
Pipe Size & Type
Rating
Plain DC (in) Zip DC (in) Nominal Size (in)
-
-
PS-21/30 65/8
Version 1
Qty of Inserts
24B-48
9-1/8
11-5/8
62
Installing the Slip in the PSVarco Technical Education Center
Ensure that hydraulic lines are disconnected before ANY work is carried out on the PS-21/30
PS-21/30
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Installing the Slip in the PSVarco Technical Education Center
Open the top covers using the tugger line Grease the ribs on the inner bore of the PS 21/30 Grease the ribs of the slip assembly
PS-21/30
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Installing the Slip in the PSVarco Technical Education Center
Note: Slip-pin engagement will be easier with the lifting arms approx. 1/3 down (45)
Control the slips down and stop the movement with the ball valve in the slips-down line
PS-21/30
Version 1
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Installing the Slip in the PSVarco Technical Education Center
Lower the slipassembly using the slip assembly lifting tool. P.N:50004551
Position the upper center-slip rib in between the actuator leversPS-21/30 Version 1
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Installing the Slip in the PSMove the slip mounting pins outward use the special operating tool for PS slip handles P.N: 50004552Varco Technical Education Center
Push the pins from inside the slotted hole and LOCK the slip assemblyPS-21/30 Version 1
67
Installing the Slip in the PSVarco Technical Education Center
4.
After lowering the slip assembly into the PS 21/30, disconnect the handling tools.
PS-21/30
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Sizing the InsertsSize inserts for slip body 10 for PS-21Varco Technical Education Center
The correct insert carrier can be measured with an OD calliper using: X = 7 ( (nominal size clamping diameter) / 2 )
PS-21/30
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Dressing the Insert CarrierVarco Technical Education Center
1.
Remove the screws and spring washers on top of the insert carrier assembly
DO NOT grease the grooves Bottom inserts must be Beveled
PS-21/30
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Dressing the Insert CarrierVarco Technical Education Center
2.
Dress the slip assembly and lock it with socket head lock-screws and lockwashers When changing insert SIZE, DO NOT forget to grind and new stamp the correct SIZE
DO NOT forget the yellow SIZING Insert (basic insert) P.N:50004570(1) Size
PS-21/30
Version 1
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Installing the Insert CarrierVarco Technical Education Center
1.
Pick up the insert carrier assembly with the revised pogo-stick for lifting insert-carriers PS P.N:50004600-1 Grease the back of the lock trigger and the big dovetail
2.
PS-21/30
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Installing the Insert CarrierVarco Technical Education Center
3. Place the insert carrier with the dove tail on the insert carrier retainer in the slip and push the latch back with the insert carrier
Lift the insert carrier with the insert carrier lifting hook DO NOT grease the back of the insert carrier!PS-21/30 Version 1
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Installing the Insert CarrierVarco Technical Education Center
4.
Lower the insert carrier
PS-21/30
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Installing the Insert CarrierVarco Technical Education Center
5. 6.
The latch will engage automatically Connect the hydraulic hoses to the PS 21/30
PS-21/30
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Removing the SlipsVarco Technical Education Center
1. 2. 3. 4.
Raise the slips Close the ball-valve in the slips down hose Operate the controls to set the slips Slightly open the ball-valve and lower the slips just enough to have slack on the slip quick-release pins Close the ball-valve and disconnect the hoses Connect a 2-way lifting sling to the lifting eyes on the right and left slip segments Gently raise the slips until the quick release slip pins can be retracted
5. 6.
7.
PS-21/30
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Removing the SlipsVarco Technical Education Center
8. Disconnect the slip quickrelease pins
PS-21/30
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Disconnecting HosesVarco Technical Education Center
Hoses could be disconnected: To allow the tool to be lifted out of the rotary table To allow the PS and rotary table to be rotated Hoses must be disconnected: To prevent unwanted slip movement especially when someone has to work on the PS
Be careful when disconnecting hydraulic hoses Ensure that pressure is off the hoses and that string weight cannot generate pressure
PS-21/30
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Disconnecting HosesWith Slips UP 1. 2. 3. 4. Raise the slips Close the ball-valve in the slips-set hose Operate the controls to set the slips Disconnect the quickconnects - keep the controls in the slip-down position and keep the ball-valve closed Reconnect the quickconnects Operate the controls to raise the slips Open the ball-valve in the slips-down hoseVarco Technical Education Center
5. 6. 7.
PS-21/30
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Disconnecting HosesWith Slips SETVarco Technical Education Center
1. Set the slips2. 3. Close the ball-valve Disconnect the quickconnects keep the controls in the slips-down position and keep the valves closed Re-connect the quickconnects
4.
5. Open the ball-valve
PS-21/30
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Varco Technical Education Center
OperationPS-21/30 Version 1
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Operating the PS21/30Remember.Varco Technical Education Center
Be aware of the limited back-up for torque
Check that the slips/carriers are set on the correct section of the pipe The PS must be set before releasing the elevator (preferably using an interlock) The PS is properly set when the slips down signal comes on When the rotary table and the PS have to be rotated, always decouple the quick disconnects on the PS prior to rotation (except for RST) - not doing so may cause severe damage to the PS, hydraulic hoses or controls
PS-21/30
Version 1
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Operating the PS21/30Varco Technical Education Center
With the string held in the PS, make-up or break the upper stand or joint and handle it Never raise the slips whilst the pipe load is suspended in the slips
Connect all hydraulic equipment & check correct tool function
Install the PS in the rotary using all 4 x lifting eyes and 4way lifting sling ALWAYS pick up the weight of the pipe string with the elevator BEFORE raising the slipsPS-21/30 Version 1
ALWAYS Set the slips before releasing the elevator
83
Operating the PS21/30Recommendations.Varco Technical Education Center
It is recommended that the PS be operated by the driller It is recommended that the pipe is lowered slightly with the elevators whilst setting the slips It is recommended that the pipe is raised slightly with the elevators whilst releasing the slips The rotary locks on the PS may only be needed on floating rigs or while floating in pipe in case the PS is pushed out of the rotary
PS-21/30
Version 1
84
Removing the PSWith Pipe in the HoleVarco Technical Education Center
BE AWARE of loose parts while lifting DO NOT lift the PS using the L-bars on the cover Lift the PS out of the rotary table ONLY using the 4-way lifting sling with curved spreader beam use ALL 4 hoist swivel rings Beware of pinching fingers between the body and the door NEVER place hands anywhere else than on the top of the door
PS-21/30
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Removing the PSWith Pipe in the HoleVarco Technical Education Center
Lift the PS & Swing the door open Disconnect the Hydraulic Hoses Raise the slips and disengage the rotary table locks
Disengage the top cover lock on the door and gently open the top cover
Remove the hinge pin
PS-21/30
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Handling ToolsHand-Slip Bowl Handling ToolLock Varco Technical Education Center
1. 3. 4.
Locate the tool Pull backward and lift the bowl Remove the bowl with a tugger line
2. Lock the tool
PS-21/30
Version 1
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Handling ToolsSlip Handle Operating ToolVarco Technical Education Center
PS-21/30
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Handling ToolsSlip Assembly Lifting ToolVarco Technical Education Center
PS-21/30
Version 1
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Varco Technical Education Center
Routine MaintenancePS-21/30 Version 1
90
Daily InspectionDaily Inspection1. 2. 3. 4. 5. 6. Check for worn and damaged parts Check for loose and missing parts Check correct sizes of slips, insert carrier and top guide/ram Check correct installation of these parts Check hoses for sign of cracks, wear or abrasion Inspect hoist ring parts. Never use hoist ring that shows: signs of corrosion wear damage 7. 8. 9. Check if bail is bent or elongated Check and clean rotary table Check locking of: bolts and nuts safety wire slotted nuts & cotter pins bent lock tabs, safety latch pins & lock bars roll and dowel pins snap rings cotter pinsVarco Technical Education Center
PS-21/30
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Functional InspectionVarco Technical Education Center
Functional Inspection1. Connect the PS 21/30 to the control manifold and check: Correct function of tool Slips Up: Slips raise then centring rams go out Slips Set: Centring rams go in first then slips set Check hydraulic pressure
2.
Check Slip Signals:Check slips down signal is on when slips are set: Check slips down signal is off when slips are up Check slips up signal is on when slips are up Check slips up signal is off when slips are down
3. 4. 5. 6. 7.
If the PS door was open on installation, check that the removable hinge-pin has been re-installed Check correct engagement of slip and insert carrier quick release mechanism Check correct installation and locking of centring rams/ram inserts Engage the top cover lock after inspection Always keep top cover lock engaged during operation
PS-21/30
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LubricationVarco Technical Education Center
Do NOT apply grease: To the back-side of the insert carriers (except for the dovetail slot) To the inner bore of the slips To the dovetail slots retaining the inserts The back-side of inserts
NEVER use tool-joint compound (pipe dope) for lubrication purposes
PS-21/30
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93
LubricationVarco Technical Education Center
Manual lubrication of the PS 21/30: After every 25 joints (average) run Prior to cementing When loads will be hanging for more than 1 hour Prior to storage
Automated lubrication of the PS 21/30: Automated greasing of the back of the slips is carried out after 25 slip movements
Carry out a manual grease cycle with the grease system at the start and finish of every tool usage.
PS-21/30
Version 1
94
Manual Lubrication with AGSAutomated Grease SystemVarco Technical Education Center
Red light indicates when grease bucket empty Push the button once for one grease sequence at start and finish of every tool usage
PS-21/30
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95
Manual LubricationVarco Technical Education Center
Action 1 2 3 4 5 6 7 8 Flushing and filtering system Grease the cylinder levers Grease the nipples on the outside of the top cover Grease the nipples on the inside of the top cover (ram guides) Grease the nipples on the top cover hinge pins Grease the nipples on the knuckle pins Grease the hinge pins Grease the door hinge pins
Nipples 4 2 2 2 2
Method After connecting the hydraulic hoses to the PS
Apply grease manually or use a grease gun until grease is seen exiting the bores
4-
PS-21/30
Version 1
96
Manual LubricationGrease the Cylinder LeversVarco Technical Education Center
PS-21/30
Version 1
97
Manual LubricationGrease the Nipples on the Outside of the Top CoverVarco Technical Education Center
PS-21/30
Version 1
98
Manual LubricationGrease the Nipples on the Inside of the Top Cover (Ram Guides)Varco Technical Education Center
PS-21/30
Version 1
99
Manual LubricationGrease the Nipples on the Hinge BossesVarco Technical Education Center
PS-21/30
Version 1
100
Manual LubricationGrease the Nipples on the Knuckle PinsVarco Technical Education Center
PS-21/30
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101
Manual LubricationGrease the Top Cover Hinge PinsVarco Technical Education Center
PS-21/30
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102
Manual LubricationGrease the Door Hinge PinsVarco Technical Education Center
PS-21/30
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103
Manual LubricationVarco Technical Education Center
Lubricate the Insert Carrier/Slip Set: Prior to installation Prior to storage
PS-21/30
Version 1
104
Manual LubricationGrease the Insert Carrier/Slip Set before installationAction 1 2 3 Grease the back of the slips Grease the lock trigger Grease the dovetail of the insert carriers Apply with a brush MethodVarco Technical Education Center
PS-21/30
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105
Manual LubricationGrease the Back of the SlipsVarco Technical Education Center
PS-21/30
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106
Manual LubricationGrease the Lock TriggerVarco Technical Education Center
PS-21/30
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Manual LubricationGrease the Dovetail SlotVarco Technical Education Center
PS-21/30
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108
Manual LubricationWeekly LubricationAction 1 2 3 Grease the slot in the ram guides Grease the cover plate lock Grease the sliding mechanism Apply with a brush MethodVarco Technical Education Center
PS-21/30
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Manual LubricationGrease the Ram Guide SlotVarco Technical Education Center
PS-21/30
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Manual LubricationGrease the Top Cover LockVarco Technical Education Center
PS-21/30
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Manual LubricationGrease the Sliding MechanismVarco Technical Education Center
PS-21/30
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112
Automated Slip GreasingVarco Technical Education Center
The performance of the PS power slip is related directly to the greasing of the back of the slipsVarco has developed an automatic greasing system which uses standard grease buckets The system greases the backside of the slip every 25 slip cycles
PS-21/30
Version 1
113
Automated Slip GreasingVarco Technical Education Center
The system uses the slips set pressure switch signal to count the slip cycles and, at a preset number of cycles the grease pump starts to pump grease from the bucket The grease is divided using a directional control valve
Directional Control Valve
PS-21/30
Version 1
114
Automated Slip GreasingVarco Technical Education Center
Port A
Ports B & C
Center Slip
Left/Right Slip
PS-21/30
Version 1
115
Automated Slip GreasingVarco Technical Education Center
Using a dedicated PLC, greasing frequency and quantity can be adjusted to meet job specific requirements
Siemens PLC
PS-21/30
Version 1
116
Automated Slip GreasingVarco Technical Education Center
Light on top of Junction Box
Manual Grease Cycle
PS-21/30
Version 1
117
Flushing and FiltrationVarco Technical Education Center
PS-21/30
Version 1
118
Flushing and FiltrationVarco Technical Education Center
Operate the flush handle for flushing
PS-21/30
Version 1
119
Varco Technical Education Center
Day 2 MaintenancePS-21/30 Version 1
120
Varco Technical Education Center
Safety Analysis
PS-21/30
Version 1
121
Dropped Pipe AnalysisVarco Technical Education Center
Ram Insert Not Installed Lynch Pin Not Used OR Lynch Pin Not Properly Fastened Ram Insert Fallen Out OR
PS-21/30
Version 1
122
Dropped Pipe AnalysisVarco Technical Education Center
Rig Movement (Floaters) OR Heavy Directional Drilling AND Malfunctioning Hydraulic Hinge Pin No Centring Device OR Malfunctioning Centring Device OR Top Cover Open Cylinder Mounting Plate Loose Knuckle Centring Device Loose Knuckle Pin Lost
No Ram Insert
PS-21/30
Version 1
123
Dropped Pipe AnalysisVarco Technical Education Center
No Insert Carriers Inserts Too Small Worn Inserts OR Opening (Slips Set) Is Too Big
Slip Actuator Defective Pipe String Tilted Sticking Slips
OR
Slips Not Fully Down
OR
Malfunctioning Interlock PS-21/30 Version 1
Dropped Pipe
Malfunctioning Hydraulics
124
PS Releasing from RSTVarco Technical Education Center
Rotary Table Lock Not In Rotary Table Locks Broken
OR
Rotary Table Not Functioning Buoyancy While Running Casing AND
BX Pulling Up AND PS Slips Set
Interlock Malfunctioning
OR
Sticking Slips Malfunctioning Hydraulics OR
Set Slips Dont Release AND
PS Releases From RST
Rig Movement OR Kicks PS-21/30
Upward Pipe Movements Version 1
125
Varco Technical Education Center
Hydraulic SystemsPS-21/30 Version 1
126
Applying Electrical PowerVarco Technical Education Center SYSTEM PRESSURE LOW POWER
SIGNAL PS 30 OPEN
SIGNAL PS 30 CLOSED
Power
SLIPS OPEN
SLIPS CLOSED
PS-21/30
Version 1
127
Applying Electrical PowerVarco Technical Education Center31 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
9
101
P Power O
11
1 2 3 4 5 6 7 8 30
1 2 3 4 5 6 7
12
13
PS-21/30
Version 1
128
Applying Hydraulic PowerVarco Technical Education Center
ACCU
To/From Grease/Flushing Kit
To Hook-Up Kit
PPS-21/30
BVersion 1
129
Low Pressure AlarmVarco Technical Education Center E1 2
3
2
1
PS1
PPS-21/30 Version 1
T
130
Low Pressure AlarmVarco Technical Education Center
E149E2 10E2 11E3 12E3 13E3 9E3 10E3 11E2 12E2 13E2 9E1 10E1 12E1 13E1 11E1 14E4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1
E9 E10
2
E11 E12
3 4 6 7 5
E13
14E1
8
PS-21/30
Version 1
131
Low Pressure AlarmVarco Technical Education Center31 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
9
101
P Power O
11
1 2 3 4 5 6 7 8 30
1 2 3 4 5 6 7
12
13
PS-21/30
Version 1
132
Low Pressure AlarmVarco Technical Education Center SYSTEM PRESSURE LOW POWER
SIGNAL PS 30 OPEN
SIGNAL PS 30 CLOSED
Power
SLIPS OPEN
SLIPS CLOSED
PS-21/30
Version 1
133
Setting the SlipsVarco Technical Education Center SYSTEM PRESSURE LOW POWER
SIGNAL PS 30 OPEN
SIGNAL PS 30 CLOSED
Power
SLIPS OPEN
SLIPS CLOSED
PS-21/30
Version 1
134
Setting the SlipsVarco Technical Education Center31 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
9
101
P Power O
11
1 2 3 4 5 6 7 8 30
1 2 3 4 5 6 7
12
13
PS-21/30
Version 1
135
Setting the SlipsVarco Technical Education Center
E149E2 10E2 11E3 12E3 13E3 9E3 10E3 11E2 12E2 13E2 9E1 10E1 12E1 13E1 11E1 14E4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1
E9E10
2
E11 E12
3 4 6 7 5
E13
14E1
8
PS-21/30
Version 1
136
Setting the SlipsVarco Technical Education Center
E9
3
2
1
1
2
3
B1PS-21/30
TVersion 1
P
A1
E1 0
137
Setting the SlipsVarco Technical Education Center
S1 B1 A1
To/From Grease/Flushing Kit
To Hook-Up Kit
PPS-21/30
TVersion 1
138
Setting the SlipsVarco Technical Education Center
B1PS-21/30
A1Version 1
S1
139
Setting the SlipsVarco Technical Education Center
E11
3
2
1
PS2
B1
SV1
S1
PS-21/30
Version 1
140
Setting the SlipsVarco Technical Education Center
E149E2 10E2 11E3 12E3 13E3 9E3 10E3 11E2 12E2 13E2 9E1 10E1 12E1 13E1 11E1 14E4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1
E9 E10
2
E11 E12
3 4 6 7 5
E13
14E1
8
PS-21/30
Version 1
141
Setting the SlipsVarco Technical Education Center31 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
9
101
P Power O
11
1 2 3 4 5 6 7 8 30
1 2 3 4 5 6 7
12
13
PS-21/30
Version 1
142
Setting the SlipsVarco Technical Education Center SYSTEM PRESSURE LOW POWER
SIGNAL PS 30 OPEN
SIGNAL PS 30 CLOSED
Power
SLIPS OPEN
SLIPS CLOSED
PS-21/30
Version 1
143
Raising the SlipsVarco Technical Education Center SYSTEM PRESSURE LOW POWER
SIGNAL PS 30 OPEN
SIGNAL PS 30 CLOSED
Power
SLIPS OPEN
SLIPS CLOSED
PS-21/30
Version 1
144
Raising the SlipsVarco Technical Education Center31 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
9
101
P Power O
11
1 2 3 4 5 6 7 8 30
1 2 3 4 5 6 7
12
13
PS-21/30
Version 1
145
Raising the SlipsVarco Technical Education Center
E149E2 10E2 11E3 12E3 13E3 9E3 10E3 11E2 12E2 13E2 9E1 10E1 12E1 13E1 11E1 14E4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1
E9 E10
2
E11 E12
3 4 6 7 5
E13
14E1
8
PS-21/30
Version 1
146
Raising the SlipsVarco Technical Education Center
E9
3
2
1
1
2
3
B1PS-21/30
T
PVersion 1
A1
E1 0
147
Raising the SlipsVarco Technical Education Center
S1 B1 A1
To/From Grease/Flushing Kit
To Hook-Up Kit
PPS-21/30
TVersion 1
148
Raising the SlipsVarco Technical Education Center
B1PS-21/30
A1Version 1
S1
149
Raising the SlipsVarco Technical Education Center
E13
3
2
1
PS3
SV2
A1
S1
PS-21/30
Version 1
150
Setting the SlipsVarco Technical Education Center
E149E2 10E2 11E3 12E3 13E3 9E3 10E3 11E2 12E2 13E2 9E1 10E1 12E1 13E1 11E1 14E4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1
E9 E10
2
E11 E12
3 4 6 7 5
E13
14E1
8
PS-21/30
Version 1
151
Raising the SlipsVarco Technical Education Center31 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
9
10 1
P Power
O
11
1 2 3 4 5 6 7 8 30
1 2 3 4 5 6 7
12
13
PS-21/30
Version 1
152
Raising the SlipsVarco Technical Education Center SYSTEM PRESSURE LOW POWER
SIGNAL PS 30 OPEN
SIGNAL PS 30 CLOSED
Power
SLIPS OPEN
SLIPS CLOSED
PS-21/30
Version 1
153
FunctionsVarco Technical Education Center
ACC
Minimizes Pressure Fluctuations and Assures Pressure for Torque Back-Up Feature
CV 1PC 1
Check Valve Protects Against Unloading of AccumulatorPressure Reducing Valve for a Constant Pressure Set @ 2500psi
PG 1DV 1 PS 1
Pressure Gauge to Check System PressureOperates Slips Low Pressure Indicator
PS 2PS 3
Pressure Switch for Signal Slip SetPressure Switch for Signal Slip Up
PS-21/30
Version 1
154
FunctionsVarco Technical Education Center
SV 1
Controls Slip Down" Signal
SV 2CV 2
Controls Slip Up" SignalProtection Against Switching P&T Line
PS 1,2,3 Pressure Switches
F1 to F5 FiltersPG 2 PG 3 Pressure Gauge to Check Slips Set Signal Pressure Gauge to Check Slips Up Signal
PS-21/30
Version 1
155
FunctionsVarco Technical Education Center
PC 1 The control manifold can be connected to a closed centre power supply with working pressure between 2,500 and 3,000psi Because the PS has a maximum working pressure of 2,500psi, PC 1 is set at 2,500psi to protect the PS against overloading ACC, CV 1 & PS 1 The accumulator ACC and check valve CV 1 reduce pressure fluctuations in the power supply and maintain the back-up feature
Should the pressure in the accumulator drop below 2,000psi, PS 1 gives a signal that the back-up feature is no longer valid
PS-21/30
Version 1
156
FunctionsVarco Technical Education Center
DV 1 This directional control valve operates the slips SV 1 & SV 2 When the slips are set, the PS gives a hydraulic signal back to the control manifold SV 1 transfers this signal to the pressure switch PS 2, eliminating a false signal in the slips up position PRV 1 & FC 1 PRV 1 (pressure relief valve) controls the slips power up force whilst FC 1 (flow control) controls slip speed
PS-21/30
Version 1
157
Varco Technical Education Center
Automated LubricationPS-21/30 Version 1
158
Automated LubricationSiemens PLC systemVarco Technical Education Center
By using the buttons on the front of the SIEMENS LOGO, the parameters for the timer can be set and changed Three settings are important; 1. The time the solenoid is operated to accomplish a full pump stroke (B20 and B22)The higher the viscosity the longer it takes to make a full pump stroke A is the centre slip whilst B and C are the left hand and right hand slips
2. The time a greasing sequence is taking (B08 and B09)The type of grease and the viscosity determines these parameters
3. B06 is the number of slips sets after which a grease cycle startsThis depends on the grease properties and field conditions
PS-21/30
Version 1
159
Automated LubricationSiemens PLC systemVarco Technical Education Center
The SIEMENS LOGO is brought up on the module by pressing the "ESC" and "OK" buttons simultaneously
The following message appears on the display:
PS-21/30
Version 1
160
Automated LubricationSiemens PLC systemVarco Technical Education Center
By using the scroll buttons, select "Set Param" option and press "OK"
By using the scroll buttons, select the function block required
PS-21/30
Version 1
161
Automated LubricationSiemens PLC systemVarco Technical Education Center
If you want to change the parameters, select the function block and press "OK"
The following message appears on the display;
B3 : T T Ta
=00.50s =00.00s
PS-21/30
Version 1
162
Automated LubricationSiemens PLC systemVarco Technical Education Center
B03 is the function block T for the set value Ta is the actual value
To close the parameter module press "ESC" twicePS-21/30 Version 1
163
Varco Technical Education Center
Regular InspectionsPS-21/30 Version 1
164
Six-Monthly InspectionVarco Technical Education Center
Inspection Tasks 1 2 Clean tool thoroughly Check that all grease restrictors are open
34 5 6 7
Check that all grease nipples are present and functionalCheck condition of in-line filters in hook-up manifold Check condition of hoist swivel rings (4 off) replace if necessary Grease tool according to normal procedures Use paper test to check PS 21/30 body v slip fit
PS-21/30
Version 1
165
Annual InspectionVarco Technical Education Center
Inspection Tasks 1 Replace top cover hinge pin seals Remove hydraulic cylinders from body check for: 2Rust Denting Cracks Damage
34 5 6 7
Replace all sealsCheck piston is still fixed on rod Apply new grease to gear Assemble cylinders and check barrel bolts for correct torque Carry out magnetic particle inspection against relevant drawing
PS-21/30
Version 1
166
Varco Technical Education Center
Part Replacement
PS-21/30
Version 1
167
Centering Device Ram InsertsVarco Technical Education Center
1. 2. 3.
Close the ball valve Disengage the top cover lock and open the top covers Remove the lynch pin clip that locks the ram insert into the universal ram guide
PS-21/30
Version 1
168
Centering Device Ram InsertsVarco Technical Education Center
4.
Replace the ram insert 2 x threaded holes for lifting eyes are provided in each ram insert to ease handling Lock the new ram insert with the lynch pin clip Close and lock the top covers Open ball valve
5. 6. 7.
PS-21/30
Version 1
169
Centering Device Ram GuidesVarco Technical Education Center
1. 2.
Close the ball valve Disengage the top cover lock and open the top covers
PS-21/30
Version 1
170
Centering Device RamVarco Technical Education Center
3.
Remove the ram hinge pin
PS-21/30
Version 1
171
Centering Device RamVarco Technical Education Center
4. 5. 6.
Remove the knuckle pin Replace the ram Re-assemble the pins and the pin retainers lock-wire the bolts on the pin retainers Open the ball valve
7.
PS-21/30
Version 1
172
Fixed GuidesPS 21 without Centring DeviceVarco Technical Education Center
1.
Open the top covers
2. Disconnect the lynch pin from pin on guide half
PS-21/30
Version 1
173
Fixed GuidesPS 21 without Centring DeviceVarco Technical Education Center
3. 4. 5.
Change out ram guide halves Re-assemble lynch pin Close & lock top covers
PS-21/30
Version 1
174
Varco Technical Education Center
TroubleshootingPS-21/30 Version 1
175
PC-POL RulesVarco Technical Education Center
P C P
Check that Pressure to the hook-up manifold is 2300psi min
Check that all hoses and quickconnects are properly Connected and the ball valve is openCheck that electrical Power is available at the control panel
O
Check for Oil leakage at the manifold block, hook-up kit, quick-connects and hoses
LPS-21/30
Check Lubrication of the PS
Version 1
176
Pipe Slipping through InsertsVarco Technical Education Center
Are teeth on inserts worn?
Yes
Replace Inserts
No
Wrong Insert Carriers?
Yes
Check/Change-Out Insert Carriers
No
Wrong Inserts?
Yes
Check/Change-Out Inserts
No
PS-21/30
Version 1
177
Pipe Slipping through InsertsVarco Technical Education Center
Slips Not Setting Correctly?
Yes
Lack of Grease or Dirt in Slip Cylinder
No
Lack of Slip Down-Force?
Yes
Check Pressure & Accumulator
PS-21/30
Version 1
178
Slips are CockingVarco Technical Education Center
Wrong Insert Carriers
Yes
Check/Change-Out Insert Carriers
No
Wrong Inserts?
Yes
Check/Change-Out Inserts
No
Radial Force On Door Side?
Yes
Rotate PS with centre slip toward deviation Install Centring Device on PS21
No
PS-21/30
Version 1
179
Slips are CockingVarco Technical Education Center
Wrong Ram Inserts In Centering Device?
Yes
Check/Change-Out Ram Inserts
No
Slips Not Setting Properly?
Yes
1. Lack of Grease 2. Slip Hinge Pins not Greased, Broken or Badly Assembled 3. Accumulator Faulty 4. Incorrect Ram Sequencing check pressure differential 5. Dirt in PS Manifold flush or clean 6. Incorrect pressure setting on sequencing valve 1900psi 7. Dirt in slip cylinder inspect and repair as necessary
PS-21/30
Version 1
180
Slips are Not Fully RetractingVarco Technical Education Center
Dirt between body and slips?
Yes
Remove slip and clean slip/body
No
Excessive Friction on Hinge Pins?
Yes
Grease Hinge Pins
NoSlip Cylinder Piston Not Stroking Fully?
Check Torsion Springs on Hinge Pins
Yes
Dirty cylinder Inspect & Repair
No
Piston is Loose Inspect & Repair
PS-21/30
Version 1
181
Slips are Not Fully RetractingVarco Technical Education Center
Incorrect Hydraulic Pressure?
Yes
Check Pressure From Power Supply to Hook-Up Kit Check In-Line Filters
NoCheck Quick-Connects
Lack of Lubrication?
Yes
Grease Slips/Body
No
Ensure Correct Grease Distribution
Check Grease System & Outlets
PS-21/30
Version 1
182
Slips are Not Fully RetractingVarco Technical Education Center
Malfunctioning Directional Valve?
Yes
Dirt in Hydraulic System
Back-Pressure Too High
PS-21/30
Version 1
183
Slips Do Not Move Up or DownVarco Technical Education Center
No/Low Hydraulic Pressure?
Yes
Set Correct Slips-Up Pressure
Back-Pressure Too High
Check Connections
Check Ball Valve
PS-21/30
Version 1
184
Slips Sagging when IsolatedVarco Technical Education Center
Worn Left Hand Cylinder Seals?
Yes
Replace Piston Seals
No
Malfunctioing Pilot Check Valve?
Yes
Check for Dirt in Pilot Check Valve
Defective Valve Inspect & Repair
PS-21/30
Version 1
185
Inappropriate SignalsVarco Technical Education Center
HUK Manifold not Getting Signal From PS?
Yes
1. 2. 3. 4.
NoNo Signal from HUK Manifold to Pressure Switch?
Check Quick-Connects Check Accumulator Check In-Line Filters Check Middle Barrel Port on RH Cylinder 5. Check Piston Seals in RH Cylinder replace if necessary
Yes
1. Dirt in HUK Manifold 2. Incorrect Setting of SV1 & SV2 Should be 1500psi 3. Back-Pressure on SV1 & SV2 Too High
No
Malfunction of Pressure Switches on HUK?
Yes
1. Dirt Inside Pressure Switch 2. Incorrect Setting Pressure Switches 3. Incorrect Wiring of Pressure Switches
PS-21/30
Version 1
186
Slip Travel Too SlowVarco Technical Education Center
Insufficient Hydraulic Pressure?
Yes
No
1. Check for Blocked Filter(s) 2. Check Accumulator 3. Check Operation of Sequencing Valves 4. Dirt in PS Manifold 5. Check Pressure Setting of Sequencing Valve 1900psi 6. Check Pressure to HUK Manifold 2300psi
Insufficient Hydraulic Flow?
Yes
1. Check Quick-Connects 2. Check Ball-Valve in Slips-Set Hose 3. Check Flow in HUK Pressure Line 5gpm Min to 10gpm Max
PS-21/30
Version 1
187
Top Cover Ram MalfunctionVarco Technical Education Center
Piston Not Fully Stroking?
Yes
Check for Dirt In Cylinder
NoKnuckle on Cylinder Rod Not Connected?
Yes
Check Assembly of Knuckle
No
Leak From Top Cover Hinges?
Yes
Disassemble & Check Condition
PS-21/30
Version 1
188
Insert Carriers SlippingVarco Technical Education Center
Insert Carriers Improperly Latched?
Yes
1. Dirt Under latches 2. Lifting Hook Not Seating Properly 3. Dirt on Top of Slip
PS-21/30
Version 1
189
Difficulty Installing SlipsVarco Technical Education Center
Center Slip Mounting Pins Stuck?
Yes
No
1. Check for Dirt in Sliding Hole Inside Centre Slip 2. Check Drain Hole in Sliding Hole 3. Check Greasing of Mounting Pins 4. Check that Pins are Not Bent 5. Check Assembly Procedure 6. Check Function of Ball-Valve in Slips-Set Hose
Handles Preventing Full Retract?
Yes
Check Orientation Of Mounting Pin Handles
PS-21/30
Version 1
190
Insert Carrier AssemblyVarco Technical Education Center
Build-Up of Dirt?
Yes
1. Clean Carriers Outer Contour and Retainer Slot 2. Clean Slip Inner Contour and Retainer
No
Bad Fit Between Carrier & Slip?
Yes
1. Remove Burrs from Both Components 2. Check Condition of Slips Carrier Retainer & Replace if Necessary
No
Malfunction of Quick Release?
Yes
1. Check Function of Latches on Top of Slip 2. Check that Lifting Eye on Top of Carrier Can Move Freely
PS-21/30
Version 1
191
Inserts Cracking or BreakingVarco Technical Education Center
Wrong Inserts?
Yes
Ensure Inserts Are Original Varco Supply
No
Pipe Impact?
Yes
1. Check Sizing of Ram Inserts 2. Check that Bevelled Inserts are Installed in Bottom Row
PS-21/30
Version 1
192
Breaking Lifting EyesVarco Technical Education Center
Have Lifting Eyes Been Overloaded?
Yes
1. Never lift PS with Top Cover LBars 2. Only Use the Dedicated Lifting Sling 3. Replace the Lifting Eyes
No
Have Lifting Eyes Been Side-Loaded?
Yes
1. Only Use the Lifting Eyes For Hoisting Purposes 2. Replace the Lifting Eyes
PS-21/30
Version 1
193
Internal Tubing LeaksVarco Technical Education Center
Is Tubing Moving During Operation?
Yes
1. Slip Cylinders May Not Be Properly Attached 2. The PS Manifold May Not Be Properly Attached to the Body 3. The Top Cover Hinge Blocks May Not be Properly Attached to the PS Body
PS-21/30
Version 1
194
Varco Technical Education Center
InspectionPS-21/30 Version 1
195
Safety!Varco Technical Education Center
Ensure that all hydraulic lines are disconnected before ANY work is carried out on the PS-21/30
PS-21/30
Version 1
196
Welding!Varco Technical Education Center
NOT
You
MUSTweld on the PS 21/30 body or any of its components
PS-21/30
Version 1
197
Hinge Pin WearVarco Technical Education Center
PS 21New Bore Max New Pin Max Worn Bore Max Total Clearance A 2.380 2.365 2.405 0.050Bore Wear
PS 303.005 2.990 3.030 0.050
PS-21/30
Version 1
198
Bore Wear Paper TestVarco Technical Education Center
Full Contact
Determine bore by making a paper print:1. Connect the PS to the power unit 2. Dress the PS with NON-WORN slips and clean NON-WORN inserts
Top Contact
3. Wrap waterproof paper around the clean insert mark free section of pipe 4. Clamp the slips using 2500psi power down pressure
PS-21/30
Version 1
199
Bore Wear - EvaluationVarco Technical Education Center
Full Insert Contact?
Yes
PS & Slips Are Good
No
Insert Contact on Top?
Yes
Replace Slip & Re-Test
Full Contact?
Yes
Return Slips to Service
NoPS Bowl is Worn Remove PS From Service
PS-21/30
Version 1
200
Varco Technical Education Center
RepairPS-21/30 Version 1
201
DisassemblyVarco Technical Education Center
Prior to disassembly of the PS, thoroughly clean the unit with a steam-cleaner in order to prevent the disassembled parts from becoming contaminated with dirt, mud etc
PS-21/30
Version 1
202
Disassembling the CylindersVarco Technical Education Center
1.
Disengage the top cover lock and open the top covers
PS-21/30
Version 1
203
Disassembling the CylindersVarco Technical Education Center
2. 3.
Ensure that the Lift Levers are at approx. 45 Disconnect all 3 x hydraulic tubes from the right hand cylinder do not remove this tubing from the manifold block
PS-21/30
Version 1
204
Disassembling the CylindersVarco Technical Education Center
4.
Remove all 4 bolts that connect the cylinder barrel to the cylinder gear box
PS-21/30
Version 1
205
Disassembling the CylindersVarco Technical Education Center
5.
Gently slide the barrel up until the barrel parts from the piston No excessive force should be needed to remove the barrel
Turning the barrel while sliding up should help ease disassembly
PS-21/30
Version 1
206
Disassembling the CylindersBevelledVarco Technical Education Center
6.
Check the configuration of the barrel )RH = pn 20220433 (sq) pn 202204-45 (bev) If the barrel has an internal bevelled shoulder, the cylinder gear box does not have to be removed from the PS body in order to reassemble the barrel later p/n 202203-45 If the barrel has an internal square shoulder, the cylinder must be removed from the PS body in order to reassemble the barrel p/ 202203-33
Square
PS-21/30
Version 1
207
Replacing the PistonVarco Technical Education Center
1.
Check if the existing piston is secured to the piston rod by means of a set screw Loosen this set screw if applicable Unwind the piston from the piston rod Assemble the new piston Secure the piston to the rod by means of the set screw inserting a nylon pellet below the set screw Insert the NPT plug on top of the set screw Check that the NPT plug is below the piston contour
2. 3. 4. 5.
6. 7.
PS-21/30
Version 1
208
Replacing the SealsVarco Technical Education Center
1.
Inspect the seals for any damage and/or scoring
2. Warm the 2 x white outer rings in hydraulic oil (65C)3. Assemble the 2 x half moon rings (delivered together with replacement seals) in the top seal groove Assemble the O-ring and white outer ring the outer ring needs to be stretched gently BY HAND over the taper on the piston and into the bottom seal groove Remove the 2 x half moon rings and assemble the top seal
4.
This sketch is not up-to-date5.
PS-21/30
Version 1
209
Reassembling the BarrelVarco Technical Education Center
1.
Always fit the barrel BY HAND never tap the barrel down with a hammer as this will damage the seals Turning the barrel fitting will help to ease assembly A special piston assembly bushing is required in the case that the barrel has an internal square shoulder Secure the barrel to the cylinder gear box by means of the 4 x bolts assemble and torque the bolts and lockwire
2. 3.
4.
PS-21/30
Version 1
210
Assembling the LeversVarco Technical Education Center
Ensure that the V-mark on the levers is lined up with the V-mark on the cylinder spline shaft
PS-21/30
Version 1
211
Installing the CylindersVarco Technical Education Center
1.
Install the hydraulic cylinders without tightening the bolts
PS-21/30
Version 1
212
Installing the CylindersVarco Technical Education Center
2.
Slide the synchronization shaft through both cylinders (new design has only 1 key)
PS-21/30
Version 1
213
Installing the CylindersVarco Technical Education Center
3. 4.
Assemble the 4 x bolts and washers in the back Torque to185 ft.lbs (250Nm)
PS-21/30
Version 1
214
Installing the CylindersVarco Technical Education Center
After bolts are tight, check alignment of the 2 x cylinders tapping the synchronisation shaft rubber mallet
by with a
The shaft must be tight but not clamped
PS-21/30
Version 1
215
Assembly of Hoisting RingsVarco Technical Education Center
Loads may slip or fall if improper hoist ring assembly and lifting procedures are employed A falling load may cause serious injury or death Ensure that spacers (washers) are NOT used between the flange and mounting surface Always be sure threads on shank and holes are clean, not damaged and fit properly
PS-21/30
Version 1
216
Assembly of Hoisting RingsVarco Technical Education Center
APPLY LOCTITE NO. 243 TO THE THREADS Torque: 5000lbs SWL hoist ring = 100 ft.lbs After installing, always ensure that the bail is free to pivot 180 and swivel 360 180
360
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Assembly of the Manifold BlockVarco Technical Education Center
1.
Put the manifold in position PS 30 Use liquid gasket PS21 Use an o-ring
2. Torque and lock-wire the securing bolts
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218
Assembly of Cover Hinge PinsVarco Technical Education Center
It is of utmost importance that the cover plate hinge pins are properly assembled to ensure proper functioning of the centring device
Clean the pin and hinge boss hole remove any sharp burrs that might seals during assemblyClean the seals
and damage the
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Assembly of Cover Hinge PinsVarco Technical Education Center
1. 2.
Apply a grease coating to all pin surfaces Assemble the o-rings, backup rings, lip seals and spacer rings
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Assembly of Cover Hinge PinsVarco Technical Education Center
3.
Apply a coating of grease to all hinge boss holes
4. Carefully insert the pin taking care not to damage the seals
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221
Assembly of the CD CylinderVarco Technical Education Center
1.
Ensure a 0.125" clearance between the knuckle and the piston rod shoulder
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