POWER CATWALK

DLMD013-SC
June,2019
 DLMD013 User Manual

CONTENTS

1 STRUCTURAL CAPITALIZE INTRODUCTION ........................................................................................... 4

1.1 SAFETY WARNINGS ...................................................................................................................................4

1.2 EQUIPMENT DESCRIPTION ..........................................................................................................................5

1.3 TECHNICAL SPECIFICATIONS ........................................................................................................................ 6

1.4 MAJOR COMPONENTS ...............................................................................................................................7

1.4.1 Major Components Overview .......................................................................................................7

1.4.2 V-Door Ramp ................................................................................................................................7

1.4.3 Catwalk .........................................................................................................................................8

1.4.4 Trough ........................................................................................................................................10

1.4.5 Trolley .........................................................................................................................................11

1.4.6 Lift Arm .......................................................................................................................................11

1.4.7 Pipe Rack ....................................................................................................................................11

1.4.8 Index pins ...................................................................................................................................13

1.4.9 Hydraulic System ........................................................................................................................ 14

1.4.10 Electrical Control System ..........................................................................................................14

1.4.11 Structural Features ...................................................................................................................14

1.5 BRIEF WORKFLOW ..................................................................................................................................14

1.6 RIG UP/DOWN PROCEDURES ....................................................................................................................16

1.6.1 Rig Up Procedures ......................................................................................................................16

1.6.2 Rig Down ....................................................................................................................................18

1.7 MAINTENANCE.......................................................................................................................................19

1.8 SAFETY RULES ........................................................................................................................................21

1.9 STORAGE, HANDING AND TRANSPORTATION .................................................................................................21

2. HYDRAULIC SYSTEM ..........................................................................................................................22

2.1 MAIN PARAMETERS OF HPU ....................................................................................................................22

2.1.1 HPU Description .........................................................................................................................22

2.1.2 Preparation Before HPU Commissioning ....................................................................................24

2.1.3 Commissioning of the HPU System .............................................................................................24

2.1.4 Operation Instruction .................................................................................................................26

2.1.5 Description of the Control System .............................................................................................. 27

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2.1.6 Initial Start-up or after prolonged layup ..................................................................................... 27

2.1.7 Start Up After Repair/Overhaul .................................................................................................. 27

2.2 HYDRAULIC PART OF POWER CATWALK........................................................................................................28

2.2.1 Directional Valve Block ...............................................................................................................28

2.2.2 Multiple Unit Valve .....................................................................................................................28

2.2.3 Control Valve Block .....................................................................................................................29

2.2.4 Actuators ....................................................................................................................................29

2.2.5 Electrical Componants ................................................................................................................30

2.2.6 Piping Components.....................................................................................................................30

2.3 EMERGENCY OPERATION SYSTEM...............................................................................................................30

2.3.1 Emergency Hydraulic Source ...................................................................................................... 31

2.3.2 Emergency Operation .................................................................................................................31

2.3.3 Conventional catwalk .................................................................................................................35

2.4 LEVELING SYSTEM ...................................................................................................................................35

2.5 MAINTENANCE.......................................................................................................................................36

2.5.1 Hydraulic Oil ...............................................................................................................................36

2.5.2 Leak ............................................................................................................................................ 36

2.5.3 Fliters ..........................................................................................................................................36

2.5.4 Pump Sets ................................................................................................................................... 37

2.5.5 Control valves ............................................................................................................................. 37

2.5.6 Actuators .................................................................................................................................... 37

2.5.7 Recommend Maintenance Plan .................................................................................................. 37

3. ELECTRIC CONTROL SYSTEM ..............................................................................................................39

3.1 MAJOR COMPONENTS .............................................................................................................................39

3.2 PLC CONTROL BOX PLC ..........................................................................................................................40

3.3 HPU ELE. CONTROL BOX ........................................................................................................................ 40

3.4 OPERATION BOX .....................................................................................................................................41

3.5 RADIO CONTROLLER ................................................................................................................................42

3.6 SENSOR ................................................................................................................................................42

4 OPERATING ........................................................................................................................................44

4.1 START-UP AND SHUT DOWN .....................................................................................................................44

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4.1.1 Operation Box Start Up Procedure..............................................................................................44

4.1.2 Radio controller Start up Procedure ...........................................................................................45

4.1.3 Shut Down Procedure .................................................................................................................46

4.2 NORMAL OPERATION .............................................................................................................................. 47

4.2.1 Local Control Console Operation ................................................................................................ 47

4.2.2 Radio controller Operation .........................................................................................................51

4.2.3 Loading Tubular to the Drill Floor ...............................................................................................56

4.2.4 Unloading Tubulars from the Drill Floor .....................................................................................58

4.2.5 Target preset procedure .............................................................................................................60

4.3 HMI OPERATION....................................................................................................................................62

4.3.1 Main page ..................................................................................................................................62

4.3.2 Operation page...........................................................................................................................63

4.3.3 System Configuration .................................................................................................................64

4.3.4 System Diagnose ........................................................................................................................71

4.4 TECHNICAL MAINTENANCE AND REPAIR ...................................................................................................... 72

4.4.1 Encoder Device name Assignment.............................................................................................. 74

4.4.2 Proximate Switch Replacement .................................................................................................. 74

4.4.3 Alarm Cause & Corrective action................................................................................................75

4.5 STORAGE ..............................................................................................................................................84

4.6 SECURITY MEASURES...............................................................................................................................84

4.7 TRANSPORTATION ...................................................................................................................................84

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1 Structural capitalize Introduction

1.1 Safety Warnings

Safety rules for operators：

 Understand rules of equipment.
 Only trained and qualified operators can install, operate and repair
equipment.
 Personnel must wear proper personal protective equipment during the
installation, operation maintenance, or repair of this equipment.
 The main personnel engaged in installation, operation and repair should
have corresponding experience.
 There shall be a chief principal designated for installation and repair, the
persons participating in work shall be assigned with clear work, and
detailed and reliable safety measures shall be available.Sufficient lighting
levels shall be maintained around the equipment to ensure safety during
operation.
 Before work is started on any high energy system (ie. HP hose/pipes
electrical connection), proper procedure for isolation and release of these
energy sources must be followed.
 During operations, the rules and instructions in this manual must be
strictly followed.
Special warnings for hydraulic system：
 Sources of ignition are forbidden around the hydraulic system.
 If the system gives out a warning signal, stop, check and resolve.System
cannot be restarted until all warnings and alarms have been resolved.
 Isolate power source/s and release system pressure before maintenance
is carried out. If applicable, ensure all system accumulators are properly
and completely discharged. All Lock Out/Tag Out procedures shall be
strictly followed to avoid incidents which may result in injury to personnel,
equipment damage and/or environmental damage.
 Oil spill measures shall be taken to control any spillage to prevent rig or
environmental contamination and keep work environment clean and safe
during maintenance operations.
 Before beginning work on any portion of the hydraulic system, personnel
must familiarize themselves with the hydraulic and electrical schematics.
 Take precautions when bleeding down residual system pressure, using
bleed valves or equivalent techniques.
 Take precautions to prevent hydraulic oil from leaking into other open
electrical components, such as junction boxes or sensors.

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 After a quick release connector (QD) is unplugged, ensure a protective

cap is installed to avoid contamination.
 Ensure cleanliness of quick release connector (QD) components prior to
re-connecting.
Special warnings for electric system：
 Make sure protection devices, warning devices, emergency stop and limit
switches, sensors and other safety equipment have been installed and
function properly.
 Electrical professionals are prohibited from modifying electrical systems
(including all electrical wiring and software parameter settings) without
authorization from superior supervisors or non-professionals.
 When performing installation, maintenance, or repairs on the equipment,
isolate all power including secondary sources such as emergency power,
UPS, etc. All Lock Out/Tag Out procedures shall be strictly followed to
avoid incidents which may result in injury to personnel, equipment
damage and/or environmental damage.
 All electrical wiring, junction boxes, sensors, glands, and related
equipment are designed for the specific application, environment and
particular zone where the equipment is intended to be used. Before
beginning work on this equipment, personnel must familiarize themselves
with the electrical schematics, including the equipment power and voltage
requirements.
 Prior to disconnecting wires, verify that all wires and terminals are
properly labeled to ensure proper reconnection.

Only trained and qualified operators can install, operate and repair
equipment, and strictly follow the rules and instructions listed in this manual
to avoid any safety accidents to people and equipment.
Warning！

1.2 Equipment Description

The function of the Power catwalk is to provide delivery of tubulars from
the pipe rack to the drill floor and vice versa. The Power catwalk positions the
box end of the tubular above the mousehole to allow the elevators to be
manually latched and is close enough to well centre to allow heavy tubulars to
be manually pushed off well centre when laying down.
The power catwalk mainly comprises V-door ramp, catwalk, trolley, lift
arm, trough, pipe rack, trolley motor, lift arm cylinder, HPU and a series of
position sensors(Usually, the following situations need to be corrected: 1:
replace the sensor. 2: 1 month or 100 hours of continuous work, whichever is
first come). Position sensors monitor the running condition of each componant
of the power catwalk to ensure running conditions are normal and confirm
drilling tools can be transported safely and reliably. For convenient operation,

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the power catwalk is equipped with a wireless remote controller, and local
control box, with Auto IN/OUT operation can be achieved.
The HPU is equipped with two motors for redundancy. The HPU can be
used within -18℃～+50℃. The power catwalk is provided with V-door ramp,
air winch, and bumper. In the event of failure of the power catwalk, the
equipment can still be used as conventional catwalk.

1.3 Technical Specifications

General Specifications
Serial Number: MD19-001

Model: DLMD45/12-D

Make: HH

Safe Working Load: 4500daN

HPU
Pumps: Two motors

Working Temperature: -18℃～+50℃

Overall Transportation Dimensions (without

trailer system,spacer and drum)
Length: 16m

Width: 3m

Height: 2.6m

Overall Working Dimensions

Length: 26m

Width: 8.6m

Height: 12m

Tubular Specifications
Weight: 4500daN

Maximum Length: 13.7m(45ft)

Diameter Allowances: 610mm(24in)

Approximate Overall Weight: 34t

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1.4 Major Components

1.4.1 Major Components Overview

The major components of the Power catwalk assembly consist of the
following equipment:

● V-Door Ramp

● Trough

● Trolley

● Catwalk

● Lift Arm

● Pipe Rack

● Hydraulic System

● Electric control system

Refer to Fig #1, and drawing DLMD013.00, Power Catwalk

1.4.2 V-Door Ramp

Refer to the V-Door Ramp, drawing DLMD013.03.00, and Fig #2 and #3.

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The Power catwalk V-door ramp provides a track and roller to support
and guide the trough as it moves. The V-door ramp is mounted on the end of
the catwalk with a hinged connection to allow the V-door ramp to fold onto the
catwalk for transportation.
With the trough kept lowered into the catwalk, the equipment can be used
as a conventional catwalk to raise and lower the tubulars.

1.4.3 Catwalk
Refer to the Catwalk, drawing DLMD013.01.00, and Fig #4.
The Power catwalk catwalk is the main body that supports/contains all of
the Power catwalk components. During rig up procedure, the catwalk is
positioned perpendicular to the drill floor and inline with well centre, the
catwalk must be completely level and well supported to ensure safe
operation.
The end of the catwalk is hinged with V-door ramp to provide support for
the V-door ramp, and there is steel rail inside, trolley can move along with the
steel rail.
Walking plate,indexers, pipe racks and pipe rack kickers are installed on
the catwalk.

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There are two cylinders mounted in each indexer which, with the indexer
pins, kick tubulars in or out of the catwalk one by one.

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1.4.4 Trough
Refer to the Trough, drawing DLMD013.06.00.
The trough is provided with roller at its front end, and its tail end is hinged
with the lift arm. With the pushing and pulling motion of the lift arm, the trough
is lifted or lowered along the V-door ramp. The trough is used for supporting
tubulars carrying pipe from the DP rack to wellhead on drill floor or carrying
and placing the pipe from the wellhead on the drill floor to the DP rack. Safety
pins and kickers are installed on the trough, the kickers can turn the pipe out
of the trough, the safety pins is used to prevent the drilling tool from leaving
the through. A hydraulic motor at front end of the trough drives the skate
forward and backward thereby pushing or pulling pipe forward and backward.
The safety pins are used to keep the tubulars safely contained in the
trough and to aid in loading the tubulars into the trough from the pipe racks.
There are two sets of safety pins contained within the trough – one set of four
on the driller’s side and one set of four on the off driller’s side.
The kickers are used to eject the tubulars off the trough onto the driller’s
or off driller’s side catwalk. There are two sets of kickers contained within the
trough – one set of four to eject a tubular towards the driller’s side pipe rack
and one set of four to eject a tubular towards the off driller’s side pipe rack.

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1.4.5 Trolley
Refer to the Trolley Assembly, drawing DLMD013.05.00.
Trolley motor is installed on the trolley The trolley is hinged with lift arm
cylinder and the lift arm. As the trolley moves along with the steel rail in the
catwalk, first lifting of trough is achieved through the lift arm pushing the
trough.

1.4.6 Lift Arm

Refer to the Lift Arm, drawing DLMD002.02.00.
The lift arm is used for supporting the trough, with front end hinged with
the trolley, middle part pinned with the lift arm cylinder and rear end hinged
with the trough. With the pushing of the lift arm cylinder, the lift arm rotates to
achieve secondary lifting of the trough.

1.4.7 Pipe Rack

Refer to the Pipe Rack, drawing DLMD013.04.00.

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There are 4 pipe racks attached to the catwalk—two on the driller’s side
and two on the off driller’s side. The capacity of the pipe racks are as follows:
Dirll pipe capacity(each side)

size 2 3/8 2 7/8 3 1/2 4 4 1/2 5 5 1/2 6 5/8

capacity 32 24 19 18 17 15 14 13

Collar and casing capacity

size 4 1/2 5 5 1/2 6 6 5/8 7 7 5/8 7 3/4

capacity 24 21 19 18 16 15 14 14

size 8 5/8 8 3/4 9 5/8 9 3/4 9 7/8 10 3/4 11 3/4 11 7/8

capacity 12 12 11 11 11 10 9 9

size 13 3/8 13 1/2 13 5/8 14 16 18 5/8 20 24

capacity 8 8 8 8 7 6 5 4

One side of pipe racks are pinned on the catwalk and the other is
supported by the cylinders, each which hold a bearing pad against the ground.
If the cylinders are in extended position, gravity will result in the pipe’s
movement towards the catwalk. By retracting (lowering) the cylinders, the
pipe is delivered away from the catwalk.
During transport condition, the leg is folded and fixed to the side of the
catwalk to reduce the overall width of the catwalk machine.

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1.4.8 Index pins

In order to ensure that only one tubular at a time enters the catwalk, it is
necessary to rely on the indexer to block the subsequent tubular. There are
two indexers arranged on the driller’s side and two indexers on the off driller’s
side of the catwalk. Each indexer has holes for the indexer pins to be installed
any of four positions depending on the tubular size. The setting for the
indexer pin position for each size of tubular is shown in the following table.
Indexer pin location vs outside diameters
No.
1 2 3 4
Pipe

2 3/8
2 7/8
3 1/2
4
4 1/2
5
5 1/2
6
6 5/8
7
7 5/8
7 3/4
8 5/8
8 3/4
9 5/8
9 3/4
9 7/8
10 3/4
11 3/4
11 7/8
13 3/8
13 1/2
13 5/8
14
16
18 5/8
20
24

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NOTE!! When the pipe is transported to the drill floor, the indexer pins
should be placed in the correct position. When pipe is laid down
from drill floor, the indexer pins should be removed.

1.4.9 Hydraulic System

It provides driving force for each mechanism of power catwalk, and it is
equipped with manual valve in hydraulic system to operate the power catwalk
to convey pipes. Please refer to Section 2 for detailed description of hydraulic
system.

1.4.10 Electrical Control System

It controls hydraulic system and Auto IN/OUT operation of local control
box and remote controller can be achieved. Please refer to Section 3 for
detailed description of electrical control system.

1.4.11 Structural Features

 This catwalk adjusts to 12m height to the drill floor, can achieve Auto
IN/OUT operation, with controllable, safe and reliable pipe carrying track.
 This catwalk can be integrally transported, and installation is straightford
with minimum effort.
 This power catwalk can function as a standard non-powered V-door ramp.
 The trough can raise up to near the well center, greatly reducing labor
intensity of laying down pipe.
 Emergency lowering feature is provided.
 Rapid landing and moving.

1.5 Brief Workflow

Please see Fig #5 for summary of pick up operation.

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Step 1 – The pipe rack and indexers load tubulars onto the trough,from
the pipe racks.
Step 2 – The trolley motor then pushes the trolley to move the trough up
the ramp. A roller is installed at the front end of the trough which rolls along
the guide to the V-door ramp, therefore, causing the trough to move upwards
along the V-door ramp.
Step 3 – After the trolley motor is in it’s end position, the lift arm cylinder
extends to carry the trough further up the ramp and towards the drill floor.
Step 4 – Tubulars are then extended to near well center by the skate to
complete the operation.

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1.6 Rig Up/Down Procedures

1.6.1 Rig Up Procedures

This procedure only used in rig. Refer to figure #6, power catwalk was
packaged when arrival.
1.6.1.1 Preparing
（1）lifting gear ：Lifting equipment with minimum capacity of SWL 25 t and
10t each.
（2）rigging line： 10t and 5m，double；25t and 5m, double.
（3）measure tape:25m.
（4）marking tool.
（5）general safety training.
（6) supervision by HSE.
1.6.1.2 Rig Up：
（1）Refer to figure #6, mark the position of equipment on the ground, then
position it with deviation in 25mm longitudinally and in 5mm transversally.
（2）Lift v-door ramp, and centring padeyes between v-door ramp and drill
floor.
（3）Install v-door ramp with pins and remove rigging lines
（4）Remove fixed shaft Ⅰ on pipe rack and rotate the pipe rack for 90°(pipe
rack perpendicular to base), and then remove positioning shaft Ⅱ on the
pipe rack.
（5）Connet cables and hoses.
Work done.

Note To ensure the catwalk operates smoothly and reliably, the weight
bearing capacity of ground foundation must be guaranteed. The
bearing capacity of the ground foundation of Pipe Rack must be ≥
0.9Mpa, and the bearing capacity of the ground foundation of the
cat channel base must be ≥ 0.01Mpa

Note When the ramp is installed, the ramp is at 50° inclination relative
to the level ground. The upper section of the ramp and the rig
base are connected via pin shaft. The lower section of the ramp
is connected to the Power cat channel base via pin shaft as well.

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Warning For lifting of the Catwalk only use designated hoisting padeyes
strictly following the lifting procedures of the crane.

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1.6.2 Rig Down

This process is opposite to the flow in 1.6.1.
V-door ramp lay down refer to Fig #7, Fig #8 and Fig #9.

Fig #7 Connect the crane to the ramp lifting point

Fig #8 Lift the V-door ramp away from the substructure

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Fig #9 Continue lift the V-door ramp until placed on catwalk

1.7 Maintenance
The power catwalk utilizes self-lubricated bearings. The bearings at lift
arm cylinder, lift arm and trough are specially made self-lubricating bearings
requiring no maintenance. The expected service life is 3.5 years, theoretically
calculated as operating system 8-hours every day, dependent upon actual
working conditions.It is recommended to check the bearings once annually.
Check the clearance between the inner and outer rings of bearing and for
abnormal sound as the bearings are rotated. When the clearance is 50%
larger than the initial clearance, or abnormal sound is noted, the bearing has
reached its service life and should be replaced immediately. If one bearing is
to be replaced, it is recommended to replace all three bearings at the same
time to ensure continued uninterrupted operability of the equipment.When
replacing the fixed pin, the swivel arm and the fixed pin of the pulley
connected to the rear of the drilling tool support beam, the retaining pins of the
drilling tool support beam and the swivel arm are removed and replaced
separately. Remove the fixing pin for connecting the tail of the trough with the
lift arm and the fixing pin for connecting the lift arm with the trolley during the
replacement, and replace the trough and the lift arm after lifted outside.
Periodic maintenance is important to ensure the equipment operates
smoothely and reliably. Periodic maintenance including regular inspections
can also identify problems or potential failures before they occur, avoiding
downtime, potential damage to equipment, injury to personnel and/or
environmental incidents. The equipment maintenance schedule is defined in
the following chart.

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Frequency
Job Days Month Year NOTE
No Job Description 1 7 1 3 6 1
Check fittings, valves, cylinders, and
X
1 hoses for leakage or wear
General inspection of catwalk for wear
X
2 & tear and loose parts
3 Check system pressure X
Lubricate equipment according to NLGI 2 or
X
4 lubrication diagram Mobil XHP222
Inspect flag indicator on hydraulic
X
5 filters
Visual inspection of all bolted
X
6 connections
7 Inspect cylinder pins for wear X
Clean any exposed hydraulic cylinder
X
8 rods
Check oil Level on gearboxes and
X
9 brakes
Inspect the drag chain and replace any
X
10 worn parts
11 Inspect the guide rollers X
12 Check the level of oil in the tank X
13 Inspect axles and shaft for play X
14 Inspect all bearing/bushings for play X
Check torque tightness of all external
X
15 bolts
16 Check the quality of oil X
17 Replace Hydraulic filters X
ISOVG220
Change oil in all gearboxes and brakes X
18 Gear oil
19 Check clearance in all guide rollers X
Check backlash on all rack/pinions -
X
20 Min 0.5mm Max 3mm
Inspect junction boxes visually both
inside and outside. Ensure all
21 terminations are tight X
Inspect all sensors and encoders.
Ensure they are free of corrosion,
accumulated dirt/grease and that
encoder couplings are tight and turn
22 freely X
NLGI 2 or
Trailer system lubrication
23 X Mobil XHP222
*Note - The service intervals listed in the table are based on average
operating conditions. Use the schedule as a guide. Some conditions
(excessive loadings, dusty or corrosive atmosphere, temperature
extremes,etc.) may require more frequent service intervals.

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1.8 Safety Rules

Carefully read this manual before using the power catwalk. Operate the
power catwalk only after being fully familiar with the working principles of the
machine. After the power catwalk was rigged up, both sides of the left and
right pipe rack of the power catwalk and the front and rear sides of the catwalk
should be pulled up a cordon to close the power catwalk as a whole in a
rectangular area.During the use of the power catwalk, this area should be
closed to personnel. This power catwalk has a remote control box
manipulation and remote controls two modes of operation, to ensure the
safety of operators.

warning It is strictly prohibited to transport pipes with Power Catwalk，

when the speed of wind beyond 11m/s。 .

warning Personnel are forbidden from entering the enclosed area while
the catwalk is in operation. In event of emergency, press the
E-stop button.

1.9 Storage, handing and transportation

The power catwalk needs folded to store after using, this process is
opposite to the flow in 1.6.1. Before the Power catwalk folded, need manual
retract trough in the position the buffer contact the catwalk back crossbeam.
Please see Fig. #7.

buffer

catwalk back crossbeam

Fig #7

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2. Hydraulic System
2.1 Main Parameters of HPU

Rate Pressure 30MPa

Rate Flow 240L/min
Output Power 119kW
Volt./Freq. 380V@50Hz
Tank Volume 900L
Main Motors (2 sets) 55kW，B35,IP55
Circ. Motors 7.5kW，B35,IP55
Cooler Moters 3kW，B5,IP55
Heater (3 sets) 3kW
Suction Filter 100μm
Return Fliter 10μm
High pressure Fliter 10μm
Air fliter 10μm
Recommend Hydr. Oil HV/HM
-18℃~25℃，ISO-VG32
25℃~55℃，ISO-VG46/ISO-VG68

2.1.1 HPU Description

The power catwalk has a special HPU, integrated at the rear of the unit.
This design makes the catwalk more compact and convenient for
transportation. The HPU includes main pumps, oil tank, circulation cooling
system, electronic control system, field instruments and other related
components.
2.1.1.1 Main Pumps
The HPU has two main motor pump sets. Both pumps must operate
simultaneously to meet the maximum flow requirements of the power catwalk.
The HPU is a load-sensing (LS) system, utilizing a load-sensing variable
displacement pump. The HPU provides corresponding pressure and flow
required for the load and speed demand. The HPU does not supply flow to the
power catwalk when there is no demand, however, there will still be a small
amount of flow that is bypassing through the pumps inner body cavity. This
load-sensing system effectively reduces the system’s energy consumption
and maintenance requirements as well as increases the life of the system.

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The piston pump utilizes load sensing at constant power which is limited
to 55kW to protect the motor. Additionally, the high pressure port of the
pumps are equipped with a high pressure filter and check valve. This allows
for one pump to remain in service while the other pump may be under
maintenance.
2.1.1.2 Oil Tank
The unit is equipped with a stainless steel (12Cr18Ni9) hydraulic oil tank
with a nominal volume of 900L and a variable volume of about 200L. The tank
is fitted with heaters, liquid level sensors, level gauges, oil temperature
sensors, oil suction filters, oil return filters, empty filters, oil ball valves and
other components, with two removable access covers on top.
2.1.1.3 Heating System
The HPU is equipped with three 3kW heaters to heat the hydraulic oil
when the oil temperature is low. When the temperature is less than 15℃, the
heaters and circulating pump will energize to heat the oil and de-energize
when the oil temperature rises above 20℃.
2.1.1.4 Cooling System
The HPU is equipped with a cooling system to cool the oil when the oil
temperature is higher than the design temperature. The cooling system
consists of a circulating pump and one air coolers (heat exchangers). Return
oil passes through the cooler, through the return oil filter then back to the tank.
The optimum oil temperature range is 35℃ to 55℃. When the oil
temperature rises above 50℃ the circulating pump（MT05） and one cooling
fan (MT03) will energize. The circulating pump（MT05） and cooling fan
(MT03) will de-energize when the oil temperature drops to less than 50℃.
2.1.1.5 Electric Control Box
The HPU can be operated by the local control box in manual mode or by
the remote control when the system is in remote mode.
The control box is mounted on the power catwalk and mainly comprised
of push buttons, indicator lights, alarm lights and E-stop buttons.
2.1.1.6 Field Instrument
The HPU is provided with the following field instruments:
 Pressure Transmitter

 Installed on the high pressure pipeline of the pump set to sense

system pressure.

 Liquid Level Transmitter

 The main functions are: high liquid level alarm, low liquid level alarm
and low-low liquid level stop.

 Temp. Transmitter

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The temp. transmitter senses the oil temperature in the oil tank. Through
the heating and cooling system, the oil temperature is maintained between
35℃ to 55℃.

2.1.2 Preparation Before HPU Commissioning

Before starting the HPU, a series of inspections shall be performed, to
ensure that the following items are satisfied.
1. Ensure all ball valves in the oil suction, discharge, and drain lines are
open.

2. Ensure that the direction of rotation on all motors, including the main,
circulation and cooling motors is correct. This can be easily checked by
quickly energizing and de-energizing (bumping) the motors.

3. Ensure all control valves are set at the “closed” position.

4. Ensure all pipelines and hoses of the HPU are securely connected.

5. Ensure that the hydraulic oil tank is filled to the correct level.

2.1.3 Commissioning of the HPU System

2.1.3.1 Commissiong of Hydraulic Functions
Test the components of the HPU to ensure correct operation.
1. Start one main motor pump. Check the system for normal running.
Listen to the main motor and pump for any abnormal noise. De-energize
and repeat this step with the second main motor and pump.

2. Start the circulation pump checking for normal running while listening
for abnormal noise.
3. Start one cooler and check the system for normal running while
listening for any abnormal noise. De-energize and repeat this step with
the second cooler.
4. Each of the main pump’s constant power is limited to 55kW and the port
LS is set to 25bar.

Note The constant power is 55kW and initial setting pressure of port LS
is 25bar, has been set at the HH factory.Do not change
them.Please contact with our hydraulic engineering department if
required.

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2.1.3.2 Interlocking Commissioning of the HPU

Electric protection commissioning includes commissioning the liquid level
alarm, oil temperature alarm (alarm message display on screen), heater
start/stop, cooler start/stop and system pressure alarm (alarm message
display on screen). These are tested under PLC control.
1. Liquid level alarm commissioning includes following three logics:

A、When volume of liquid level is lower than 310L (liquid level is 190mm),
stop pump;

B、When volume of liquid level is below 440L (liquid level is 260mm),

low-level alarms;

C、When volume of liquid level is higher than 660L (liquid level is

400mm), high-level alarms;

2. Oil temperature alarming commissioning includes following three

logics:

A、When oil temperature is less than 15℃, pump set can not be started;

B、When oil temperature is less than 15℃, start circ. pump and heaters;

C、When oil temperature higher than 20℃, stop circ. pump and heaters;

D、When oil temperature higher than 50℃, start circ. Pump MT05 and
air cooler MT03;

E、When oil temperature is less than 50℃, stop circ. Pump MT05 and
air cooler MT03;
F、When oil temperature reaches to 65℃, it alarms;

I、When oil temperature higher than 75℃, stop main pump running;

Note When the oil temperature is less than 15 ℃ or more than 75 ℃

the main pumps stop. If a main pump is required, it can be
manually started from the local operation box mounted on the
frame for limited operation.

3. When system pressure exceeds 30MPa, the system will alarm.

4. Whether E-stop function is normally or not.

5. Power catwalk E-stop when DS & ODS barrier is broken.

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2.1.4 Operation Instruction

Before operating this Hydraulic Power Unit (HPU) the operator must
know and understand HPU controls and emergency stop function. For
detailed description of the HPU Control System refer to the Control System
Functional Description for HPU. When the HPU is installed, checked
according to specifications and commissioning completed it is ready for
operation.
2.1.4.1 Preparation
 Oil temperature in hydraulic oil tank shall be above 15℃ and below
75℃.

 Check oil level in hydraulic tank. Oil level shall be between low level
and high level.
2.1.4.2 Normal Operation
HPU can be operated on local control panel (manual mode), and related
control details shall refer to electric control part. Local operation mode is used
in maintenance or commissioning only.
The HPU can run continuously for extended periods ,however, it is
recommended to de-energize the HPU when it is not needed to increase the
service life of hydraulic pump.
During Operation

 Check oil level in tank.

 Check oil temperature in tank.

 Check that there is no hydraulic leaks

 Check that no alarms related to the HPU are active.

Alarm Reasons

 Liquid level of oil tank is too high:

Activated when the volume of liquid level exceeds 660L (high-level of

liquid level is 400mm);

 Liquid level of oil tank is too low:

Activated when the volume of liquid level falls below 440L (low-level of
liquid level is 260mm);

 Hydraulic oil temperature is too high:

 When oil temperature of hydraulic oil in the oil tank exceeds 70℃;

Shut Down Reasons

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 E-stop

 Low-low liquid level (< 310 L)

When the liquid level of the tank is less than 310L, the HPU will
automatically stop. The hydraulic station can only be restarted after
sufficient hydraulic oil has been added and the cause of the low level
has been identified and corrected.

 Low oil temperature (< 15℃) during remote control

 High oil temperature (> 75℃) during remote control

 DS or ODS barrier is broken

While in remote control mode, the HPU will stop automatically when
the oil temperature reaches 75℃. The HPU can be started again
when the oil temperature drops below 75℃, or if operated from the
local control box. Motor Overload

E-stop

Local E-stop buttons will stop all motors in any mode. The E-stop can
feed back a signal to the driller’s cabin to generate an alarm.

Note After the E-stop is pressed, check and eliminate cause for the E-stop and
then lift the E-stop to start the HPU only after the cause has been
eliminated.

2.1.5 Description of the Control System

Please refer to the electrical section for details.

2.1.6 Initial Start-up or after prolonged layup

Perform commissioning procedure when HPU is run for the first time or
not run for more than 1 month.

2.1.7 Start Up After Repair/Overhaul

Start up after overhaul / repair depends on the extent of work executed.
For this reason only general guidelines are provided herein.
 Ensure all components or parts are installed correctly after repair or
overhaul.

 Confirm all repair tools are removed and secured.

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 Check the cleanliness hydraulic oil and that the cleanliness must be
above the NAS9.

 Evaluate for any negative consequences that may be caused by start

up.

 Before start up, perform preparation procedures as per commissioning

procedure.

2.2 Hydraulic Part of Power catwalk

The hydraulic part of power catwalk is comprised of the following
components:
 Directional valve block

 Multiple Unit Valve

 Control valve block

 Actuators

 Electric components

 Piping components
For more detailed information please refer to drawing
DLMD007.07.120YLT attached in drawing lists.

2.2.1 Directional Valve Block

The high pressure directional valve block acts as the main component for
external ports. There are three ports: P, D, and X. The block has a high
pressure filter, to remove particulates from the oil; an unloading valve to limit
the maximum system pressure and a safety relief valve to protect the system
from overpressure. Setting pressure of unloading valve is 30Mpa, relief valve
is 33Mpa
For more detailed information please refer to directional valve block
drawing attached in drawing lists.

2.2.2 Multiple Unit Valve

Multiplex (directional control) valves are used to control the movement of
each mechanism. The valves are separated to four groups according to the
location of each mechanism/function: Two groups are mounted on the catwalk
to control the movement of mechanisms mounted on both sides of the catwalk.
One group is mounted on the trolley to control the trolley movement. One
group is mounted on the trough to control the movement of the mechanisms
that are mounted on the trolley.
The catwalk is symmetrical. Both sides have pipe rack leg cylinders as
well as kick-in and kick-out cylinders so use two multiple valve groups to

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control these functions. One set is mounted on the driller’s side (DS) and the
other set on the off-driller’s side (ODS) at about the middle of the catwalk
base.
The forward/backward movement of the trolley is driven by a hydraulic
motor. The multiple valve group which controls the trolley motor and the
cylinder is mounted on the trolley.
There are satety pin cylinders & kicker cylinder mounted symmetrically
on each side of the trough. The skate is driven by a hydraulic motor which is
mounted at the head of the trough (the end that is towards well center). The
multiplex valve group that controls these functions are mounted at the tail end
of the trough (away from well center).
For more detailed information of the locations of the valve groups please
refer to the attachment: Valve group distribution drawings.
The multiplex valves of each mechanism are as follows: The trolley motor,
skate motor, and the lift arm cylinder are controlled by proportional valves.
The hydraulic winch uses a manual control valve. The remaining multiplex
valves are controlled by electrical switch signal.

2.2.3 Control Valve Block

The control valve mainly comprises the flow divider valve block, counter
balance valve block and motor control valve block.
2.2.3.1 Flow Divider Valve Block
The flow divider valve block is used for speed synchronization by
controlling flow. Its primary function to control speed when mechanisms need
operate simultaneously such as the indexer, pipe rack, kicker, and safety pin
cylinders.
2.2.3.2 Counterbalance Valve Block
The counterbalance valve block has two functions. One is hydraulic lock
and the other is a back-pressure valve.
Mechanism positions can be held for extended periods because they are
hydraulically locked due to zero leakage of the counter balance valve. The
hydraulic lock function is used on every cylinder and motor.
The back-pressure valve is used for the lift arm cylinder. Due to gravity,
the lift arm cylinder hydraulic circuit comes under negative loading while
lowering. The counter balance valve produces sufficient back-pressure to hold
the weight of the trough and its load to order to maintain speed control.
2.2.3.3 Motor Control Valve Block
The motor control valve block is used to control the trolley and skate
motors to make the motor runs smoothly.

2.2.4 Actuators
Pipe rack cylinder: used for moving tubulars.
Indexer Inner cylinder: used to move pipe from pipe rack to the trough.

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Kicker cylinder: used to move pipe from the trough to the pipe rack kicker.
Indexer Outer cylinder: used to move pipe from pipe rack kick to
piperack.
Safety Pin cylinder: used to prevent drilling pipe from overturning from
the trough.
Skate motor: used to move the skate forward and backward.
Trolley motor: used to move the trolley forward and backward.
Lift arm cylinder: used to move trough from the base to the drill floor.
The pipe rack cylinder, lifting arm cylinder, indexer inner cylinder and
indexer outer cylinder all have rod end dust covers.

2.2.5 Electrical Componants

Electrical components include pressure sensors, proximity switches,
displacement sensors, and encoders
 The pressure transmitter is used for sensing the oil pressure. When the
pressure is too high, (>30MPa) the electric control system will alarm.

 The proximity switch is used for sensing the position of cylinders, such
as the kicker cylinders and safety pin cylinders. For indexer cylinder,
proximity switch which are installed on rod end of the cylinder. For
safety pin cylinder, proximity switch which are installed on rod end of
the cylinder.
 The displacement sensor is installed inside the lift arm cylinder to
detect the stroke of the lift arm cylinder.
 The encoder is used to detect the position of the trolley the skate.

2.2.6 Piping Components

Piping components include the stainless steel tubes, connectors, hose
assemblies, etc., for connecting the functional parts of the hydraulic system to
achieve the transmission of hydraulic oil.

2.3 Emergency Operation System

The power catwalk can be used as a conventional catwalk in the event of
power outage of the main motors. When used as a conventional catwalk, the
trough needs to be restored to horizontal position, and the skate to its initial
position. Considering the power outage occurred with the trough in the raised
position, it is necessary to operate the lift arm cylinder and the skate to restore
the trough to the horizontal position.

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2.3.1 Emergency Hydraulic Source

The hydraulic source for emergency operation is supplied by a manualy
operation pump, mounted at the tail of the power catwalk. Through pipelines
the pump connects to the lift arm cylinder and skate. When the pump is not in
use close the ball valve at the pressure port.

2.3.2 Emergency Operation

1. When the power catwalk failure occurs at the raised position, the status is
as shown in fig. 3.1. The skate at the middle of the trough, and the trough is
at the raised position.

Trough

Skate

Lift arm cylinder

fig.3.1 The initial position for emergency operation

Note When performing emergency lowering operation, there must be

no tubular on the trough or ensure the tubular is firmly fixed on
the trough.

2. Rotate ball valve 25.2 handle 90°clockwise so that the manual pump
pressure port is connected to the lift arm cylinder’s control valve. Operate
the pump slowly to raise the pressure until the counterbalance valve on the
lift arm cylinder opens. The cylinder will retract slowly by force of gravity.

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When the lift arm cylinder is fully retracted, the trough is returned to the
position shown in fig. 3.3. When the emergency load lowering is complete,
stop operating the manual pump and rotate ball valve 25.2 handle 90°
counterclockwise.

manual pump

25.2 ball valve

25.1 ball valve

fig.3.2 The position of manual pump

fig3.3 The status of trough retract fully

3. Remove the bolts attaching the skate to the chain, as shown in Figure
3.4.

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skate

bolts

fig 3.4 The position of bolts connect the skate and the chain
4. After the bolts are removed, the skate can be moved manually to the tail
of the trough.
5. Rotate ball valve 25.1 handle 90° counterclockwise so that the manual
pump pressure port is connected to the trolley motor control valve.
Operate the pump slowly to raise the pressure to release the brake on the
hydraulic motor and simultaneously open the ports of motor directional
control valve. At this time gravity will slowly move the trolley toward its
home position until the trough is back to the horizontal position as shown in
fig. 3.5. When the emergency load lowering is complete, stop operating the
manual pump and rotate ball valve 25.1 handle 90° clockwise.

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skate

fig. 3.5 The termination position of emergency operation

Waring When performing emergency operation, pay strict attention to the

following items:
1. Personnel performing the emergency operation need to fully
understand the procedure before commencing the operation.
2. Evacuate all personnel from the power catwalk work area. No
one is to be allowed under or near the lift arm or trough.
3. When performing emergency lowering operation, there must
be no tubular on the trough or ensure the tubular is firmly fixed on
the trough.
4. When the lift arm cylinder begins to move, stop operating the
pump until the cylinder stops movement, then slowly operate the
manual pump again.
5. While operating the manual pump there should be smooth
operation paying close attention to the lowering speed. If the
speed is too fast, quickly close the ball valve 25.1 or 25.2, to stop
the emergency operation.
6. While performing the emergency procedure the operator must
pay close attention during the entire operation and strictly control
the rate of lowering to avoid large impact.
7. The throttle valve has been set at the factory. Field adjustment

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is strictly prohibited. If adjustment is needed, you must consult

HH company.
8. The emergency operation procedure is only to be used in the
event of power outage and cannot be used as a conventional
means of cantilever lowering.

2.3.3 Conventional catwalk

When the power catwalk is used as a conventional catwalk, if the safety
pin cylinder is in the extended position the pin is threaded onto the retaining
cylinder for easy removal.
If the kicker cylinder is extended, it will need to be retracted. There is no
counterbalance valve on the retract circuit, so the cylinder should be simply
retracted by external force. If it is still too difficult to retract, disconnect the
hose connected to the cylinder to reduce the force required.

Note The kicker cylinder can be retracted by external force. If the

kicker cylinder is extended for lengthy time, it may retract slightly
by force of gravity. This does not affect the performance of the
equipment.

When used as a conventional catwalk, the air winch is used to transport

the tubulars. The air source is on the dirll floor, through V-door vamp, through
catwalk to the air winch. There is a ball valve between air source and air
winch for control the air source to air winch.

2.4 Leveling System

The power catwalk is equipped a leveling system for adjust planeness
which includes four leveing cylinder. When the installation of power catwalk is
unsteady, the cylinders can lift the whole power catwalk to fill shims or fillers
under the catwalk and keep the power catwalk flat.
Open the ball valves on block and cylinder before leveling; retracte the
four jacking cylinder and close the ball valves after operation.
The four leveling cylinder can operate together, or operate one by one.
When operate one leveling cylinder, all ball of other cylinders should be
closed.

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Note The leveling cylinder only work to lift power catwalk when the
power catwalk adjust level. When power catwalk start to work, the
catwalk support the weight of power catwalk, the four leveling
cylinder need to be completely retracted and support nothing.

2.5 Maintenance

2.5.1 Hydraulic Oil

It's necessary to inspect the level of oil tank frequently and replenish in
timely manner if required. When the level decreases below the minimum level,
this may lead to abnormally high oil temperature, pumps may become starved
of oil (cavitate), the heater may become exposed and cause high temperature,
all leading to degradation of the oil, leading to system breakdown. If the oil
level drops, this may indicate there is a leak in the system requiring timely
inspection, troubleshooting and correction.
In principle the hydraulic system uses different oil type during summer
and winter. and changes every six months.
Recommend Hydr. Oil: HV/HM
-18℃~25℃，ISO-VG32

25℃~55℃，ISO-VG46/ISO-VG68

Note During the installation, dismantling and handling of pipelines and

components it is important to ensure cleanliness at all times.

2.5.2 Leak
It's necessary to inspect the pipes, hoses, fittings, valves blocks timely,
repairing any leak immediately, especially the pipelines and fittings of the lift
arm cylinder and trolley motor (load carrying mechanisms). When dealing with
an oil leak, stop power and relief the residual pressure in system.

2.5.3 Fliters
Under normal operating conditions, it is recommended to replace the high
pressure, suction and, return filter every six months.
The air breather filter is used to filter the air entering and leaving the tank
as the tank level rises and falls. Check and clean or replace the filter element
every one to three months.

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2.5.4 Pump Sets

The pump set should be inspected frequently, including the main pump
set, the circulating pump set, and the cooling pump assemblies. The pump set
must be kept in good working condition to ensure there is no abnormal
temperature rise, abnormal noise or oil leaks.

2.5.5 Control valves

Multiple unit valves are used to control the direction of motion of the
hydraulic components and can adjust the motion speed proportionally. The
valves make multi operating components work without interference of
pressure differential, or different speeds simultaneously.
Flow divider and counterbalances valves are the essential for achieving
the catwalk functions and ensure correct motion. Pay strict attention to the
conditions of these valves by frequently checking the valves' mounting bolts
for tightness and for any external damage.

2.5.6 Actuators
The actuators on catwalk include the hydraulic motors and cylinders.
Inspect the operation and condition of hydraulic motors frequently to
avoid brake slipping or failure, abnormal noise, unstable motion, leaks etc.
Frequently check the operation of the hydraulic cylinders to prevent
impact, creep, jitter, uneven movement, piston rods from sand damage, worn
surfaces, seal damage, oil leaks, etc.
In particular, pay close attention to the cylinders which are fitted with
canvas dust proof covers to ensure the dust covers do not become stuck, torn,
or otherwise damaged which will cause them to decrease or entirely lose their
protective effect for the cylinder rods. It is recommended to replace the dust
covers annually. Cylinder for lifting arm and cylinders for indexer have dust
cover

*NOTE – Annual replacement of the dust covers is not on the maintenance

schedules listed on pages 22 & 23.

2.5.7 Recommend Maintenance Plan

During the use of this equipment periodic inspections should be carried
out in accordance with the following table. Components are to be repaired or
replaced as required.

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Hydraulic System Maintenance Plan

Item Maintenance
Inspection Item Requirement
Number Cycle
Below the maximum and
1 Oil Level
above the minimum level.
Optimum working
2 35℃～55℃
temperature Per shift
3 System pressure 30MPa
Sound and temperature of No abnormal noise, or
4
pump sets heat
5 Cylinder sealability 油 No leaks
Sealed and no leaks and or
6 All pipelines Daily
damage
Are tight with no leaks or
7 Fittings
damage.
All fixing bolts, screws,
8 All fixxing bolts fasteners etc. are tight Weekly
and secured.
Every six
9 Oil sample Cleanliness and clarity
months
Every six
10 Fliter element Change
months

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3. Electric control system

3.1 Major Components
 HPU ELE. Control Box
 PCW Control Box
 Operation Box
 Radio controller
 Sensor

Photo: Catwalk electrical layout

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3.2 PLC Control Box PLC

The PCW control box is mainly consists of PLC, I/O module, power switch etc.
The control box is installed on the connection between V-DOOR and Catwalk
near the driller's side.

Photo: PLC Control Box

3.3 HPU ELE. Control Box

The main power cable of catwalk is connected to the power distribution box.
Main power switch is at the front to energize the whole system. A green lamp
illuminate if the switch is on.
The power distribution box is installed on the connection between V-DOOR
and Catwalk near the driller's side.

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Photo: Power Distribution Box

3.4 Operation Box

The console provides operating interface, which consists of paddle, push
buttons indicator lamps and HMI. The console is installed at the end of catwalk
near the hydraulic station.
The HMI is mainly used for maintenance purposes, such as sensor reset,
position settings, status indication, system diagnosis function exist on the screen.
Normally, radio control is recommended to turns off the HMI When it does not
need to be used.
More details please see chapter 4.1.1

Photo: Local Control Console

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3.5 Radio controller

The Radio controller operation is available after the selector at the side of
operation box is switched to Remote mode. More details please see chapter 4.1.2

Photo: Wireless Remoter Controller

3.6 Sensor
The Power catwalk sensors including: Skate encoder, Trolley encoder, Lift
arm displacement sensor and proximity switch.
The skate motor is installed with an absolute encoder for measuring the
position of the skate. When the skate is approaching the target point, skate will
automatically slow down and stop until arrived at the target point.
The trolley motor is installed with an absolute encoder for measuring the
position of the trolley. When the trolley is approaching the target point, trolley will
automatically slow down and stop until arrived at the target point.
The lift arm cylinder has a built-in sensor for measuring the position of lift arm.
When the lift arm approaching the target point, lift arm will automatically slow
down and stop until it arrives at the target point.
The 4 kicker cylinders are all installed proximity switches to detect whether
the cylinders are retracted fully.
A proximate sensor is installed in the middle of the trough rail to detect
whether the trolley is returned to home position.

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NOTE
Trolley return movement will stop until the proximate switch is
active, so the proximate switch installation location is so
important to the operation safety.

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4 Operating
Safety Instruction
Prior to equipment operation and maintenance, please read the safety
instructions carefully, or else there will be a risk of human injury or even death,
and serious equipment damages. This manual includes two kinds of safety notice:
warning and caution.
WARNING
Without applying proper preventive method, there will be a risk of serious
human injury or even death as well as equipment damages.
NOTE
Without enough attention to the corresponding instruction, there will probably
appear undesirable consequence or status.
The warning symbols as follows:

Hazardous warning: it warns that there is high voltage which could

probably lead to human injury or equipment damages.

Common warning: it warns that there is non-electric factor which could

probably lead to human injury or equipment damages.

4.1 Start-up And Shut Down

4.1.1 Operation Box Start Up Procedure

The following procedure is performed before the catwalk is operated by local
control console.

1. Ensure correct connection of power cable and control cable.

2. Ensure the emergency valves handle position is correct.

3. Ensure the external main power supply (MCC) is energized.

4. Ensure the emergency stop button at the side of operation box is released.

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5. Ensure all breakers and switches located in power distribution box/PLC

control box/Operation Box are energized.

6. Observe the PLC running status in PLC control box.

The light of “RUN” on CPU turns green, indicating that the control system
has boot up completely.

7. At the local operation box, turn on the HMI, ensure the counter on the main
page is rolling and no alarm exist, if not, click “Fault Reset” button.

8. Switch to “Local mode” at the side of operation box.

9. Switch to “HPU Start” at the side of operation box.

Make sure the HPU is working properly, then the local control console start up
procedure is complete and power catwalk is ready to work.

4.1.2 Radio controller Start up Procedure

The following procedure is performed before the catwalk is operated by

Radio controller.

1. Ensure correct connection of power cable and control cable.

2. Ensure the emergency valves handle position is correct.

3. Ensure the external main power supply (MCC) is energized.

4. Ensure the emergency stop button at the side of operation box and on
wireless controller is released.

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5. Ensure all breakers and switches located in power distribution box/PLC

control box/Operation Box are energized.

6. Observe the PLC running status in PLC control box.

The light of “RUN” on CPU turns green, indicating that the control system
has boot up completely.

7. At the local operation box, turn on the HMI, ensure the counter on the main
page is rolling and no alarm exist, if not, click “Fault Reset” button.

8. Switch to “Remote mode” at the side of operation box.

9. Press the reset button of the Radio controller to enable the wireless
communication, and wait until the light of “pump #1”, “pump #2”, “interlock”
and “alarm” stopped blinking. Otherwise, check the Radio controller or
receiver.

10. Ensure the alarm light on the radio controller is off. Otherwise, check the
alarm details on local operation HMI.

11. Press the “HPU ON” button on Radio controller.

Make sure the HPU is working properly (Light HPU#1 and HPU#2
illuminate green), then the radio controller start up procedure is complete and
power catwalk is ready to work.

4.1.3 Shut Down Procedure

Shut down the catwalk by the following procedure.

1. Ensure the lift arm and trolley located at lowest position and the skate is
located at home position close to Operation Box.

2. Press all E-stop buttons on operation box and Radio controller.

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3. Turn off Radio controller.

4. Shut down all breakers and switches in power distribution box, PLC control
box, and Operation Box.

5. Shut down the external power supply (MCC).

6. Catwalk shutdown procedure is complete.

4.2 Normal Operation

Catwalk can be operated by local control console or Radio controller. The
mode of operation is manually switched by a selector at the side of local control
console

4.2.1 Local Control Console Operation

The local control console is a backup operation but full function same as
Radio controller. Consideration of better view and safety, wireless remote
control is recommended in operation.

Drawing: Catwalk Local Control Console,Top

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Drawing: Catwalk Local Control Console,Left side Drawing: Catwalk Local Control Console,Right side

NOTE All paddle controls will automatically return to their

center/neutral position when released.

○
A Safety pins auto Selection Switch

 Switch to “ON”, DS safety pin will automatically raise when the ODS indexers outer
raise to stop the pipe rolling out of trough.
 Switching to “ON” is recommended for normal operation.

○
B Work Side Selection Switch

 Select ODS or DS to decide the cylinder on which side is allowed to move.

○
C Auto IN/OUT

 Switch and hold selector “AUTO IN”, catwalk will move from ground to target position
on drill floor automatically. During the movement, the catwalk will stop immediately if
the selector is released.
.

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 Switch and hold selector “AUTO OUT”, catwalk will move from drill floor to target
position on ground automatically. During the movement, the catwalk will stop
immediately if the selector is released.

○
D Trolley FWD/BACK Paddle

 The trolley will move forward while pushing and holding the paddle in “TROLLEY
FWD” direction.
The trolley will move backward while pushing and holding the paddle in “TROLLEY
BACK” direction.
 The tilt angle paddle is pushed decides the movement speed. More tilt angle means
higher speed.
 In normal operation, it is recommended to push the paddle fully to improve operation
efficiency. The control system will limit speed if the trolley approaching the target
position or stop the trolley if it arrived at the target position.

○
E Lift Arm UP/DOWN paddle

 The trough will rise up while pushing and holding the paddle in “LIFT ARM UP”
direction.
The trough will lower down while pushing and holding the paddle in “LIFT ARM
DOWN” direction.
 The tilt angle paddle is pushed decides the movement speed. More tilt angle means
higher speed.
 In normal operation, it is recommended to push the paddle fully to improve operation
efficiency. The control system will limit speed if the lift arm approaching the target
position or stop the lift arm if it arrived at the target position.

○
F Kicker paddle

 Pushing and hold the paddle “KICK OUT” will raise the kickers to eject a single
tubular from the trolley to the pipe rack. The paddle must be held in the KICKER
OUT position to keep the kickers raised.
 Releasing the paddle will lower the kickers into the trough automatically.

○
G Indexer OUTER/INNER paddle

 Pushing and hold the paddle “OUTER RAISE” will raise the outer to load a tubular
from the pipe rack to catwalk.

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 Pushing and hold the paddle “INNER RAISE” will raise the inner cylinder causing
tubular to eject from the catwalk to the pipe racks.
 Indexers will automatically lower when the control is released.
 The indexer is available only when the trolley is fully lowered into the catwalk.

○
H Pipe rack UP/DOWN paddle

 Pushing and hold the paddle “PIPE RACK UP”, the pipe rack goes up. Releasing the
paddle will stop the pipe rack action.
 Pushing and hold the paddle “PIPE RACK DOWN”, the pipe rack goes down.
Releasing the paddle will stop the pipe rack action.
 The pipe rack is available only when the trolley is fully lowered into the catwalk.

○
I Skate FWD/BACK paddle

 The skate will move forward while pushing and holding the paddle in “SKATE FWD”
direction.
The trolley will move backward while pushing and holding the paddle in “SKATE
BACK” direction.
 The tilt angle paddle is pushed decides the movement speed. More tilt angle means
higher speed.

○
R Local/Remote Selection Switch

 Switch to “LOCAL”, Operation box control is available.

 Switch to “REMOTE”, radio controller is available.

○
S HPU Start/Stop

 Switch to “HPU ON”, HPU start up.

 Select “HPU OFF”, HPU Stop.

○
T Reset Button

 Fault reset.
 Press and hold the reset button, all the target position will be bypassed until release
the button. This operation is often used if the target value is not configured or
incorrect.

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○
U E-STOP Button

 Press to immediately stop catwalk movement.

○
V Power On Indicator

 Illuminated green when Power is on.

4.2.2 Radio controller Operation

The Radio controller is the primary operator control for the catwalk.

Drawing: Radio controller

NOTE All paddle controls will automatically return to their

center/neutral position when released.

○
A HPU ON BUTTON

 Press down the button HPU ON, HPU start up

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○
B HPU OFF BUTTON

 Press down the button HPU OFF, HPU stop

○
C Trolley FWD/BACK Paddle

 The trolley will move forward while pushing and holding the paddle in “TROLLEY
FWD” direction.
The trolley will move backward while pushing and holding the paddle in “TROLLEY
BACK” direction.
 The tilt angle paddle is pushed decides the movement speed. More tilt angle means
higher speed.
 In normal operation, it is recommended to push the paddle fully to improve operation
efficiency. The control system will limit speed if the trolley approaching the target
position or stop the trolley if it arrived at the target position.

○
D Lift Arm UP/DOWN paddle

 The trough will raise up while pushing and holding the paddle in “LIFT ARM UP”
direction.
The trough will lower down while pushing and holding the paddle in “LIFT ARM
DOWN” direction.
 The tilt angle paddle is pushed decides the movement speed. More tilt angle means
higher speed.
 In normal operation, it is recommended to push the paddle fully to improve operation
efficiency. The control system will limit speed if the lift arm approaching the target
position or stop the lift arm if it arrived at the target position.

○
E Kicker paddle

 Pushing and hold the paddle “KICK OUT” will raise the kickers to eject a single
tubular from the trolley to the pipe rack. The paddle must be held in the KICKER
OUT position to keep the kickers raised.
 Releasing the paddle will lower the kickers into the trough automatically.

○
F Indexer OUTER/INNER paddle

 Pushing and hold the paddle “OUTER RAISE” will raise the outer to load a tubular
from the pipe rack to catwalk.

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 Pushing and hold the paddle “INNER RAISE” will raise the inner cylinder causing
tubular to eject from the catwalk to the pipe racks.
 Indexers will automatically lower when the control is released.
 The indexer is available only when the trolley is fully lowered into the catwalk.

○
G Pipe rack UP/DOWN paddle

 Pushing and hold the paddle “PIPE RACK UP”, the pipe rack goes up. Releasing the
paddle will stop the pipe rack action.
 Pushing and hold the paddle “PIPE RACK DOWN”, the pipe rack goes down.
Releasing the paddle will stop the pipe rack action.
 The pipe rack is available only when the trolley is fully lowered into the catwalk.

○
H Skate FWD/BACK paddle

 The skate will move forward while pushing and holding the paddle in “SKATE FWD”
direction.
The trolley will move backward while pushing and holding the paddle in “SKATE
BACK” direction.
 The tilt angle paddle is pushed decides the movement speed. More tilt angle means
higher speed.

○
I Reset Button

 Fault reset.
 Press and hold the reset button, all the target position will be bypassed until release
the button. This operation is often used if the target value is not configured or
incorrect.
 Press the reset button once after remote control is started every time.

○
J Setpoint Button

 The target position function is activated only when press and hold the SETPOINT
button for 2 seconds. More details about target preset please see chapter 4.2.5.

○
K ON/OFF Key-Switch

 Switch to the “ON” position to power on the Radio controller.

 Switch to the “OFF” position to power off the Radio controller.

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○
L Auto IN/OUT

 Push and hold selector “AUTO IN”, catwalk will move from ground to target position
on drill floor automatically. During the movement, the catwalk will stop immediately if
the selector is released.

 Push and hold selector “AUTO OUT”, catwalk will move from drill floor to target
position on ground automatically. During the movement, the catwalk will stop
immediately if the selector is released.

○
M Work Side Selection Switch

 Select ODS or DS to decide the cylinder on which side is allowed to move.

○
N E-STOP Button

 Press to immediately stop catwalk movement.

○
P Safety pins auto Selection Switch

 Switch to “ON”, DS safety pin will automatically raise when the ODS indexers outer
raise to stop the pipe rolling out of trough.
 Switching to “ON” is recommended for normal operation.

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○
Q HPU#1 State Lamp

 The lamp “HPU#1” illuminated green means that HPU#1 is running.

○
R HPU#2 State Lamp

 The lamp “HPU#2” illuminated green means that HPU#2 is running.

○
S Interlock state lamp

 In normal operation, the lamp illuminated red indicating that some interlock takes
effect and relative movement is not allowed.
 Target preset function indication purpose. More details please see chapter 4.2.5.

○
T Alarm lamp

 The lamp illuminated red, indicating an alarm exists.

○
U Battery Volume Status lamp

 The lamp flashed red, indicating battery low.

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○
V Communication Status lamp

 Flashed green during wireless control transmission.

4.2.3 Loading Tubular to the Drill Floor

The following procedure describes load tubular to the drill floor.

1. Confirm that the safety pin auto function switch is set to ON position.

2. Set the indexer pins in the proper socket so that the Indexer delivers one
tubular at a time.

NOTE The indexer should be able to catch more than half of the
tubular when resting against the indexer pins.

3. Confirming the tubular on the pipe rack, control the pipe rack to rise and
let the tubular roll to the indexer pin.

WARNING Ensure all personnel maintain a safe distance from the pipe
racks as they are adjusted. Do NOT rely solely on the
anti-rollback or indexer pins to protect personnel from rolling
tubular.

4. Ensure that the skate is backward to the initial position, so that the skate
is located behind the tubular, and prevent interference with the tubular.

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WARNING
The skate must be in a safe position which is clear of any
tubulars
before operating the indexers outer. It is the responsibility of
the operator to ensure the indexers outer do not send a tubular
into the side of the skate, because the initial location of the
tubular in pipe rack can not be detected by the system. A risk
that rolling tubular hits the skate exists.

5. Controlling the indexer outer turn the tubular over the indexer pin, the
opposite safety pins will automatically extend to prevent tubular rolling
out.

6. Release the indexer outer after the tubular is turned over the indexer pin,
and the indexer outer will retract automatically.

7. Ensure the tubular enters the trough, move skate contact with the tubular,
so that the tail of the tubular enters the skate completely.

8. Control the trolley forward by applying “AUTO IN” function simultaneously

the safety pin is automatically extended. The trough automatic
deceleration and stop at the forward end stop position.

9. Control the lift arm up and automatic deceleration and stop at the target
position by applying “AUTO IN” function.

10. Control the skate and push the end of the tubular to the elevators.

WARNING
Ensure all personnel maintain a safe distance from the
trough when the skate pushes tubulars.

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11. The elevators catches the tubular and closed.

12. Lift the tubular off the trough.

WARNING

Ensure all personnel maintain a safe distance from the free end
of the tubular as it slides off the end of the trough.

13. The catwalk can be operated back to its initial position by applying “AUTO
OUT” function to prepare for the next cycle of loading.

4.2.4 Unloading Tubulars from the Drill Floor

The following procedure describes unload tubular from the drill floor.

1. Lower the pipe rack to ensure that the tubulars can roll sideways.

WARNING
Ensure all personnel maintain a safe distance from the pipe
racks as they are adjusted. Do NOT rely solely on the
anti-rollback or indexer pins to protect personnel from rolling
tubulars.

2. Remove the indexer pins on the working side.

3. Control the trolley, the lift arm and the skate to the appropriate position
and prepare to catch the tubulars on drill floor.

4. Ensure that the safety pin is automatically extended.

5. Place a thread protector on the end of the tubular.

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6. Push the end of the tubular over the end of the trough.

7. Carefully place the tubular onto the trough.

8. Open the elevators when the tubular is completely supported by trough.

9. Control the skate to move the backward, check that no part is

overhanging, and ensure full access to the trough.

10. If the tubular sticks to the trough and does not slide with the skate, the
angle can be increased by controlling the distance of the lift arm until
the tubular begins to slide.

WARNING
Ensure all personnel maintain a safe distance from the end of
the tubular as it slides down to the end of the trough.

11. Lower the lift arm to a low position, then trolley move back to initial
position by applying “AUTO OUT” function, while the safety pins
automatically retracts.

12. Control the skate to move to the appropriate position.

13. Control the kicker to roll the tubular out of the trough and to the pipe
rack.
If the tubular does not roll into the pipe rack, control the indexer inner
raise to send the tubular as well.

14. Prepare for the next cycle of unloading.

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4.2.5 Target preset procedure

The positioning function is used in “AUTO/ IN/OUT” operation or manual
operation may improve the efficiency.
During the operation load tubular to drill floor.
Lift arm “Target” position decides the trough location on drill floor.
Skate “Forward” position decides the skate location when the skate just in
contact with the tubular joint.
Skate “Back” Position decides the skate returning back location.
More details please see following picture.

During the operation unload tubular to Ground.

Lift arm “Target” position decides the trough location on drill floor.
Skate “Forward” position decides the skate standby location.
Skate “Back” Position decides the skate location ready to eject the tubular.
More details please see following picture.

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Preset Lift arm target position procedure on Radio controller as follows:

1. Move the lift arm to the desired target position.
2. Press and hold the “Setpoint” button for the whole procedure. Any time
releasing the “Setpoint ” button will abort the process.
3. 2 seconds after the “Setpoint” button is pressed, the “interlock” lamp
flashed indicating the preset request is received.
4. Push paddle “LIFT ARM UP” once then control system will store the current
lift arm position as the target position. If the “interlock” lamp illuminates red
permanently indicating the lift arm preset is successful.
5. Release the “Setpoint” button. The preset process finished.

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Preset Lift arm target position procedure on operation box as follows:

1. Move the lift arm to the desired target position.
2. Energized the HMI and switch to “Target preset” page.
3. Click on the button “Target” on lift arm label and check whether the “Target
position” value is the same as the “Act.Pos”. If yes, the preset process is
successful.
4. Turn off the HMI. The preset process finished.

The skate “Forward” and “Back” preset process is the same as Lift arm.

4.3 HMI Operation

HMI is installed on the Operation Box to monitor catwalk data, system
diagnosis, alarm information, parameter setting and maintenance operation.

4.3.1 Main page

HMI main page mainly indicates the catwalk position value and HPU working
status as follows.

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4.3.2 Operation page

In this page, it consist of all catwalk movement operation including: HPU
start/stop, Trolley/Lift Arm/Skate operation, kicker operation, Safety pin operation,
Indexer operation, Pipe rack operation.
Please mention that the HMI operation is used in maintenance or commission
purpose, so it is required to enable “Maintenance mode” on screen before
operation. If Maintenance mode is selected, all interlock is invalid, no
automatically function at all. Press down and hold the command button,
equipment is moving; Release the button, equipment stop. Maintenance mode
enable function please see chapter 4.3.3.

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4.3.3 System Configuration

System configuration page is mainly used to reset sensors, preset target
position for local operation purpose, signal bypass and so on. The system setting
function is only valid when the maintenance mode is selected. The only way to
enable maintenance mode is clicking on “Configure” screen. In maintenance
mode, the interlock and protection functions of the control system will be invalid.

WARNING
All personnel are to remain clear of the Catwalk is maintained

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actuation as unexpected movements could result in personal

injury.

HMI Configrue
Path:Configure -> HMI
Configure

Choice in Chinese or English.

Clean screen.

Maintenance.

Path:
Configure->Maintenance

Some Configuration function

requires Maintenance mode
selected.

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Trolley Config

Path: Configure-> Trolley

Encoder

Skate Config

Path: Configure-> Skate

Encoder

Lift arm Config

Path: Configure-> Lift arm

Min.Current/Creep speed Set NOTICE:

1. Two direction. The positive means the direction equipment moves to drill
floor. negative means the direction equipment moves to the ground.
2. Min.Current adjustment requirement: 5mA +/- per time, then to check the
movement. DO NOT change too much comparing with the last value. More
details please contact OEM support.
3. Creep speed adjustment requirement: 0.01% +/- per time then to check the
movement. DO NOT change too much comparing with the last value. More
details please contact OEM support.

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Parameter Config
Path:

Configure-> Para. Config

Taking the trolley as an example, the function settings of each part are explained.

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NOTE Pay attention to the unit when setting parameters, incorrect

setting may cause the equipment to be unable to operate
normally and damage equipment.

Parameter Set NOTICE:

1. Two direction. The positive means the direction equipment moves to drill
floor. The negative means the direction equipment moves to the ground.
2. The limit position adjustment requirement: By observing when approaching
a mechanical limit or buffer block, input the current actual position into the
settings box, Successful target location setting. More details please contact
OEM support.
3.The Speed adjustment requirement: 0.1 +/- per time , Maximum Speed of
Regulating movement Process. More details please contact OEM support.
4. Other parameters adjustment requirement: Adjust the deceleration effect to
meet the actual demand: Smooth deceleration and accurate positioning. More
details please contact OEM support.

During the operation, if some sensor fails, the interlock related to the sensor
is affected, which may cause the catwalk working not properly even shut down.
For non-stop working consideration, it is possible to bypass the damaged sensor
then continue the operation.
Please NOTICE that the trolley/skate encoder and lift arm displacement
sensor relations to equipment operation safety seriously is not allowed to bypass!

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WARNING
After the sensor is bypassed, the interlock failure associated
with the sensor exists certain risks in operation, so the bypass
operation should be very cautious and cancel the bypass once
the sensor is fixed up.

TWO types signal is available to bypass:

Type 1, Kicker low position detection proximity switch.
The following interlock will invalid if kicker low switch is bypassed.
 Only if kicker is at low position, trolley is able to move.
 Only if kicker is at low position, skate is able to move.
 Only if kicker is at low position, lift arm is able to move.
Type 2, HPU sensors.
There are HPU system pressure sensor, oil temp sensor and oil level sensor.
If HPU pressure sensor is bypassed, Pressure high alarm will be invalid.
The following interlock will invalid if HPU oil temperature sensor is
bypassed.

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 When oil temperature is more than 80 c and lasts 10 seconds, HPU

stopped.
 When oil temperature is less than 15 c and lasts 10 seconds, HPU
stopped.
The following interlock will invalid if HPU oil level sensor is bypassed.
 When oil level is less than 100mm and lasts 10 seconds, HPU stopped.
 When oil level is less than 420mm and lasts 10 seconds, HPU stopped.

WARNING

If HPU sensor is bypassed, it is strongly recommended to

check the HPU oil level or temperature per hour for equipment
safety concern.

Target preset
The target position is set on the local touch screen in the following way:

Path: Config -> Target preset

Press down the target location button, system will restore the current position
as the target. More details about please see chapter 4.2.5

System config
Path: Config -> HMI config

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The page is used to switch language and clean screen.

4.3.4 System Diagnose

The following is the main screen of system diagnose

Network Diag

Path: Diagnose -> Network

Encoder Diag
Radio controller Diag
Path: Diagnose -> Encoder
Path: Diagnose -> Radio

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IO module Diagnose

Interlock Diagnose
Interlock page indicates all Catwalk interlock signals. If the interlock is normal,
the indication is green, otherwise it will change to red.

4.4 Technical Maintenance and Repair

In order to ensure the reliable and smooth operation of power equipment, it
must meet the requirements in the “Regulations for the Use of Power Installation
Technologies” and the “Regulations on Labor Protection for the Use of Electrical
Installations”. The main personnel must regularly check the power equipment.
The maintenance system should be checked for maintenance, status and
equipment cleaning.
The number of regular maintenance and inspections shall include the
equipment characteristics, status, and working conditions in accordance with the
applicable codes and instructions for the respective product. The maintenance of
electrical installations depends on the form of different periods:
Current electrical machinery maintenance - 6 months;

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Operation box current and average maintenance - 1 month;

The main maintenance period depends on the local conditions, but not less
than the requirements of the rules for the use of electrical installation technology.
Technical maintenance and repair of motors, automatic switches, starting
appliances and other electrical equipment must be carried out in accordance with
the manufacturer's instructions.
Operation of the operation box requires system maintenance. The inspection
and inspection period depends on the conditions of use. The equipment must be
protected from contamination and mechanical damage. All equipment should be
tested on a regular basis and the entire box should be inspected not less than
once a year.
Regular maintenance work includes:
1) Cleaning equipment and dust on the operation panel;

2) Check and reinforce contact points and terminals;

3) Inspection and cleaning of the relay and contactor operating points burns
and sticking occurs;
4) Lubricate the contactor and the bearing of the motor's movable part;
5) Check the operational status of the operating cabinet system.
The contactor activity system is disassembled and cleaned, and worn
working relays and contactors are replaced when necessary;
Check the route of operation and the adjustment of the relay when
necessary;
Check the insulation of the main current part of the housing;
During the monthly maintenance, the normality of the indicator and the
automatic switch, the working status of the thermal relay, and the reliability of the
grounding should be checked. There is no char smell and abnormal noise.
During the monthly maintenance, the status of bolted connections, insulation
of the cable products, protective equipment, contact surfaces, thermal relays and
contactors shall be checked and the dust of all control boxes shall be cleaned.

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4.4.1 Encoder Device name Assignment

The trolley/skate encoder is filed bus communication to control system with
profinet protocol, it is required to assign Profinet name in the situation of replacing
a new encoder before install it. Following text & pictures will describe how to
realize the assignment process.
Step1. Install a free tool name is “PST”(Primary Setup Toll) produced by
Siemens.
Step2. Prepare a 24v power to energize the encoder.
Step3.Connect the encoder to your computer which is installed PST with an
Ethernet cable.
Step4. Start the PST on your computer, Select the network adapter first.
Step5. Scan the network node. “Network – Browse”
Step6. Assign the profinet name with scanned node.
Step7. Click on “Apply” and the assignment process is done.

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4.4.2 Proximate Switch Replacement

Two types proximate switch are used on power catwalk.
One is the cylinder proximate switch installed on the kicker cylinder to detect
the cylinder retract fully. The replacement action is not complicated.
Anther proximate switch is installed on the middle rail of catwalk to detect the
trolley returned to initial position.

Please NOTICE that the trolley return movement will stop until the proximate
switch is active, so the proximate switch installation location is so important to the
operation safety! It has to be understood above information before a new trolley
initial proximate switch replacement job begins.

WARNING
A wrong trolley initial position proximate switch installation
location may cause the trolley hit the backward mechanical
stopper. It is harmful to the equipment.

4.4.3 Alarm Cause & Corrective action

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4.5 Storage
Before installation, electrical equipment should be stored in a gas that is free
from dust and damaging insulation and must be kept in a moisture-proof
environment.
There should be no significant changes in temperature and moisture in
places where electrical equipment is stored.
When storing electrical equipment, follow the instructions provided by the
factory to preserve the oil seal.

4.6 Security Measures

In order to ensure the reliable and smooth operation of power equipment, it
must meet the requirements in the “Regulations for the Use of Power Installation
Technologies” and the “Regulations on Labor Protection for the Use of Electrical
Installations”.
Maintenance of electrical equipment in hydraulic stations should be carried
out by professional power technicians and personnel who are familiar with safety
rules and who can rescue the injured.
Prohibited!!!!
Power equipment must not be used without professional training personnel
and reliable housing grounding.
All installation and maintenance work is performed in the event of a power
failure.
When the cooling fan starts, the fuel pump must be started to achieve a good
cooling effect.

4.7 Transportation
The hydraulic power unit can use any mode of transportation that meets the
weight of the vehicle: railroads, maritime transport, motor transport, etc.
In order to lift the module with special lifting components. Lift according to the
lifting route

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The utilized drilling pump should be stored in dry and ventilating places without
corrosive gas, 100mm above the ground.
During storage, discharge the lubricating oil in the oil tank completely, discharge
water in the valve bodies completely, and rinse the inside of the suction filter of the
mud pump clearly with clear water. Check once per three months.

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