CONTENTS Q MAINTENANCE ITEM. DESCRIPTION i “Paije GENERAL ...sescsssssssesstsnstnneentssssnereneeeseentnnetneeee 44 ACCUMULATORS Precharging Instructions 44 Service and Repair Instructions 46-46 Precharging Procedure for 3000 PSI Top Repairable Accumulators......» 47-49 Replacing the Accumulator Bladder 50 Required Toots, Tools, Preparation, Removal 50 Installation .. sss 51 5.3 ACCUMULATORS UNIT 5.3.1 Fluid Reservoir i 53 5.3.2. Reliof Valves 5.3.3 Piping...... 5.4 AIR OPERATED PUMPS 5.4.1 Hydro-pneumatic Pressure Switch 5.4.2 Aird.ubricator 5.4.3 Filters 5.4.4 Strainers . 5.4.5 Pump Packing 5.4.6 Air Exhaust 5.5 ELECTRIC PUMPS 5.5.1 Hydro-electric Pressure Switch .. 5.5.2 Crankcase a 5.5.3 Chain Guard 5.5.4 Motor bearings 5.5.5 Pump Packing 5.5.6 Strainers 5.6 HYDRAULIC MANIFOLD For-way Control Valves ... 56.1 87 2 5.6.2 Cylinders ... 57 56.3 Filters ... 57 ‘ 564 Gauges....... 57 5.6.5. Regulator Routing Maintenance . 57 5.6.6 Removing Regulator from Service. essen 5.6.7 Removing Subplates and Spring Control head Assemblies - amen 5B 5.6.8 Disassembly Instructions for TR-4 Regulator Body 5.6.2 Assembly Instructions for TR-4 Regulator Body ...@ maintenance (CONTINUE) [EM ” DESGRIPTION x c , 5.6 HYDRAULIC MANIFOLD ; 5.6.10 Disassembly & Assembly Instructions for TR-5 Regulator Body 5 5.6.11 Disassembly & Assembly Instructions for Internal Override... i 5.8.12 Disassembly & Assembly Instructions for Manual Operator .. 5.6.13 Disassembly & Assembly Instructions for Pneumatic Motor Operator 5.6.14 Pneumatic Motor for TR-4 & TR-5 Regulators oss. . 5.6.15 Disassembly & Assembly Instructions for Hydraulic Motor Operator... 64 5.6.16 Hydraulic Motor Servicing .. eee . 5.6.17 Disassembly & Assembly Instructions for Spring control Head 5.7 AIR PANEL 5 8.7.1. Air Lubrication 65 E 5.7.2 Air Filter 65 5.7.3 Gauges 65 5.7.4 Air Junction Boxes 66 5.7.5 Panel Check Out 66 > 5.7.6 Air Transmitters 66 i 5.7.7 Optional Position Indicating Lights 66TON od General Aregularly scheduled maintenance program must be developed to sufficiently maintain the BOP Control System. The operator must develop an appropriate program based on the operating, testing and driling programs. The entire system should be tested a minimum of once a week. This may involve simply Operating all functions and noting gauge readings. When performing routine maintenance and/or major service and repair around high pressure and electrical equipment, care should be taken to ensure the safety of all personnel. Remove and verity line pressure is released before attempting to disconnect pressure lines. Accumulators Precharging Instructions A. PRECHARGING PROCEDURE FOR 3000 PSI STANDARD ACCUMULATORS. 1. Relieve system pressure. 3. Close the bleed valve on the charging and gauging assembly. Retract the T-handle on t the air chuck by turning counter clockwise direction.5 | | ' 4. Install Charging and Gauging Assembly on the accumulator by screwing the air chuck to the gas valve and tighten sufficiently to prevent any leakage. Turn the T-handle on the air chuck clockwise to depress the valve core. Connect the hose to the nitrogen bottle regulator. 5. Remove the seal cap from the gas charging tank valve and connect the swivel connector on the hose assembly. Hand tighten sufficiently to prevent leakage. 6. Open the regulator valve on the nitrogen bottle carefully to let nitrogen flow at a slow rale into the accumulator. Proceed to charge until the accumulator reaches desired precharge pressure. Close the regulator and let the nitrogen stabilize and obtain gauge reading. Adjust the pressure if necessary. 7. Retract the T handle on the air chuck by turning counter clockwise to close the valve core.DEN L=N Nas o a 8 | 8. Open the bleed valve to bleed of nitrogen in the hose. Disconnect the charging a ‘assembly from the accumulator and the gas bottle. é e 9. Check for leakage through the valve core by soap solution or snoop. Ifthe core is é leaking, then relight the valve core to 4 in-b torque. IFleakage persists then replace the 4 valve adapter. ‘ 10. Replace the valve seal cap and the protective cap. i 41. Check precharge pressure once in the first week of operation, and then every six 1 months during normal working or every month during high cycling or high temperature condition. ]SENET NN B. PRECHARGING PROCEDURE FOR 3000 PSI TOP REPAIRABLE ACCUMULATORS 1 2. Close the bleed valve on the charging and gauging assembly. Retract the T-handle on the air chuck by turning counter clockwise direction. 3. Install Charging and Gauging Assembly on the accumulator by screwing the charging block directly on to the bladder valve stem. Hand tighten sufficiently to prevent any leakage. Turn the T-handle on the block clockwise to depress the valve core. Connect the hose to the nitrogen bottle regulator.6 ANCE cb ey Pree a o a 4. Remove the seal cap from the gas charging tank valve and conneet the swivel connector on the hose assembly. Hand tighten sufficiently to prevent leakage. a 5. Open the regulator valve on the nitrogen boitle carefully to let nitrogen flow at a slow rate into the accumulator. Proceed to charge until the accumulator reaches desired Precharge pressure. Close the regulator and let the nitrogen stabilize and oblain gauge Feading. Adjust the pressure if necessary. oo a BARR Rn > oo 7. Open the bleed valve to bleed off nitrogen in the hose. Disconnect the charging : assembly from the accumulator and the gas bottle.TNL ols 8. Check for leakage through the valve core by soap solution or snoop. If the core is leaking, then retighten the valve core to 4 in-Ib torque. If leakage persists then replace the vaive adapter. 9. Replace the valve seal cap and the valve guard. 10, Check precharge pressure once in the first week of operation, and then every six months during normal working or every month during high cycling or high temperature condition, Pressurize system, Use Nitrogen Only - Do Not Use OxygenReplacing the Accumulator Bladder Required Tools Tools eS Core Too! Bladder Pull Rod Charging and Gauging Assy. (3,000 psi) Valve Extension id a Preparation Replacing the accumulator bladder requires all hydraulic pressure to be vented from the accumulator in accordance with the following steps: 1. Isolate the accumulator bottles from th appropriate ball valve, Ventthe residual nitrogen precharge pressure from the bottle to atmosphere using the charging and gauging assembly. Orain the fluid from the accumulator by opening the 3/4? ball valve. 'e main hydraulic supply by closing the 2, 3, Removal 1. Remove the gas protective cap and valve cap from accumulator. 2. Install the proper charging and gauging assembly on the gas valve stem. Attach the air chuck to the accumulator bladder gas valve by hand tightening the swivel hex connection, Open the valve by turning its top (small) hex nut counter clockwise. Sues o5 ’ ue oe DAT a Bleed off all nitrogen gas pressure by opening the bleed valve completely. Open the gas valve fully and then remove the gas valve. Remove the gauging device from the gas valve stem, Remove the accumulator bottle from the bottle rack. Remove the hex jam nut and name plate. Remove the lock nut from the bottom of unit using a spanner wrench Remove the spacer and the rings. 0. Push the plug assembly into the accumulator and through the anti-extrusion ring. Remove the anti-extrusion ring by folding it and pulling it through the hole. 11. Remove the plug assembly and pull the old bladder out from the bottom of the accumulator. Installation Remove the valve core and the gas valve from the new bladder and squeeze all air from the bladder. Replace the valve core. Unfold the bladder completely. Lubricate the bladder and shell with system fluid, Altach a bladder pull rod to the bladder by carefully threading over the Schrader connection. Insert the rod through the accumulator (bottom to top). Pull the bladder into the shell. Do not allow the bladder to bind or kink 5. Attach the name plate and hex jam nut to the exposed gas valve stem and handtighten. Remove the pull rod, 6. Push the plug assembly and then the anti-extrusion ring into the shell. 7. Pull the plug assembly through the anti-extrusion ring. Seat the ring in the hole, metal side up. 8. Install a new metal backup ring and a new O-ring, making sure not to pinch the O-ring. Install a new rubber backup ring, spacer, and lock nut, Hand-tighten the lock nut. 9. Precharge the accumulator. 10.Tighten the hex jam nut, making sure the gas valve stem does not rotate. 11-Tighten the lock nut on the fluid end.Cs VA Plug and Poppet Assembly consists of Items 8, 9, 16, 18 and Port Assembly A Consists of one (1) each of Items 10, 11, 12, 13, 14, 15, PLUS tems 8, 9, 16, e 48 and 19. a Dimensions: Dim, “A” ~ 59-1/2" Dim, "B* ~ 53-1/2" Diameter ~ 9-1/16" : Weight - 240 pounds feutidi oue UU wu wr we ww MAINTENANCE 5.3 5.34 5.3 ACCUMULATORS UNIT Fluid Reservoir 1. The fluid reservoir should be checked regularly, drained and cleaned to eliminate sludge build-up. The control fluid should be kept clean and free of debris. A high quality WES 10W hydraulic oil or suitable lightweight oil should be used in the system. NEVER USE FUEL OIL, KEROSENE OR SALT WATER IN THE RESERVOIR, 2. To clean the reservoir use the following procedure : a. Stop pumps. b. Open manifold bleeder valve and release system pressure. ¢. Drain the fluid from the system. Remove any sludge/slime or other material from the reservoir. d. Flush the entire system with 140°F (60°) hot water. e. Circulate @ mixture of hot water and Trisodium Phosphate (2 pounds in § gallons water) until the sludge and oil are removed from the metal parts. Optional - Circulate a warmto- hot bacteriacidal solution through the system. f. Rinse the system thoroughly with hot water. g. Refill the system with hydraulic fluid mixture. h. Start pumps and operate to ensure that pumps are primed. i. Close manifold bleeder valve. Relief Valves Check the high-préssure relief valves for leaks. Open the 4" inspection ports on the side of the reservoir and check the vent lines from the relief valves for leakage, Piping Visually check all fluid lines and connections for possible leaks. AIR OPERATED PUMPS Hydro-pneumatic Pressure Switch 1. Tum the spring adjustment nut from left to right to increase pressure setting and from Tight to left to decrease pressure setting. 2. Check air pressure switch bypass valve for leaks. Air Lubricator 1. Check the air lubricator to make sure it is full of WES 10W lubricating oil. Open the petcock of lubricator to drain moisture that may have accumulated. Check that drip setting flows 6 drops per minute. To adjust setting see Troubleshooting Section.5.4.3 5.4.4 5.4.5 5.4.6 55 5.51 Filters Drain and flush accumulated moisture. Open the manual drain on the filter housing, as pumps are running. Clean elements. a. Stop pumps. b. Unscrew housing and lift out o-ring and louver. s ¢. Remove filter elements and wash in warm water or kerosene. ‘ 4. Dry elements and check that bow! gasket is in good condition. e. Replace parts and housing. S Strainers € 1, Clean Y-type strainers. Ensure lines are free of pressure before attempting © maintenance. Stop pumps. Close pump suction valves. Remove Y-type strainer plugs. € Remove strainer elements. Open pump section valves to flush piping, then close valves. e Clean strainer elements in warm water or kerosene. Replace elements and Y-type strainer plugs, |. Open pump suction valves. > ‘Startpumps. rsve@reaorp Pump Packing ‘The pump packing is spring loaded and spring adjusted. No maintenance is requirec| Air Exhaust 1. Clean sludge build-up. ¢ 2. Check end caps for leaks. an ELECTRIC PUMPS o Hydro-electric Pressure Switch o 4. To adjust the pressure setting for : ” a. Pump Start-up . Close air supply valves. Remove explosion-proof cover of electric pressure switch. Open manifold bleeder valve and bleed system pressure to desired star-up pressure Close manifold bleeder. € Move the adjustment wheel upward until the pump comes on, reaches shutoff __ Pressure, and stops. : oe eNoDUD 6. Open manifold bleeder and check that start-up is at-proper pressure. 7. Close manifold bleeder valve. 8. Replace explosion-proof cover. 9. Open air supply valves. b. Pump Shut Off 1. Remove access screw on right hand side of switch. 2. Turn the adjusting screw counterclockwise to increase pressure setting. 3. Tur adjusting screw clockwise to decrease pressure setting, 2 To replace limit switch: a. Loosen the set screw(s) on housing stem. b, Remove the pressure fitting from housing, c. Remove the extension fitting of adjustment screw. d. Remove the mounting screws from terminal bracket. e. Loosen the screws of terminal wire connections. f. Pull away the terminal assembly. g. Loosen the retaining nut at base of bourdon tube assembly. h. Remove the tube and switch assembly. i Replace with new tube and switch assembly from the repair kit. If replacing the | limit switch only: 1, Remove screws (Switch mounting bracket to bourdon tube). 2. Pulloff switch assembly. 3. Replace new switch assembly to bourdon tube. 4, Replace mounting bracket screws. J. Replace the tube and switch assembly. k. Tighten retaining socket nut. 1 m. Pull wires through terminal assembly. . Replace the mounting screws through terminal bracket. n. Replace wires to terminate connection screws and tighten. ©. Replace the extension fitting of adjustment screw. p. Replace pressure fitting to housing base. q. Tighten the set screws on housing stem. | r. Replace the leads from starter to pressure switch 5.5.2 Crankcase 1 1. Check the pump crankcase to make sure it is full of good, clean engine oil. Eight will vary depending on the ambient temperature (See Table ), 2. Clean the pump crankcase of accumulated sludge.CONN es eS PARTNUMBER | CAPACITY (OTS) OIL TYPE . Triplex pump, Bx- a 10, 3/4" Plunger 512 & 7/8" Plunger & 1" WES 20 @40°F-115°F € Plunger WES 10 @0°F-60°F Triplex pump, 1-1/4" % Plunger 8D30 2 Triplex pump, 1-3/8" 5 e Plunger BD60 é DUPLEX AND TRIPLEX PUMP CRANKCASE OIL SPECIFICATIONS e Table 5-1 a 5.5.3. Chain Guard é 4. Remove the lower drain plug and check for water or sludge build-up. € 2. Check the oil level in the oil bath chain guard. It should be filled up to the spill plug, a. Above 20° F use WES 90° Compound Chain Oil, a b. Below 20° F use WES 80° Compound Chain Oil. : 3. Chain Tension Adjustment and Initial Setting a. Adjust Drive Centers and Chain Tension. 1. Horizontal drives should be installed with initial sag equal to two percent (2%) of sprocket centers. € 2. Vertical center drives should be operated with both spans of chain close to being taut. Periodic inspection of such drives should be made to avoid © operation with excessive slack and, to maintain proper chain tension. b. Determine the Amount of Sag. ¢ 1. Pull one side of the chain taut, allowing all the excess chain to accumulate in = the opposite span 2 2. Place a straight edge over the slack span and, pulling the chain down at the Genter, measure the amount of sag. When necessary, adjust drive centers for Proper sag that will result in correct chain tension. 5.5.4 Motor Bearings n 4. Disassemble motor and lubricate bearings. ” 5.5.5 Pump Packing o 1. The packing glands should be tight enough to eliminate leaking and loose enough to lubricate the plungers with a fine oily film. Over tightening the packing will dantage the motors. > ae ouuuvwuwe wo uud J To 5.5.6 Strainers 1. Clean Y-lype strainers. Ensure lines are free of pressure before attempting maintenance. a. Stop pumps. b. Close pump suction valves. c. Remove Y-lype strainer plugs. d. Remove strainer elements, . Open pump suction valves'to flush piping, then close valves. f. Clean strainer elements in warm water or kerosene. g. Replace elements and Y-type strainer plugs. h. Open pump suction valves. i. Startpumps. 5.6 HYDRAULIC MANIFOLD 5.6.1. Four-way Control Valves 1. Apply grease to the detents on the four-way control valves. 2. Open view ports and check that control valves are not leaking. 5.6.2 Cylinders 4. Clean piston rods of corrosion by wiping with an emery cloth. 2. Lubricate the piston rods on the cylinders with a good quality silicone based lubricant. 3. Grease the mounting bolt on the cylinder. 5.6.3 Filters 1. Drain and flush accumulated moisture. Open the manual drain on the filter housing as pumps are running. 2. Clean elements Stop pumps. Unscrew housing, lift out o-ring and louver, Remove filter elements and wash in warm water or kerosene. Dry elements and check that bowl gasket is in good condition. Replace parts and housing. paoge Gauges 4. Check that system pressures are maintained at proper levels, 2. When there is no pressure in system ensure that gauges are properly zeroed. If gauges are not properly zeroed see Troubleshooting Section. 3. When system is pressurized ensure that gauges on the control manifold match gauges on the remote control panel|s), 5.6.5 Regulator Routine Maintenance When conducting maintenance repairs on the Regulator, always ensure that the air and electric powered pump assemblies which generate the high-pressure hydraulic power toCS e the regulator have been shut down. Also, ensure that all high pressure in the system has @= been relieved. The system bleeder valve should be left open and the system pressure gauges should read "O" PSI Sc 5.6.5.1 Manually Operated Regulator GI Periodically apply 10W cil to the manual adjusting screw. To prolong the service Life of © the Regulator a high pressure tee strainer is installed in the hydraulic supply line ‘o the _ regulator. This strainer should be cleaned periodically. Ensure that pumps are stopped © and the system pressure relieved before servicing strainer. The element can be cleaned = with warm water or kerosene. Se 5.6.5.2 Pneumatic Motor Operated Regulator 4 é The pneumatic motor requires a clean, lubricated air supply of at least 90 psi for proper _ operation. The airline to the motor should be fitted with a 50-micron filter and a lubricator © set to provide one drop of oil every 50-75 cfm of air. Accumulated moisture should be ~ drained from the filter and the element should he cleaned periodically. Cheo« the © lubricator for proper level of WES 10W lubricating oil. The maintenance Instructions in Section 5.6.5.1 also apply to this regulator. 5.6.6 Removing Regulator From Service 4 € The Regulator includes a porting sub plate, which enables the regulator to be removed without disturbing the flow piping. It is only necessary to remove the sub plate when a“ leak is detected between the Sub plate and the body of the regulator. e 5.6.6.1 Disconnecting Control Lines € Regulators fitted with an intemal override assembly have one (1) 1/4" tubing line that © must be disconnected before removing the regulator from service. Regulators fittec with _. pneumatic or hydraulic operated motors have two (2) additional 3/8" control lines © (Pneumatic Motors) and 1/4" control ines (Hydraulic Motors) that must be disconnected = before the regulator can be removed from service. These lines are used to contrall the forward and reverse rotation of the motors, which increases and decreases the output > pressure setting of the regulator. When disconnecting these lines, they should be appropriately marked to enable proper installation of the now or repaired regulator. € 5.6.7 Removing Sub plates and Spring Control Head Assemblies o 1. The sub plates for the Regulators are connected to the regulator body by four (4) mounting screws. The TR-4 regulators use 3/8" alien head screws and the TRS regulators use 1/2" alien head screws. | i 2. Check the condition of the o-rings and the sealing surfaces of the sub plate. The _ TR-4 regulator has three (3) o-rings and the TR-5 regulator has four (4) o-tings. © ‘These o-rings are included in both the seal kit and the repair kit. 3. The spring control head assembly for both the TR-4 and TR-6 regulators without the internal override assembly is connected directly to the regulator body by 3/8” alien head screws. Removing these screws removes both the spring control head © assembly and the operator assembly.PN 4, For TR-4 and TR-5 regulators with internal override assemblies, four (4) 3/8" Allen ) head screws attach both the spring control head assembly and the internal override assembly to the regulator body. 5. The spring control head and operator assembly can now be removed. See Section ; 5.6.13 thru 5.6.17 for disassembly and repair instructions for the operator assembly and Section 5.6.18 for disassembly and repair instructions for the spring control head assembly. 6. The internal override assembly should be removed. See Section 5.6.12 for disassembly and repair instructions. 5.6.8 Disassembly Instructions for TR-4 Regulator Body 4, Remove bottom flange from valve body using 3/8" hex key. 5 2. Use W/2"-13 body bolts as jack screws to remove bottom flange, 3. Inspect bottom flange o-ring and back-up ring. Check orifice plug and o-ring on seal container. 4. Remove side flange from body by using 3/6" hex key. 5. Use I/2"-13 body holes as jack screws to remove side flange. 6. Extract piston and seal container by pushing on ball end of piston. 7. 8 . Remove port plate retaining screw by using 3/16" hex key. . Select a nonmetallic hammer or push rod. 9. Protect flow plate with several layers or cloth or paper and drive port plate. . Inspect seal and back-up ring in port plate and check surface of flow plate. 11, Protect piston guide with cloth or paper and push out with nonmetallic object. 12. Inspect piston guide seal and back-up ring. Check piston bore. . Remove flow plate from flange by using 5/32" hex key. 14, Flow plate and flange surface should be clean and smooth, 15. Remove flow plate from port plate by using 5/32" hex key. Inspect two (2) o-rings. > 16. Inspect o-rings and back-up rings and condition of seats’ scaling surfaces. 5 17. Extract seats and springs. Note location of back-up rings, out- board on primary seats. 48. Note location of back up rings, inboard on vent seats. 3 3 5.5.9 Assembly Instructions for TR-4 Regulator Body Use replacement parts from Seal Kit and/or Repair Kit, 4. Install new o-rings (28 & 29) and back-up ring (30) into grooves of piston guide (27) as shown 2. Push piston guide into top opening of body (1) as shown. = 3. Install o-rings (6 & 7) in port plate (5) and mount to flow plate (13) with two screws (12). Use 5/32" hex key and torque to 40 Inch-pounds. 4. Install flow plate (14) to flange (15) with two screws (12). S) Use 5/32" hex key and torque to 40 inch-pounds. 5. Install o-ring (10) and back-up ring (11) into groove on side flange (15), bottom flange (25) and port plate (5). 6. To install flow and port plate assembly into body, line up retaining screw holes.(17), Install o-rings (22) and back-up rings (23) to hydra seats (21). 10. Note position of back up rings on seats, outboard on primary and inboard on vent. 11. Install seats into seal container from one side and springs (20 & 24) and remaining & seats from the other side. 12. When installed, seats should extend equally from each side with o-rings and ack- up rings confined. 13. Install seal container assembly so that vent and primary ports align with vent and primary ports of the flow and port plate previously installed, 14. Insert piston at top of seal container assembly into piston guide while holding ‘ower Cry e 7. Push flow and port plate assembly into body by hand. Se 8. Install retaining screw (4) with 3/16" hex key. Tighten to 90 inch-pounds torque. | 9. Install o-rings (18) and back up rings (19) onto seal container (31) And hydra seats. © € seats above flow plate to avoid nicking seats. ‘ 15. Align dowel pin with dowel hole and push side flange assembly into body by hand. © 46. Secure side flange to body using four screws (16) with 5/8" hex key and tighten to 100 foot-pounds. & 17. To ensure proper assembly, stroke seal container assembly by hand. It should take 10 to 15 pounds force 18. Align holes in bottom flange with tapped holes in body and push flange into body by hand, Secure with four screws (16) using 3/8" hex key and tighten to 100 foot- pounds torque. 5.6.10 Disassembly and Assembly Instructions for TR-5 Regulator Body 4. Remove bottom flange from valve body using 3/8" hex key, ¢ 2. Use l/2"-13 body bolts as jack screws to remove bottom flange. 3. Inspect bottom flange o-ring and back-up ring. Check orifice plug and o-ring on seal © container. - 4, Remove side flange from body by using 3/8" hex key. 5 5. Use I/2"-13 body bolts as jack screws to remove side flange. € 6. Check o-ring and back-up ring. Inspect condition of flow plate surface. < 7. After removing flange and flow plate, check valve interior for contamination andlor obstructions. € 8. Extract piston and seal container by pushing on ball end of piston while holding end = of seal container. ; 9. Remove port plate retaining screw using 3/16" hex key. 10. Use paper or cloth to protect flow plate & push out port plate with nonmetallic object. 11. Inspect seal and back-up ring in port plate and check surface of flow plate. 42. Examine flow plate surface for wear marks, nicks or scoring. 43. Protect piston guide with cloth or paper and push out with non metallic object. 14, Remove flow plate from flange using 5/32" hex key. 415. Flow plate and flange surface should be clean and smooth, Inspect condition of three o-ring. 16. With 1/8" hex key push seal plug out of flow plate. Inspect o-rings and back-up rings. 17. Inspect o-ring and back-up rings on seal container. 18, Extract seats and, inboard on vent seats, outboard on primary seats. nemDENN oS 5.6.11. Assembly Instructions for TR-5 Regulator Body Use replacement parts from Seal Kit, part number 1110-6897, and/or Repair Kit, part number 1110-6899.ltem numbers in text refer to drawing D.10-0150-1588 located in the Parts Section. 1. Install new o-rings (31 & 32) and back-up ring (33) into grooves of piston guide (30). 2. Push piston guide into top opening of body (1). 3. Install an o-ring (11) and two back-up rings (12) on each seal plug (10) and insert one seal plug into each flow plate (16). 4 4. Install an o-ring (11) and two back-up rings (12) on seal plug (10) and insert seal ¥ plug into port plate (5). 4 5. Install two o-rings (6) and o-ring (7) in port plate (5) and mount to flow plate (16). Re 6. Install two o-rings (6) and o-ring (7) in flange (17) and mount to flow plate (16). 7. Secure flow plates (16) to port plate (5) and flange (17) with two screws (15) each. 4 Use 5/32" hex key and torque to 40 inch-pounds. : 8. Install o-rings (13) and back-up rings (14) on port plate, flange (17) and flange (28). : Note location of back-up rings. ~ 9. Install o-rings (8,9 and two item 25) on port plate. Check that three seal plugs (See Step 5.8.3) are installed and pipe plug (19) is installed in flange (17) > 10. Inspect flow plate for nicks and burrs gently sliding a seat over the sealing surface. ~ 11. Install o-rings (21) and back-up rings (22) onto seal container (34) and hydra seats (20). Install o-ring (25) and back-up rings (26) to hydra seats (24). Note position of > back-up rings on seats, outboard on primary and inboard on vent. 12. Install seats into seal container from one side and springs. (23 & 27) and remaining seats from the other side. > 13. When installed, seats should extend equally from each side with o-tings and back-up rings confined 14. To install flow and port plate assembly into body, line up retaining screw holes. > 15. Push flow and port plate assembly into body by hand. Install retaining screw (4) with 3/16" hex key. Tighten to 80 inch-pounds torque. > 16. Insert piston at top of seal container assembly into piston guide while holding lower seats above flow plate to avoid nicking seats. E 17. Align dowel pin with dowel hole and push side flange assembly into body by hand. > Note seal plugs and orifice plug. z 18. Secure side flange to body using six screws (18) with 3/8" hex key and tighten to 100 foot-pounds. > 19. To ensure proper assembly, stroke seal container assembly by hand. It should take 15 to 20 pounds force. 20. Align holes in bottom flange with tapped holes in body and push flange into body by > hand. gE 21. Secure with six screws (18) using 3/8" hex key and tighten to 100 foot-pounds torque 5.6.12 Disassembly and Assembly Instructions for Internal Override The disassembly and assembly instructions for both the 1500-psi and 3000 psi intemal override assemblies are the same. The internal override assemblies are stamped with the pressure rating but also can be easily visually identified. The 1500-psi intemal override assembly has a square flange and body and the 3000-psi internal overridena Ne assembly has a round flange and body. Replacement parts for both assemblies are included in the TR-4 Seal Kit and the TR-5 Seal Kit. Remove four (4) body flange screws (1) with a 3/8" hex key. Remove spring contro! head assembly. Remove the internal override assembly. Push out plunger and ball assembly (4). Drive out as necessary using the head of flange screw (1). Check condition of o-rings (5 & 7) and back-up rings (6 & 8). Push out plunger body sleeve (11) and inspect o-rings (9) and back-up rings (10). . Note position of o-rings (§ & 7) and back-up rings (6 & 8) on plunger anc! ball assembly (4). 8. Note position of o-rings (9) and back-up rings (10) on plunger body sleeve (11) 9. Vent hole and pilot port should be unobstructed. 40. To assemble the internal override assemblies, reverse the order of the disassembly instructions. Pers Nee ananananaen amg 5.6.13 Disassembly and Assembly Instructions for Manual Operator _ The manual operator for both the TR-4 and TR-S regulators are identical. To disassemble, turn the lock lever (5) counterclockwise: To assemble, Insert adjustment ¢ screw into stopnut of the spring control head assembly and rotate clockwise until tight. ‘To adjust, loosen lock lever (5) and hold, then rotate adjustment handle (4) clockwise to. § increase pressure and counterclockwise to decrease pressure. Tighten lock lever when desired pressure is reached. 6.6.14 Disassembly and Assembly Instructions for Pneumatic Motor Operator The pneumatic motor operator is identical for both the TR-4 and TR-5 regulators and mounts to either the 1500-psi or 3000 psi spring control Head assembly. Replacement parts for the pneumatic motor operator are included in the TR-4 Seal Kit and the TR-5 seal Kit. 4. Remove four (4) mounting screws (12) using 3/8" hex key. 2, Loosen lock lever (7) and rotate adjustment handle (4) counterclockwise to rernove pneumatic motor operator from spring control head assembly. 3. Loosen set screw (1) in adjustment handle (4) with 3/16" hex key and rernove manual operator assembly. Extract adjustment drive screw (3) and drive bushing (8). Loosen conical set screw (25) with 3/16” hex key. Loosen other conical set screw (25) on other side. Remove air motor (22) and inspect o-ring (24). Remove four (4) gear box screws (19) using 5/16" hex key. Remove gear box cap (17) and inspect shaft seal (18) and face seal (16). 40. Extract bearings (14) and worm wheel. (15). Inspect bearing, shaft and gear tect. 44. Extract worm (20) and worm bearings (21). Inspect bearings and worm spiral. PEN OnE 5.6.14 Pneumatic Motor for TR-4 and TR-5 Regulators? 56.141 Pneumatic Motor Description The pneumatic motor is a rotary type with four (4) vanes that take up thelr own wear and 5 wi gesast 8000 to 18,000 hours depending upon speed, method of olling, Pressure and the precautions maintaining the motor. The type of shaft seal u: Not land itself to operating above 100 psi, 5.6.14.2 Pneumatic Motor Operation operating ised does For proper operation, a moisture trap and filter should be installed in the air supply line ‘ to the motor. Excessive moisture in the airline can cause rust formation in the motor and also required to properly lubricate the internal moving parts to provide maximum service If The lubricator oll for every 50 to 75 cim of air flow through the motor. The air motor should not be \ allowed to “run free” at high speeds with no load and improper lubrication. Running under these conditions can cause excessive internal heat build-up, loss of intemal ) clearances and rapid motor damage. } §.6.14.3 Pneumatic Motor Servicing tea Description 1 Body 1 End Plate, Drive 1 End Plate, Dead 4 Rotor Assembly 4 Vane 4 Push Pin +2 Vane Spring 1 Bearing 1 Shaft Seal 2 BodyGasket 1 End Cap, Dead 1 Gasket, End Cap Included in Repair Kits If the motor is sluggish or inefficient, flush with a Nontoxic, cleaning solvent. To flush unit, teaspoonsful of solvent. Rotate the shaft by hand in both dires! Qty. i tik Rede nonflammable industrial | disconnect airline and muffler and add several t ions for a few minutes, chree the airline and slowly apply pressure until there is no trace of solvent in the {Self It may dent the surface of the plate and body and cause leaks A be used which will remove the end plate while maintainin vanes should have the notched edge towards the bottom of the vane slot. CAUTION a ee v7 ee TS Bienen puller tool should ig the position of the shaft. New5.6.15 Disassembly and Assembly Instructions for Hydraulic Motor Operator The hydraulic motor operator is identical for both the TR-4 and TR-5 regulators and mounts to either the 1500-psi or 3000 psi spring control head assembly. Replacement parts for the hydraulic motor operator are inciuded in the TR-4 Seal Kit and the TR-5 Seal Kit. 4. Remove four (4) mounting screws (12) using 3/8" hex key. 2. Loosen lock lover (7) and rotate adjustment handle (4) counterclockwise 10 remove hydraulic motor operator from spring control head assembly. 3. Loosen set screw (1) in adjustment handle (4) with 3/16" hex key and remove manual operator assembly. Extract Adjusiment drive screw (3) and drive bushing (8), Loosen conical set screw (25) with 3/16" hex key. Loosen other conical set screw (25) on other side. Remove hydraulic motor (22), adapter (29), and inspect o-ring (28). Remove four (4) gear box screws (19) using 5/16" hex key, |. Remove gearbox cap (17) and inspect shaft seal (18) and face seal (16). 40. Extract bearings (14) and worm wheel (15). Inspect bearing, shaft and gear teeth. 11. Extract worm (20) and worm bearings (21). Inspect bearings and worm spiral, COTS penome 5.6.16 Hydraulic Motor Servicing For proper operation, the supply line to the hydraulic motor should be fitted with a 10 micron filter and the ‘supply Pressure should be limited to 2000 PSI but not less than 500 PSI. Lubrication for the motor is provided by system fluid flow. If motor operates erratically, clean filter, check for proper supply pressure and ensure that vent lines are not clogged or restricted. If motor bearings are_ making noise and there is excessive heat (over 400DgF or hot in comparison to circuit lines) check shaft alignment. tighten set screws (5) and mounting screws (28). Tighten motor body screws to 40-45 inch-pounds. If shaft seal is leaking or if noise persists, the motor must be replaced. there are no replaced. There are no replacement parts available for the hydraulic motor used on the TR-4 and TR-5 hydraulic motor operated regulators. Be sure to remove the four (4) screws, item 28 and adapter, item 29 from the old motor before replacing new motor. They are required for mounting the new motor. 5.6.17 Disassembly and Assembly Instructions for the Spring Control Head Assembly The following instructions apply to both the 1500-psi and 3000 PSI spring control head assemblies. which pertain to the parts Replacement parts for both (1500 psi and '3000 psi) spring control head assemblies are included in the TR-4 Seal Kit and Repair Kit and the TR-5 Seal Kit and Repair Kit. See Section 5.6.7 for instructions on removing the spring control head assembly from the regulator body and Section 5.6.13 for instructions on removing the manual operator assembly from the spring control head assembly. See Sections 56.14 and 5.6.15 for instructions on removing pneumatic motor operator assembly and Sections 5.6.16 and 5.6.17 for removing a hydraulic motor operator assembly from the spring control head assembly. 4. Remove spring plate (11) and check springs (9 & 10): »ow Cee eu u TOUT sre wu w w 57 5.7.4 57.2 57.3 1500 PSI- Outer Spring (Red) 3000 PSI- Outer Spring (Yellow) 2" OD X5" Long 2" OD X 4-1/2" Long Inner Spring (Blue) Inner Spring (Red) 1"OD X 6-1/2" Long 1" OD X 5" Long 2. Unlock set screw (4) using 1/8" hex key. 3. Remove cap (3) by tuming counterclockwise, remove spring guide (6) and check o-ting (5). Note position of ball side. 4. Replace components as necessary from the repair or seal kits. For assembly, reypise the order of disassembly. When installing the spring control head assembly {0 the regulator body, the 1" inner spring (10) fits in the counter bore of the spring Plate (11). The drill spot on the spring plate (11) locates on the piston ball on top of the plunger in the body assembly. AIR PANEL Air Lubrication 1. Check the air lubricator to make sure it is full of SAE 10w lubricating oil. 2. Open the petcock of lubricator to drain accumulated moisture. 3. Check that drip settin, 9 flows 6 drops per minute. To adjust setting see Troubleshooting Section. Air Filter 1. Drain and flush accumulated moisture. 0} pen the manual drain on the filter housing, as pumps are running, 2. Clean elements, a. Stop pumps. b. Unscrew housing, lift out o-ring and louvre. ¢. Remove filter elements and wash in warm water or kerosene, d. Dry elements and check that bowl gasket is in good condition. ©. Replace parts and housings. Gauges 1. Ensure that gauges are properly zeroed when there is no pressure in the system. Use zero adjustment screw on face of gauge to zero needle. 2. If the readings of the air receiver gauges on the air remote control panel do not natch the readings of the gauges on the control manifold, adjust the setting of the transmitter air regulator until readings correspond.n MAINTENANCE € 5.7.4 Air Junction Boxes € 1. Check for leaks around gasket. Evenly tighten junction box mounting screws. ¢ 2. Periodically separate junction box plates and ensure ports are clean and clear of © sludge. 2 € 5.7.5 Panel Check-out a 1. Visually check all connections for possible leaks. Repair as necessary. < 5.7.6 Air Transmitters € 1. The air regulator for the air transmitters should be set at 15 psi. € 2. If the gauges on the control manifold do not match the readings of the air receiver © gauges on the air remote control panel (s), adjust the setting of the transmitter air regulator until readings correspond. 5.7.7 Optional Position Indicating Lights 1. Visually Inspect panel and check lights to make sure bulbs have not bumed out During weekly BOP function test the driller should check that all indicating lights © function properly. a. To replace light bulbs in exlosion-proof panels ¢ 1. Disconnect power supply to panel by switching the circuit breaker, on the pressure switch box to the " OFF" position. 2. Unscrew outer ring of bulb enclosure, 3. Unscrew lens housing, 4. Pull out bad bulb and replace. 5. Replace lens and outer ring. x 6. Turn power supply " ON" and check for proper operation. 3@ FLOW METER FLOW METER Turbine Flow Meter is a state of the art microprocessor based flow monitor, designed to Provide the exact and appropriate valve of fluid low rate. Ituses the mechanical energy of the fluid to rotate a rotor in the flow stream. Blades on the rotor are angled to transform energy from the flow energy into rotational energy. The rotor shaft spins on bearings. When the fluid moves faster, the rotor spins proportionally faster. Rotor movement sensed magnetically by pick up amplifier, which displays the corresponding flow valve into meter display. Input power supply : 24 VDC Acsuracy : + 0.1% Meunting classification : NEMA/ULICSA Type 4 (JP 66) Display : 8 Digit, 0.5" high numeric display Fig. Turbine Flow Meter iay OB TROUBLESHOOTING (TEM DESCRIPTION. TA 72 73 7.4 75 7.6 WT 78 79 Pagit GENERAL........ even ACCUMULATORS PROBLEMS 7.2.1 Loss of Accumulator Precharge Pressure AIR SUPPLY PROBLEMS 7.3.1 Lack of Air Lubrication. 7.3.2. Excessive Air Lubrication... — 7.3.3 Air Operated Pumps Icing Over or Freezing Up PUMP PROBLEMS 7.4.1. Pumps Run Excessively. eee 7.4.2, Pumps Shut Down at Wrong Pressure 7.4.3, Pumps Cannot Reach Full Pressure..... 7.4.4 Pumps Produce No Pressure 7.4.5 Pump Leaking . ELECTRIC MOTOR PROBLEMS 7.5.1. Motor Fails to Start . 7.5.2. Motor Runs Erratically.. : lees FOUR-WAY VALVE PROBLEMS 83-84 GAUGE PROBLEMS 7.7.1 Out of Adjustment 7.7.2. Responds Slowly. REGULATOR PROBLEMS 7.8.1, Regulator will not adjust to zero pressure .. 7.8.2. Regulator will not adjust to maximum 7.8.3 Regulator pressure cycles... 7.8.4 Regulate pressure cycle up. 7.8.5 Excessive Chatter hammer. 7.8.6 External leakage. 7.8.7 External leakage From vent 7.8.8 Excessive and Continuous. 7.8.9 Excessive and Continuous Flow. 7.8.10 Ai or hydraulic operator.. 7.8.10 Ai or hydraulic operator 7.8.11 Air or hydraulic driver 7.8.12 Air driver not. 7.8.13 Air driver motor wil 7.8.14 Hydraulic driver Motor. 7.8.15 Leakage from interface. AIR PANEL PROBLEMS 7.9.1 Slow or no Function... 7.9.2 Valve Handle Hard to move. 7.9.3 Panel gauge do not match. 7.9.4 Position indicating Lights......5 mM Biel Teco Icy TROUBLESHOOTING INSTRUCTIONS GENERAL The purpose of the Troubleshooting Section is to enable the operator to quickly identify and correct each malfunction. The action taken will resultin minimum downtime and prevention of additional damage. Although the information in this section is comprehensive, other problems may arise which are not listed. As these are solved, either locally or with the aid of a Windlass Engineers & Services Pvt, Ltd. representative, all steps taken should be documented and inserted into this manual, Some repairs may void the Windlass Engineers & Services Pvt. Ltd, Warranty on certain components. Before such repairs are contemplated, contact Windlass Engineers & Services Pvt. Ltd. or it's nearest service representative. The Troubleshooting Charts contain information presented in three vertical columns. The first column identifies the problem or symptom, the second column lists probable causes and the third column describes corrective action. In preparing these Troubleshooting Charts, it is assumed that normal preventative maintenance procedures have been followed. It may be necessary to consult other sections of the manual to become familiar with the BOP Control System. The Operation Section includes a more detailed description of the system operation. To make repairs, first locate the faulty component. Use the Grawings and material lists located in the Parts Section to determine the part number of the component. Many components are field repairable. Refer to the Parts Section for repair instructions and available repair parts. Always order replacement parts by partnumber, Pay particular attention tonotes, cautions and bold type words as these are added to ensure safety during all phases of equipment use. The following instructions are major steps that must be performed during the maintenance and troubleshooting procedures. Wherever these instructions are given, refer to these steps:- Stop Pumps a. Closeair supply valves. b. —Tumtriplexpump motorstarterto OFF position Start Pumps a. Openthe air supply valves. b. Turn triplex pump motor starter to AUTO position. NOTE: THE TROUBLESHOOTING PROCEDURES SHOULD BE PERFORMED ONLY AT TIMES THAT WILL NOT AFFECT THE SAFETY OF DRILLING OPERATIONS. REMEMBER TOREPLENISH THE FLUID SUPPLY AFTER FLUSHING LINES.7.2 ACCUMULATOR PROBLEMS c (Cetin) Problem Remedy = € 7.2.4 Loss of Accumu- Faulty precharge 1. Stop pumps. < lator Precharge valve permits 2. Open manifold bleeder valve and Pressure nitrogen to relieveall system pressure. € (Blader type) escape 3. Check precharge pressure i on each accumulator and record, € 4, Tighten valve cores snugly with valve core tool 5. Precharge each accumulator e with 1000 PSI of nitrogen, starting - with accumulator that had < highest recorded pressure. This will conserve nitrogen < NEVER USE OXYGEN 4 6. Observe precharge pressure on € precharge gauge. E 7. Check all precharge valves for gas leaks by placing drops of s Light oil across tops of valves. 7 8. Ifvalve: ¢ 1) Bubbles, nitrogen is escaping. Replace valve core € 2) Does not bubble, . accumulators are ready for 4 normal use. ‘ 9. Close manifold bleeder valve. || ‘ 10. Start pumps | Ruplured Bladder 1. Stop pumps. < 2. Bleed fluid system pressure by slowly opening bleeder valve. e 3. Listen for poppet valves to close while observing accumulator s pressure gauge. d 4. If poppet valves do not close at 5 pressure, and pressure « continues to drop to zero, at least one accumulator has lost 4 its precharge. i CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE . BEING MADE TO THE BOP CONTROL SYSTEM. jlt eco 3 =a > rr )) 7.2.4 (Continued) Ruptured Bladder 5. Check and record precharge > (Continued) Pressure of each accumulator. 6. Those with zero precharge may , have faulty bladders. To check 5 this: E a. Tighten valve cores snugly 5 with valve core tool. [ b. Precharge with 200 PSI of > nitrogen. If pressure does not decrease; ? ©. Precharge with 1000 PSI of nitrogen, 7. If an accumulator does not sustain 200 PSI precharge, the bladder is ruptured and must be replaced, . Close manifold bleeder valve. Start pump. 7.3 AIR SUPPLY PROBLEM 7.3.4 Lack Of Air No Lubricant In 1. Cut of f main ai r supply to Lubrication Bow! unit. 2. Open pet cock at bottom of air lubrication, bowl 3. Drain off any moisture or emulsified oil 4, Unscrew fill cap and refill lubricator with 10W motor oil CAUTION: Do not tise synthetic or ‘aromatic type cil. ‘Open main air supply valve to unit > s CAUTION ; DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE BEING MADE TO THE BOP CONTROL SYSTEMiL Ritter) Gia oe) ee) 782 Excessive Air Lubricator Out or |||] 1. Close accumulator isotator, 2 Lubrication Adjustment valves. = 2. Turn motor starter to OFF q position. c 3. Open manifold bleeder valve, 7 4. Operate air pumps at full e capacity, 5. Open lubricator fill cap. e 6. Use a thin screwdriver to ad just lubricator to provide 6 (ix) drops of oll per minute . Rotation of metering screw: | a. Clockwise-increases flow, b. Counterciockwise-decreases flow, ¢ 7. Close manifold bleeder vaive. 8. Open accumulator isolator valves. . 9, Turn motor starter to AUTO position. + 73.3 Air Operated Moisture In Rig 1. Make sure unit is being sup- e Pumps leing Air Supply plied with clean , dry air. 4 ‘Over Or 2. Cut off main air supply to freezing unit. 6 3. Close accumulator isolator valves. < 4, Turn motor starter to OFF position. € 5. Open petcock at bottom of air 4 lubrication bow 6. Remove plug from ¥-type Ps strainer. 5 7. Open main air supply valve : to the unit. i 8. Open manifold bleeder valve. 4 9. Run air pumps at full capacity until all moisture has been ° removed. CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE BEING MADE TO THE BOP CONTROL SYSTEM. meBi eles (aay 7.3.3 (Continued) Moisture in Rig 10. Close air supply valves to stop Air Supply pumps. (Continued) 11. Cut off main air supply to unit. 12. Replace plug in ¥-type strainer. 13. Open main air supply to unit. 14. Close manifold bleeder valve. 18. Open accumulator isolator valves. 16. Open air supply valves. 17. Tur motor starter to AUTO position 74 PUMP PROBLEMS 74.1 Pumps Run Air pump pressure 4. Close the bypass valve tightly. Excessively switch bypass. 2. Reset automatic pressure switch valve is open or (See Maintenance Section) to ] faulty. shut off air pumps at: a. 2900 PSI for units with air and electric pumps. ul b. 3000 PSI for units with air pumps only. 3. If air pumps continue operating, bypass valve may be defective, a. Loosen tubing connector downstream from air bypass valve. b. Ifairis escaping, replace the bypass valve. ©. Close bypass valve tightly, 4. Check pump shutoff pressure. CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE BEING MADE TO THE BOP CONTROL SYSTEM.Bisel] TR =-1aCoLe e ce cS : 1 e 7.4.1 (Continued) Hydraulic seals 1, ‘Stop pumps. | 4 in automatic 2. Open manifold bleeder valve and © pressure switch Telieve system pressure, c ‘Switch for inspection. ¢ 5. Close manifold bleeder valve. i ~ 6. Start pumps, 3 7. Check pressure switch settings. i e e Valve (Bladder 2. Open manifold bleeder valve. a ‘Type Separator) 3. Check precharge pressure on 4. Tighten each precharge valve | 6 assembly by using valve core | a 1000 PSI of nitrogen starting with 4 accumulator that had highest é conserve nitrogen. . i 6. Check all precharge valves for gas leaks by placing drops of saliva across tops of valves S (Light oll may also be used) if: a. Bubbles appear, replace x b. No bubbles appear, for normal use. 7. Close manifold bleeder valve. 8. Start pumps. - CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE cS BEING MADE TO THE BOP CONTROL SYSTEM. a (alaeRoles elon 7.4.4 (Continued) Four-way Valve Open inspection ports located Leaking at each end of reservoir. ‘Observe which valve is leaking, Operate valve several times, If leaking persists, remove valve. Use special repair kits containing necessary paris for overhaul (See Parts Section), | 6. The maintenance instructions supplied with the kit must be consulted for proper assembly. Improper or reverse assembly ccan result in high pressure and geen ‘cause injury. Relief Valve 1. Open inspection ports at each I Leaking end of reservoir. } 2. Observe relief valve return lines to see which one is leaking ; 3. Note pressure reading on gauge when flow begins to check if ) sotting is incorrect. | 4, Remove and replace faulty | valve. | Regulator 1, Open inspection ports at each } Leaking end of reservoir 2. Observe regulator retum lines ' to check If leaking. 5 3. Remove and replace faulty regulator. Bleeder Valve 1. Close manifold bleeder valve ? Leaking tightly. 2. Check for leakage by looking through inspection ports located 5 at each end of reservoir. E CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE > BEING MADE TO THE BOP CONTROL SYSTEM. Ak 22 eee aRiel ser 7.4.4 (Continued) Visually inspect : Bleeder Valve 3, Leaking (Continued) Leaks In Fluid ‘System 1 2 3. 4. Loss Of Precharge 1 Pressure 2. 3. 4. 5. 6 7. 8 9. I valve is leaking, remove and replace it. All piping and connections on ‘The accumulator unit. | All connecting lines Co the BOP | stack Relieve all system pressure. Repair all fuid leaks. | Stop pumps. Bleed fluid system pressure by Slowly opening bleeder valve. Listen for poppet valves to close while observing accumula- tor pressure gauge. If poppet valves do not close at precharge pressure, and pressure continues to drop to zero, at least one accumulator has lost its precharge. Check and record precharge pressures of each accumulator. Those with zero precharge may have faulty bladders. To check this = a. Tighten valve cores snuggly with valve core tool. b. Precharge with 200 PSI of nitrogen, fan accumulator does not sustain 200 PSI precharge, the bladder is ruptured and must be replaced. Close manifold bleeder valve. Start pumps. CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE BEING MADE TO THE BOP CONTROL SYSTEM. o DORAN MANONHHAHDOAOODMD a ae eeRECURS Ted ae Se) 7.42 Pumps Shut Down ||| Air pump pressure Stop pumps. At Wrong switch is out of 2, Closes accumulator Isolator Pressure adjustment valves 3. Make sure air bypass valve Is tightly closed. 4. Open manifold bleeder valve to relieve system pressure. Close manifold bleeder valve. | Open air pump supply valves. ‘Adjust pump shutoff pressure setting (See Maintenance Section) until pump stops running when desired fluid pressure has been reached on accumulator pressure gauge. 8. Bleed off manifold pressure through bleeder valve and repeat procedure to check accuracy of setting. 8. Open accumulator isolator valves. 410. Turn motor starter to AUTO position. Noe Electric pressure Pressure switch settings have @ Switch is out of tendency to drift and require Adjustment. periodic Calibration. This is especially true when the Equipment has been moved to a ° different location. To adjust the selting, see Maintenance Section. 74.3 Pump Cannot Faully Check I pump discharge pressure Reach Full Valve In Air reaches a certain point and pump Pressure ) Pump(s) still continues to run, the check valve in the pump'is stuck in open | position or has been damaged: 4. Stop pumps. 2. Close isolator valves with pressured up accumulators, CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE BEING MADE TO THE BOP CONTROL SYSTEM. ee ee eee |Bicol oun) Gi Problem ff ono o 7.43. (Continued) Faulty Check 3. Open bleeder valve and bleed Valve In Air off manifold pressure. Pump(s) 4, Remove suspected air pump, | (Continued) 5. Clean, repair, or replace as Necessary, 6. Install pump, i 7. Start air pump and operate with & bleeder valve open to make sure Pa that the pump is properly primed. 5 8. Close bleeder valve. e 9, Open isolator valves. 10.Start pumps and. pressure up e system. Low Air Supply 1. Check rig air supply gauge for proper air supply (See Installation © Data Section. 2. Correct air supply at main ait ; ‘compressor. ‘ 7.44 Pumps Produce Loss of pump to restore fluid level g No Pressure prime because j Of low fluid 4. Close accumulator isolator level Valves if accumulator pressure 4 Gauge shows pressure is intained. 2. Stop pumps, 4 3, Open manifold bleeder valve and bleed system pressure. 4, Add fluid to at least twelve (12) Inches above pump suction lines. 5. Start one pump and operate at full pressure. 6. Observe fluid flow through inspection ports, ‘Stop pumps, ‘Open isolator valves. Check reservoir fluid level. Add oil if needed. CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE BEING MADE TO THE BOP CONTROL SYSTEM. 2 ee ee |Biol STs oot , —;k= 7.44 (Continued) Loss of pump 10. Close bleeder valve. > | Prime because 11, Start system. “4 Of low fluid Level. = (Continued) 3 E Suction Valve ‘Check that pump suction valves i} closed are in full open position 3 Fluid Contamina- 1. Close accumulator isolator y tlon valves if accumulator pressure : Gauge shows pressure is > contained. r 2. Stop pumps. a Open manifold bleeder valve. 4. Open air pump supply valves and start air-operated pumps. Observe fluid flow through inspection ports. If slight or no fluid flow is observed: 6. Stop air pumps. 7. Close pump suction vaive(s). 4 8 Remove ype strainer plugs. 9. 1 uuTwdg . Remove strainer elements. }. Open pump suction valves and flush out debris from piping. U > 11. Close pump suction valves. x 12. Clean and replace strainer and > plug. & 13. Start pump and observe fluid | flow through inspection ports > | 14, Repeat procedure until system t is clean, > 15. Close manifold bleeder valve. S 16. Open accumulator isolator > valves. > 17. Start pumps, p P CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE 5 BEING MADE TO THE BOP CONTROL SYSTEM. uRiles echo} 7.4.5 Pumps Leaking Plunger packing on the older style pumps (Model : Is worn or no. 88550) damaged on air pump(s). 1. Tighten packing nut. 2. Ifleak stops: Check for proper plunger lubrication. The plunger should be coated with a thin film of hydraulic fluid. 3. If leak persists : Remove pumps and replace, a ‘Worn packing on Replace packing ‘ Electric driven Pump. Damaged valve 1. Stop pumps, | t ‘cover gasket or 2. Close pump suction vaive, ‘ loose cover 3. Remove valve cover plate, plate on electric 4, Remove and inspect valve cover ‘ driven pump. Gaskets. 5. Replace gaskets if they appear to be distorted, washed out or compressed excessively. 6. If the gaskets appear to be good, invert and reinstall ¢ 7. Replace cover plate and tighten bolts ‘ 8. Open. Suction valve. 9. Open manifold bleeder valve, : 10. Tum motor starter to AUTO. position, ‘11. Operate pump and check for é new leaks. 42. Open air supply valves. 13. Close manifold bleeder valve. CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE BEING MADE TO THE BOP CONTROL SYSTEM.RCo Te Sot 7.5 ELECTRIC MOTOR PROBLEMS (eee) 7.54 Motor Fails To Pressure Switch 1. Turn motor starter to OFF position Start Faulty 2. Turn off power at rig main ; generator panel. 3, Remove pressure switch explosion-proof cover. 4. Disconnect leads from electrical pressure switch to starter. 5. Check resistance across terminals of pressure switch with an ohmmeter. If resistance to observed, the switch is working properly. ) 6. If no resistance Ls found, replace the limit switch or, if time is limited, replace the entire pressure switch assembly. 7. Replace the leads from starter to pressure switch (See Starter Wiring Diagram in Equipment Section) 8, Turn on power at rig main generator panel. 9. Turn motor starter to AUTO position f 10. Check for proper adjustment of } settings (See Maintenance Section). 11. Replace pressure switch explosion-proof housing cover. Starter Tripped If power supply had a thermal Overload : 1. Turn motor starter to OFF Position, 2. Press reset button on motor starter. 3. Turn motor starter to AUTO position. fi CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE BEING MADE TO THE BOP CONTROL SYSTEM.? Riel TecTe) ae =| y 7.5.4 (Continued) Loss Of Power 1. Turn motor starter to OFF position Supply 2. Check voltage of power supply to scarcer at rig main generator panel. 3, Restore power supply from rig ‘main generator panel. 4, Turn motor starter to AUTO position. 7.5.2. Motor Runs Voltage Fluctuation |||! If pump pressure is at proper setting Enatically and pump stops frequently, Input voltage may be too low. 1. Turn motor starter to OFF position. 2. Check and correct voltage at rig main generator panel, 3. Turn motor starter to AUTO e e Se Se = = e eS e co eS Pressure switch IF pump continues to stop and start Span is out of afler reaching the proper Satting, Adjustment switch adjustment may be Necessary. 4. Close air supply valves, 2. Check that starter switch is in ‘ AUTO position. CAUTION : ELECTRICAL CONTACTS HAVE LIVE POWER. 3. Remove pressure switch cover. 4, Move white adjustment wheel © down or toward the front. 5. Open manifold bieeder valve and reduce pressure to desired pump > starting pressure. 6. Close manifold bleeder valve. o 7. Move adjustment lever back (Up or towards rear) until pump starts. < CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE q BEING MADE TO THE BOP CONTROL SYSTEM. =TROUBLESHOOTING 7.8.2 (Continued) ' 1.6 FOUR- WAY VALVE PROBLEMS 6.6.1 Interfowing Pressure switch span is out of adjustment (Continued) ) Debrisin the Valve Washed Out Or Damaged Seals ‘Actuator rod is out of adjustment. ‘After pump stops, check results to ‘make sure that proper setting has been obtained. Replace pressure switch cover. (Open air supply valves. ‘Stop pumps, ‘Open manifold bleeder valve. Distodge debris by manually shifting the valve handle through the full range. Repeat shifting several times until interflow has been cleared up. Close manifold bleeder valve. Start pumps. Remove and replace the valve. Use special repair kits containing necessary parts for overhaul (See Parts Section), ‘The maintenance instructions supplied for proper assembly. Improper or feverse assembly can result in high pressure and cause injury. Adjust clevis locknut so actuator rod oblains full travel Checklevertravel. a. Start pumps, b. Pressure up system. ©, _Operatefunctiontrom remote panel CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE BEING MADE TO THE BOP CONTROL SYSTEM.ere) 7.6.1 (Continued) Actuator Faulty 1, Remove cylinder. 2. Inspect for debris, wear or other damage. 3. Ifdirtwiperis blown out, either: a. Therod sealis leaking b. There is excess grease in the grease fitting, 4, Repairorreplaceas necessary. 5. Install eylinder. InsufficientPressure |||] Check all interface points for leaks or open connections. 7.7 GAUGE PROBLEMS 7.74 OutofAdjustment |||] Shock Due To Roun tieeticnt 1. Non-fluid filed pressure gauge (Note: When checking the accumulator Pressure gauge do not close the ‘accumulator isolator valve.) 8. Close accumulatorisolator valves. b. Stoppumps. ©. Open bleeder valve and bleed off manifold pressure. d. Remove gauge face covering. e. Adjust gauge indicator to zero setting with a thin screwdriver blade. f. Replace gauge face cover. g. Loosen gauge fitting and bleed off any trapped air. h. Retighten fitting, i. Close bleedervaive. J. Openaccumulatorisotator valves. Shock Due To k. Start_pumps and pressure up Rough Treatment system, (Continued) — St CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE BEING MADE TO THE BOP CONTROL SYSTEM.Iolo} 7.7.4 (Continued) |. Afterfullpressure is indicated : > 1) Close accumulator isolator valves. 2) Stoppumps. 3) Open manifold bleeder valve and bleed off pressure at 500 psiincrements. 4) Observe gauge reaction each Sy time. , 5) When no manifold pressure . remains, gauge should read 4 zero (0) psi > m, Close manifold bleeder valve. n. Openaccumulator isolator valves. > ©. Start pumps and restore system > pressure E 2. Fluidfiled gauges: a Remove defective gauge and replace with a workable unit | b. Send the defective gauge to vendor for factory calibration: 3. An alternate method of checking a gE faully gauge canbeused: > ‘a. Connect the faulty gauge supply line to a common manifold with a gauge of known accuracy. > b. Adjust faulty gauge supply line toa ‘common manifold with a gauge of known accuracy. | ©. Acceptable indication limits are + > ‘50psi from true pressure. > V7.2 Responds Siowly ||!) Supply tine or |fl] When gauge responds slowly or in an — snubber Is clogged erraticmanner during operation > (Accumulator |}|] 1. stoppumps. > Pressure) 2. Close accumulator isolator valves. & CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE > BEING MADE TO THE BOP CONTROL SYSTEM.Rot ese ( 7.7.2 (Continued) Supply line or snubber is clogged (Manifold Pressure) ‘Open manifold bleeder valve to relieve system pressure. Disconnect gauge supply line. if pressure gauge is installed with snubber. ‘a, Remove snubber from gauge and connect to gauge supply line. b. Startairoperated pump, c. Slowly close bleeder valve, d. If fluid does not pass. through snubbertis blocked and should be replaced, 1), Stop pump. 2) Open the manifold bleeder valve. 3) Remove snubber and install @ new oneon the gauge. Purge supply line with hydraulic fluid by starting one air operated pump only. Reconnect supply line to gauge assembly. Close bleeder valve. (Open accumulatorisolator valves. Operate air pump. WF gauge is sli sluggish or erratic, replace the gauge Place valvesin center position. Reduce hydraulic pressure to zero by adjusting regulators. Remove tubing and snubber from gauge. If gauge indicates pressure, recalibrate tozero. While hydraulic tubing is disconnected from gauge, increase pressure from regulator. if: a. Fluid flows freely from open tube CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE BEING MADE TO THE BOP CONTROL SYSTEM. an a aBiol Teco 7.7.2 (Continued) 7.8 REGULATOR PROBLEMS 7.8.1 Regulator will not adjust to zero pressure 7.8.2 Regulator will not adjust to maximum set pressure “TR-1500:1600 psi TR-3000:3100 psi ‘Smaller adjustment spring (1° diameter) in the spring control headis too long, Positive stop is set too high, Heavy springs (2"diameter) are too short =I | 2. Fluid flows freely from open tube 1) Reduce pressure back tozero. 2) Attach snubber to the hydraulictubing. 3) Increase pressure. b. No fluid escapes, the snubber is blocked and should be replaced Reassembly tubing, snubber, and ‘gauge. Cycle regulated fluid pressure to 1000 siand back down again tozero. Check that gauge indicates zero. {fit does not, replace gauge with a workable unit. Check spring for length. For disassembly instructions see Maintenance Section, 1"diameter spring specifications : a. TR-1500-5-1/2" Long (Blue) b. TR-3000-5" Long (Red) NOTE: Heavy springs (2" diameter) Do not effect minimum set pressure Remove adjusting actuator (Manual handle and lock or power drive unit) by turning handle counterclockwise. Loosen lock nut, set stop nut lower and tighten lock nut. Check spring for length. For disassembly instructions see Maintenance Section. CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE BEING MADE TO THE BOP CONTROL SYSTEM.Rote c ce © en : — c 7.8.2 (Continued) 2. 2"diameter spring specifications: a a. TR-1500-5* Long (Red) © b. TR+3000-4-1/2" Long (Yellow) < 7.83 Regulated Leakage in 4. Visually inspect hydraulic manifold for A pressures cycles ||| Hydraulic Manifold piping or tubing connection leaks. < up down. Up to downstream of Repairas necessary. 4 set point and regulator. 2, Ensure that 4-Way valves on hydraulic € down to bottom of manifold are properly positioned 4 search band. Incorrect positioning of the valve S (Search band is handles willeause interNowing 4 gene went 3. Ifvalves are positioned properly, open S i inspection ports or break common a adjustable SRY Ine andl ingoeet fa ¢ retum line and inspect for leakage. pressure range of Repair or replace leaking valve. regulator. See TR™ Regulator Specification Replace missing or damaged o-rings from < Sheet in Equipme- seal kit. See Maintenance Section for nt Section.) disassembly instructions and the Parts ¢ Section for reference drawings. Internal leakage Replace worn (Scored) vent seat and! or from secondary flow plate from repair kit. See Maintenance € region (Regulated Section for disassembly instructions and Pressure) to vent : the Part Section forreference drawings. € 1. Damaged o-ring under flow plate around vent port. 2 2, Damaged seal plug o-ring in i flow plate. | j 3. Damaged o-ting : seal inventseat CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE j BEING MADE TO THE BOP CONTROL SYSTEM. .Biol reel { Problem! l Cause a 7.8.3. (Continued) Worn (scored ) vent |||} Replace wom (Scored) vent seat and/ or seator flow plate. flow plate from repair kit. See Maintenance Section for disassembly instructions and the Part Section forreference drawings. Replace missing or damaged o-rings, 7.84 Regulated pres- |j|| internal leakage hydraseat and/or flow plate from repair kit. 5 down. Oe vat HT eet etimary Ill See Maintenance Section for disassembly f down. Up to vent || (Accumulator Pres- |Il! instructions and the Parle Seetnn ier \ pressure and ||| sure) to secondary |IH reference rawicas i down to top of |fl| (Regulated Pres- 5 search band. |||! surey: f (Search band is / equal to lowest || 1. No o-ring or E pressure in adjus- damaged o-ring { fable pres-sure |||| under flow plate ? fange of regulator. |||] around primary port t See TR™ Regula- orports. ’ tor specification |||! 2." Damaged o-ring , Sheet in Equip- || innydrasest ? rmentSection.) 3. Scored’ hydra- , seat seal surface ? and/or scored flow Plate at seal point, 7.8.5 Excessive chatter, |||] Orifice plug in seal Remove 1/4" pipe plug in bottom flange. 4 hammer or vibra- || container tail piece |Il] Yse's/32" allen wrench, una install orifice ; tion when 4-way |||] ismissing. plug and replace 1/4" pipe plug. This valves on hyd- ‘operation can be performed without ' raulic manifold are removing regulator if it is accessible, | operated. Relieve system pressure while servicing any high pressure component. 7.8.6 Exteral leakage Damaged o-ring Replace with new o- ring seal and back-up Com gent hole | seal on contro! Iill rings from seal hil. See Memes (1/8" dia.) in spring piston ‘Section for disassembly instructions and controthead, the Parts Section for reference drawings. ? CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE } BEING MADE TO THE BOP CONTROL SYSTEM"Problem 7.8.7 External leakage from vent hole (18" dia.) in inter- nal override hou- sing 7.8.8 Excessive and continuous exha- ust flow from secondary (Regu- lated) pressure out vent port of TR-5 valve only. 7.8.9 Excessive and continuous flow from primary (Accumulator) pressure to both secondary and vent ports of the TR-4 valve only. 7.8.10. Air or hydraulic ‘operator does not change regulated pressure wher ‘motor is running. Damaged o-ring seal or seals on override plunger. Seal_plug missing from TR-S valve flow plate. Seal carrier installed incorrectly . Primary’ and vent — hyd- raseats do not line up with their res- pective ports. Lock lever is not engaged which allows the gear box hub to turn while the adjustment handle andlock lever donot. Motor drive shaftkey is not engaged in worm keyway thus neithter the drive the drive hub nor the adjustment handle and. look lever turns while the motor is running. Biel) Replace with o-ring seal and back-up rings from seal kit. See Maintenance Section for disassembly instructions and the Parts Section for reference drawings. Remove bottom flange and check that brass. plugs are. installed. if not, the regulator must be disassembled and plugs installed, See maintenance Section for disassembly instructions and the Parts Section for reference drawing. 4. Remove flange from side opposite subplate. 2. Remove bottom flange from end ‘opposite spring control head, 3. Extract seal carrier, rotate 180° and re- install. NOTE : See Maintenance Section for detailed instructions and parts Section for reference drawings. ‘Tum the lock lever clockwise and tighten securely. Disengage drive motor from gear box and check drive key. A gnug fit of key in keyway facilitates proper insertion into worm bore keyway. CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE BEING MADE TO THE BOP CONTROL SYSTEM. =eT elo ed ’ \ | Problem | 7.8.11 Air or hydraulic Damaged threads |||! Examine drive threads for galling or | river will not onadjustmentscrew |||! binding. Drive screw and head cep should t reverse aft or in spring head |||} defile hard reaching minimum |}|| cap. t ormaximum set pressure. \ 1.8.12 Air driver will not Air supply pressure |||} Setairregulator to 60 psiminimum ? drive tomaximum ||} istootow. set pressure. Smaller adjustment |||] See Troubleshooting Section. j spring (1" diameter) in the spring control headistoo long, 7.8.13 Aircrivermotorwill I Air motor rusted or |||] Disassemble motor, inspect, clean, not run when |i] gummedup. recondition and assemble per motor disengaged from service instructions in Maintenance gearbox Section. Ensure that fillerstrainer and | lubricator are installed in the air motor , supply line , 78.14 Hydraulic driver ||!) Hydraulic_motor ||| Disassemble motor, inspect, clean, remove motor won't run |||] scored or jammed |}|| burrs or interference and assemble, Motor ’ when disengaged with foreign particles, should tum freely by hand. from gear box 78.18 Leakage from |ll! Damagedormissing |||] Replace seals romseal kit ; interface between ||| o-ring seals in port valve body and I] plate face | sub-plate, TR-4(3)o-rings } TR-5 (4) o-rings } Missing or damaged ||| Extract port plate and replace o-ting seal seal plug o-ring in |}|| and back-up rings from seal ki” See ; flangectportplatete |] maintenance Section for disassembly seal oross-drilled |||! instructions and Parts Section for reference ' vent passage. drawings. CAUTION : DRILLING OPERATIONS SHOULD CEASE WHILE REPAIRS ARE } BEING MADE TO THE BOP CONTROL SYSTEM.7.9 AIR PANEL PROBLEMS: 7.9.4 Slow or No Function Operation 7.8.2 Valve Handle Hard To Move 7.9.3 Panel gauges do not match gauges on hydraulic manifold Low air supply pressure topanel. Obstruction pre- venting movement of handle on hy- > 3 > Pa Air Motor Drive Regulator, TR-4 / TR-5 PART NO. 0150-1913 Part No, Description Tram ese | Se Saew 2 _| 0160-1620 | Name Plate 3 | eswoa0o| Tore Sew 01501503 | Adusimen Hende cisotiTa| De Shak ‘ing 7 ack | o1s125 | orve austin | oeo-645 | Toiss 717.2026 | O-ing (1017) Heas Flange 5044024 | Socket Head Cap Seu a0 oso ose Box Body [14 | ensue | eaing | 451 ois0-s19 | Worn Wize 717.2252 |Oving Cp 3| ong _| Socket Hesd Cap Suen Besing A9t8 [TWom 3150-0900 Ai ote 10044 | Tkey (it hows) 2204 Ong _| | 25__| 805490 _| Set Screw. zo: | or1r2113 | ovina arf eri72iet [Og i + ined in Standard Uvesal TRA Seal KH 110.6697 + Incdedin Standard Unverel TRS Seal Kt 11108897* Internal Override, 1500 PSI Regulator, TR-4 / TR-5 PART NO. 0150-1581 Part No. Description | ty. 606414 | Socket ead Cap Sow | a | org0-2028 | Punger ody Case | 1 117.2226 | Ong 01504587 | Plunger and Ball * Included in Standard Univorsl TR4 Sea Kit 1110.9497 * Included in Standard Universal TRS Seal Kit #1110.8897Ces AIR REGULATOR =“ Dowson” | Panne. | Renae Tee PT rse.o0 | riee-00 {ie Ai Rageloy Pra Hount Bepivah | sissao0 | asa-n00 caupanbciae, clears |e ‘it Regu Pert Heys 8Spacat” | siso4e00 | sost00 i a Raa Fal wun o280palvan'™ | aaes7o0 | asseaao a Descrpion | Pano. | Ropar $ Se RTrOUTT wR | avaztc0 | v7eatee aa He AtkepaoaT [rsa | Baio Ear Reauator, wT srra-a00 | nro 300 Description PartNo. Repair Kit “V4 Air Rlogulator, with yeni Bikes Gauge, 0-30 psi AIR FILTER Element som | seat PartNo Deserption | (somren) | pow! | Seatac Micron) | pono. | Panto. 2620-700 | Ft A, aa Bo aeaooror | zozo.owe | 2ez0are7 2620-3300 | Filler, Air, 1/2"; Metal Bow with | | Sight Glass, Auto Drain. oe 1806636. eae [2620-3600 | Filer Air, 1", Mlal Bowl with Sigh] — Eis eoss33 | 05538 | a0ssa7 Description PartNo. | Repair kit “U8” Air Lubricator, Metal Sod aemtoene 810257 att643 2" Air Lubricator, Metall oy | gy ; Bow w/Sight Gauge. nN [gk eee ee 1 Ar Lubricator, Metal Bow wiSight Gauge = pres AIR LUBRICATOR idd J d J Part No. AIR CONTROL VALVES 114" THREE-WAY, 150 PSI AIR CONTROL VALVE, Part No. 1222-0100 Deseription ay 1222-0700 122.0109, TA" Throo-Way Air Vave Major Repair Kit (Incl) Cartridge Ropair Kit, _Cartidge Ropai Kit Knob Handle — Hub Hana Nameplate ‘Washer ‘Scr ‘Shaft Handle Washer ‘Spacer ‘Cam Housing Retaining Ring ‘Arbor, ne, Vale Ralahing O-Ring aa (Guide, Plunger O-Ring ‘Scrow (Not Show) Included in Major Repair Kit Included in Cartridge Repair KitAIR CONTROL VALVES 1/4" FOUR-WAY, 150 PSI AIR CONTROL VALVE Part No. 1240-0100 ane - tem | PartNo. Description ay S ‘Assy. | 1240-0100 | FourWay Al Vatvo A Ki | 1240-0199 _| Repair Kit ¢ 2119p) 124001229 Nut, Mounting Aaptarny 3) 4240.0107 | Tie Road 4 < ‘3; 1240-01049 rage, Spxng 4 4 NA | Rall Pin é ‘| 14240-01130 Sleeve, Retainer Bia S 6 NA” | Stop 2 ms ae ati € 8 NA 2 ‘gis or 240-0108 2 s 10 NA 4 € reg NA 4 12+ | 240.0102 | Retainer 6 ¢ 43) NAS =| iBody Segment 3 4 NA | Covor (“A" End ) 4 é AB 1014-01069 Pin; Cote 2 € 16 NA | Link 2 w NAN) (Pla 4 € 18 | 1240-0108 | Pin 1 49 N/A (Adapter Maung! a a 20 | 1240-0110 | Rall Pin 1 e rm |/1240-01199 Lever fi 2a | sa40-0121 | Knob 4 « Dy ao a an w " aOEE UE ew uu ase w Ure Ee Se EE UY ww VALVES 114" FOUR-WAY, THREE-POSITION, SPRING CENTERED, 250 PSI, PANEL MOUNT Part No. 1242-0100 Description l Briraii a Paz OTT | THe (24129 —|—Soring Bin =| Sina, ceniar S| Jet A Retaining Ring wash ‘—freerows—|¢ marr przszowrs | shianate EI oA 1 A= Not Avaliable - Must Replace Valve, CROWN BLOCK SAVER COMPONENTS PART NO. 1250-0100 - THREE-WAY RESET AIR VALVE FOR CBS-ST ————— Part No. Description Qty 1250-0100 | 772"3-Way Ar Valve 1250-0199 _| RepairKit 18510:20507]/Screw. a 1250-0107 | Ball | 6. B717-22170E (O-RING (GVZWRKIN| Ta t 7 ‘O-Ring 2 ‘O-Ring 1 BTiS 2113 |(ORing = “1260-0101 | Tumblar Cap. 1 Screw aaa Scr 2 ee 107m all HaRaTey * Included in Repair Kit Note: items 2, 3,67, 10, 11, 12, 15 & 16 are Not Sold Separate - Must Roplace Valve.HYDRAULIC CONTROL VALVES 5000 PSI HYDRAULIC, FOUR-WAY, THREE POSITION, SHEAR-SEAL SELECTOR TYPE CONTROL VALVES Description a Ropar i (includes Seals)_| 670008 Leckwashor eisz0-41200| a of Soring, Dalene Ball, Detent Screw ‘Nut 4 ['Bod 1 Dowel Pin 920-4120 _| + szoanta | S| = agg 10TH] 120-4116 | B7722a | O-Ring erirats | + Thrust Waste aazoati3n | json 12 3204109 3204115 1320-4102) | 1320-4101 1320-8103 1320-4105 {1320-6126 | 1920-4110 | 4 1320-4107_| | 1320:4105_| * Included in Repair Kit ry‘sa py | HYDRAULIC CONTROL VALVES r 5000 PSI HYDRAULIC, FOUR-WAY, THREE POSITION ‘SHEAR-SEAL, BYPASS TYPE CONTROL VALVES 4 Description 1 ay * Kit_| Repair Kit incudes Seals) _| —airas7 |__| a} Leek 320-4120] 1320-4123 | 4 | 317496 1300-1107 320-4116. ~ |rerr-2212) = 8717-2115, ~ S20-4114. (B11G-2263) ~~ ~ Step Pin $ | Soring, Daten Ball, Detent Serew Oise, Dotent “1320-4107 | 320-4115) rm 1320-6108. Ex 820-102) 1320-4101, Included in Repair KitCHECK VALVE, 5,000 PSI Part No. Description 7601-0100 _| Valve Check Poppet, —_| Valve Check Bopoat Inline/4/4" NPT Port 1601-6100 _| Valve Check Poppet, Inline 2° NPT Port _ _ VALVES GLOBE VALVES10,000 PSI NEEDLE VALVES a) BALL VALVES HI-PRESSURE Description nay 10,000 PSI NEEDLE VALVE Description Tesdie vate, 3° FPT ‘Neoalo Vale -122° FBT: [522.1700 | 62-2100 [-1522:3100-| ai 1 TCS 7300 pe ‘$56 000pa pst 4° 858,000 psi sie 6 00s F123 6,000 [28S 000s. ‘Needle valve. V8 FPT eestee on aonnoea ao arwnnanaen o 6,000 PSI NEEDLE VALVE Description TisedleVatve 6000 psi, WP Fer. SS. Description Ball Valve, 36° FPT Z (2a Ball Vave, 34° FPT 1510-2100 FET =1S10:31001| Ball Valve, 1-12" FFT 1510-4100 ea r 1610551007 il Vale, 14° FBT 4510-6400 Gala Val 2-12" FET 510-7100 cr 5,000 PSI NEEDLE VALVES PartNo. Ta Tbe 55. 7522-1200) iia Ba ie “Tube, S.S. 45003001 _.ary RELIEF VALVES Pat fo. Pat No. Description | aly TBIO0 Rett vavo, 2750 pat 1700-8200 Rae Vatve; 1750 pai | A7OO=TOON| Y=] Aronss00 [treba Rotat vane | [reer aerate Te pa CPO [pastes Ret Va 71700-8500 Relief Vave, 9800 psi | | aig00 pel Reet Valve | | [1700-8600 Rit Vavo, 4000 pai_| [Senos Role ee | 700:8700 Reker vara, S500 pst |1700:31007| 909: Replbt Kil for "1700-8800 Relief Valve, 6500 psi_| 1700-4100] 200 Ret Vah ' f1700:8000 Rate Vales #900 bat | 170029100 ET ES ee al eeal | 1,750 Relat vane. Rabbi Kilo = 2.500 Relat Vato ' [Rea Kitfor 3.200 Relief vaio } a | 1700-8903 ; ‘ Sai 700-8006 | Fo 1200 pai R } ts =a (ed) 700-8206 | Fo 1750 psi Rebel , , =o 3300, pa Rolet ) | t ? 1700-8907, a 1700-8008. + 5 [78717-2122 "|| O-Ring) + 1700-8910 _| Seal Cap Asset + > + tncuded Rep Ki * NotSold Sopbibte ’ ? QUICK RELEASE VALVE > MAXIMUM WORKING PRESSURES : Auiiiuiom popy 5 200 PSI on 1/4" and 3/8", 150 PSI on 1/2" thru 1" sizes, 5 MATERIAL : Die-cast aluminum body. h ‘Synthetic rubber diapragm. > ORDER REFERENCE —$< <— $$ 4 we | moon | oatmmue | om | an | 2m > > >AIR CYLINDERS 2 POSITION AIR CYLINDER - 200 PSI WORKING PRESSURE 000.0700, 0 2000-0199, 3 POSITION AIR CYLINDER - 200 PSI WORKING PRESSURE Description Bore 7esy._| Ri Ojinder wih Cleve 2001-0500_| eoaar2 Kit) Repair kt [2001-0588 ‘Assy. | lows Ay. 2000-4110 | FILTERS / SNUBBERS HIGH PRESSURE DISCHARGE FILTERS Description Filter Element 1/2" NPT, 10 Micron 2633-1100 2634-1210 TA" NPT, 40 Micron 7 7 2634-220C1 | 2" NPT, 40 Micron 2634-4200, =, Element 21026 | (7469 819368 Description 7730-0100, TEMPT XA/2"FPT 011303 SS 114° MPT x 1/4" FPT Waler 303 Stainless Steel Grade E ja Male TubaXx 1/4" MPT@16 SS Grade D be x 1/2" FPT 316 SS Grade D - [AS Tube Union Swagel0k Grade ES16 S50 PT Grade E (water, light oll) 316 SS X/aF MPT Grade E 316 SSStS | PRESSURE TRANSMITTERS HYDRAULIC TO AIR PRESSURE TRANSMITTERS - 3,000, 6,000 AND 10,000 PSI | Patho, Deseiplon oy 71000100 6300p Tesmiter | 21004100 | 08000 pal anny Zio02i00 | 610000 ps arate Zoot | Rapor ie ' Zrooove | Tubing it 17000186 | Comeron kt ton 04 So ' PTO tew Ses | 2AOOOOT i Amoi z } 008 a 2b a10. + 5 {2100-0103 7} f I Hoosio7 “| NK i > WA z Fuvawee| 3 ; ~ 009109 [et + NA ste DE i ata | nt z , ODS Li 4 [paar WA ° NA ? ‘Sew fnchdes 18 819 Lock Washer , [Na =} casa > , 2 |" Scockel Tanenior ME | 2100-0128 [Screw 5 |=sonaa | Wes a Zio0i2s0 ero i > 21009181_| Sen Cov 2 aes Asanti [TT 5 }yonaise | For 0 ps Tre np Foc 10000 pa E ‘Sc 2 ® ‘Was 2 Pigg | 8 {Clamp Sei 4 ’ Canola Pale 1 Ta SEELEA 5 eo Aust Aseos i E | Hiracket & Stud 4 [antl (rey) 1 5 TO-A1OHT [15 pel Rogue bGwed [TY + Included and Sold nln Repl Kt 8 Part No. 2100-0100 ‘included and Sold en in Tubing Kit Dios ‘ Arent Sock Res Way ory Not be Ava as Separate s Mepis 7" tts. Mavala a. Separate a, Dever i 0 Weeks ARO oes Minimum. Contact Our eoston Teas Sly Oi, Depth - 5* Weight: 8 Pounds vue2 Se PRESSURE SWITCHES € PART NO. 2200-0100 - HYDRO-ELECTRIC PRESSURE SWITCH e PART NO. 2200-0199 - REPAIR KIT Se —E, Panne, Description | ay Description | ayy é 2200-0100 | FivsroEeatie Todavasnar 3 Pressure Switch Stop Pat 4 ¢ eK >| Nut z Holi, piston reat | A z | Monning Brea i é Retainer Extension + Insulator + € 2200.01260 [Sow Extension | “Terns Biba 1 Zora | Song. 1 Sew 2 e | a200-0 12505 | AslustmI FR SE | | eave Explosion Pool | ‘Ascoss Scr 4 Serow é 2 € oI or | e575-0100, a 22000107 2200-0132 ¢€ 2200016 2200101 72000110 3527-4010 6 [siz200-0104s| 22000113 Spring é zi Bracket Accor g ‘Surge Damponer 5 Part No. 2200-0100 Dimensions : Width ~ 6-1/2" Depth - 4-3/8" | Weight : 6 PoundsPRESSURE SWITCHES PART NO. 2250-0100 - HYDRO-PNEUMATIC PRESSURE SWITCH won \ MP ponte | boner ay ° 7290-0100 | tydro-Preumaie Preseure Swich 3000 pe 3 2250-0200 | Hyde Pneumatic Pressure ’ ‘Sw 8000 pa ‘Assy | 22500300 | Hycro-Proumate Pressure 5 Sieh 1500 pa b 5 4 f | ate Teeaded inser { rena , | Seaex————— 5 ’ 4 ‘Width 31 Dopin— 3.14" ‘Weight! 47 Pounds )2 ee a STRAINERS a Y-TYPE STRAINER : Part No. Description 2600-0104 Screen Only, Y-Type, 1/2" FPT _ | Screen Only, Type, 3/4 FPT 5 | Screen ily, Y-Type, 4" FPT < ‘Screen Only, Y-lype, 1-1/2" EPT | en Only, Y-Type, 2" FPT 2600-5101 | |/' Screen Only, Y=Type, 21/2" FPT: . a a ; Part No. Description < 2600-0100 Strainer, Y-Type, 1/2" FPT. ‘ 2600-1100 Strainer,Y-Type, 3/4" FPT 2600-2100 _| Strainer, Y-Type, 1" FPT 7 2600-3100 | Strainer, Y-Type, 14/2" FPT ; 2600-4100 _| Strainer, Y-Type, 2" FPT ® _ 2600-5100 Strainer,Y-Type, 2-1/2" FPT * 2600-6100 Strainer, Y-Type, 1-1/2" FPT, 3000 psi_ 2600-6101 Bonnet Sub-Assy. wiElement fw ud T-TYPE STRAINER Part No. Description é 2610-0100 _| Strainer T-Type, 6000 psi ] | 2610-0101 | Element ; 8717-2218 O-Ring ‘i aE | PUMPS PART NO. 3012-2100 - AIR OPERATED PUMP 60:1 RATIO, 8-1/2" DIA. AIR MOTOR bb00d 6 606 ® © © © ©66® Tiany PUMPS PART NO, 3012-2100 - AIR OPERATED PUMP 60:1 RATIO, 8-1/2" DIA. AIR MOTOR Part No. Description Part No. Description Assy | S012 2100 | A Opataled Hycraulc Pump "3023-0712 _| Valve Rod Assomby 3023-0100 | Air Motor, 8-1/2" Diameter Assy 3022-0107" Piston Nut 033-0100 | Fluid End Assembly Pieton Nut Washer. 30122199 | Complete Repair Kit Piston (Contains Air Motor And | Valve Trip Collar Fluid End Repair Ki) Ring. 3023-0199 | Air Motor Repair Kit 3033-0199 _| Fiuié End Ropar Kit S001 [Ai Line 302.0104 | Adapter S00 [Nut oo a "3022-0517 | ip Spring Rotainer Nut lnari2115 | 033-0101] Plunger Rod 3022-0120 | Ti “3033-0104 | Washer, Pst rat 3023-01087 Bal '3032-0109_| Lower Packing Spring —| 3029-010 |Fa0ss-o108" | Packing Set woiK 3032-0108 | ea | 3022-0125 a [3033-0105 "| Piston BoaTASSeMBI. | ana2-0r22 Re 033.0103 | Lower Pump Block ‘g022-0121_| 3033-0102 | Upper Packing Sora 3072-01725] Nut [3039-0110 _| washer ‘072.0102 | [nara7-21973| BTIT2138 30330111 ‘30220714 S0se071_| oat Slop Son2-0115 | 3093-0106 | en | 3022-0103 [23093-0107 | Foot Valve AsseRBT IN| (15721287 '3082.0101_} Sanction Washer 3023-0100 9032.0102 | Cesar 30 HP 0HP SOHP. — Plunger | 1-18" Plunger | 4aie"Pnger | Gy > Tinlex Pure soo2-0100 | 3003-200] ~ 3008-1200 3002-0199, 3003-1390 > 83 va Cover Gasket 3 Valve Spring 2 Lake . | Vale Seat Nor Shown) | rat * Fluid Oyinder [3002-2118 [=r ‘17018 1119_| 3 > TIBI 7eo ae | erase ess IBS|. Bo Ga 5002-2128 ‘e17e43___| 3003-1124 | ~ =} Stung 2130 | er reea ’ Stung Box 3002-2127 817842 ‘Stufing Box Flange 30022125 17841 > | Packing | s9621 | e17eaa — land Folower 817645; : 16" | Pinger 317847 > Suing BCC 817886; ‘Crosshead Siu Defector 3005-1108, > “| Crosshead Stub Seal 817825, Crosshead Slub Seal Cap 3003-1113, 5 [rosshead Stub Seal Gasket | 53002-2116 | 817878 > ‘Screw 300-14 1623] > ‘et6258 817910) a —ar7art > | at7aze E | 3003-1147 > [= airo13m + | 3003-1108 | — ~ 3009-1740) v 817822 re |=ars003-1708 aaa ~ ‘Connecting ~s ee Es | Crankshaft Frame CapnBoar| : ‘Sight Gla gon.2ia1 | Crosshesd 02-0106 ~s % * Included in Repair Kit > Dimensions: Height — 14-1176" = Width ~ 25-172" Depth 36-14" ~ Weight: 1020 Pounds JPUMPS NEW T-SERIES TRIPLEX PUMPS 30, 40 AND 50 HORSEPOWERda lr Code ESHUDUVODODEDEEDCOUDEKEODOOOOase eer rr vo 4 Day PUSHBUTTONS - XP PART NO.: 6201-0100, PUSHBUTTON, EXPLOSION-PROOF, LONG ASSEMBLY 6201-0150, PUSHBUTTON, EXPLOSION-PROOF, SHORT ASSEMBLY 818203, CLOSE-UP PLUG FOR OPERATOR BLANKING, 3/4" NPSM. PartNo, Doseription TExplosion-proaf Pushibution ‘Buton Ela mai [ Retaining Cole INDICATING LIGHTS - XP LONG SERIES EXPLOSION-PROOF INDICATING LIGHT ASSEMBLIES 120 VOLT ASSEMBLIES: PartNo, | Lons Base 202-1100 [Rea Candelabra 6202-2100 | Green Candelabra 2023100 | Blue Candelabra 202-4100 | Amber | | Gandelabre Red ‘tide 6202-1300 | Green, 3h e173 Blue ‘ste 617430 | Amber Sido PARTS: Part No. Description 6240-1000 } Bulb, 120 V Candelabra 249.2000 | Bulb, 120 side 210.0400 | Lens, Rea 6210-0800 | Lens, Green, 210-0600 | Lens, alve SIOOTOON | ens AbePUSHBUTTONILIGHTS - INDICATORS LONG SERIES EXPLOSION-PROOF INDICATING PUSHBUTTONILIGHT ASSEMBLIES 120 VOLT ASSEMBLIES ‘ PartNo, | Lens Base ( 200-4100, sie 6200-1200 side (6200-1700 Sl 6200-1300 | Amber sido 200-1800 | Clear Side PARTS Description Lens, Red Lens, Green Lens, Amber PUSHBUTTONILIGHTS - INDICATORS DIVISION Il EXPLOSION-PROOF PUSHBUTTON LIGHT ASSEMBLIES 4120 VAC ASSEMBLIES PartNo. | Lons exoo-s140_| Rod DIVISION Il EXPLOSION-PROOF INDICATOR LIGHT ASSEMBLIES 420 VAC TRANSFORMER,