PS 21 & PS 30

Training
 Course Objectives
After this programme, you should:

One Day Course

 Fully understand the importance of safety and how it relates
to the operation/maintenance of the PS 21/30
 Understand why the PS 21/30 was developed and the design
criteria behind its development
 Understand the system hook-up
 Show competency in the safe and correct operation of the PS
21/30
 Know how to troubleshoot the operation of the PS 21/30
Two Day Course
 Be able to do all the above
 Show a high level of competency in the maintenance
procedures associated with the PS 21/30
 Program Contents
Day 1 – General Overview

Safety
 General Safety Review
 PS 21/30 Safety
General Information
 Background to PS 21/30 Development
 General Description
 System Configurations
 Major Components
 System Requirements
 Program Contents
Day 1 – Operation

Installing the PS 21/30

 Installation Process
 Hooking Up the PS 21/30
 Installation Check List
Equipment Set-Up
 Calculating Crushing Loads
 Selecting Slips/Inserts
 Installing the Slips in the PS 21/30
 Dressing & Installing the Insert Carriers
System Operation
 Operating the PS 21/30
 Routine Maintenance
Examination
 Program Contents
Day 2 – Maintenance

Safety Analysis
 Dropped Pipe Analysis
 PS Releasing from RST
Hydraulic Systems
 Applying Electrical Power
 Applying Hydraulic Power
 Setting the Slips
 Raising the Slips
 Program Contents
Day 2 – Maintenance

Automated Lubrication
 General Discussion
 Controls & Programming
Part Replacement
 Changing the Centring-Device Ram Inserts
 Changing the Centring-Device Ram Guides
Troubleshooting
 PC-POL Rules
 Troubleshooting Flowcharts
 Program Contents
Day 2 – Maintenance

Inspection
 Hinge Pin Wear
 Bore Wear (The Paper Test)
Repair
 Disassembling the Main Cylinders
 Replacing the Piston
 Replacing the Seals
 Reinstalling the Main Cylinders
 Hoisting Rings
 Hydraulic Manifold Block
 Cover Hinge Pins
 Centring Device Cylinders
Examination
The Day Ahead
This Facility
This Facility
This Facility
In Case of Fire
Ground Rules!
 Day 1
Operation
Safety!
 Safety at Varco!

Varco drilling equipment is installed and operated in a controlled

drilling rig environment that involves hazardous operations and
situations
Safety is our FIRST Consideration!
General Safety

 Isolate all energy sources

before beginning work
 During installation, operation,
maintenance, or repair of this
equipment, personnel must
wear the appropriate
Personal Protective
Equipment
Equipment Use

 Varco equipment is designed

for specific functions and
applications and should be
used only for the intended
purpose
 Under no circumstances
should the loads applied
exceed the rated load
Limited Warranty

The warranty will be void if the

equipment is either:
 Repaired or serviced by a
service facility which is not
authorized by Varco
 Replacement parts not
manufactured by Varco are
utilised
 Modifications are made to
the goods which are not
approved by Varco
Personnel Training

 All personnel installing,

operating, repairing, or
maintaining equipment, or
those in the vicinity, must be
trained in rig safety, tool
operation, and maintenance
 This measure helps ensure
the safety of everyone
exposed to the equipment for
whatever purpose
 Contact Varco’s Training
Department for further
training on equipment
operation and maintenance
Motion Hazards

 Some Varco equipment

travels either horizontally,
vertically on rails, or both
 Avoid placing objects in or
near the path of this
equipment as such
interference could cause
personnel to become trapped
or crushed by the equipment
 Keep the working
envelope/zone of the
equipment free from
personnel
Maintenance Hazards

 Failure to conduct regular

maintenance may result in
injury to personnel or
equipment damage
 During disassembly of any
equipment, verify that all
components are clearly
tagged and labelled to ensure
that components are re-
installed correctly
 Always replace failed or
damaged components with
Varco certified parts as
failure to do so may result in
personal injury or equipment
damage
Equipment Visibility

 Clear, unobstructed visibility

of all equipment functions is
critical to safe operation
 Do not block or impair the
equipment operator’s field of
view
 In cases where this is not
possible, video cameras must
be installed to ensure
adequate visibility
Electrical Systems

 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
 When performing installation,
maintenance, or repairs,
isolate all power - lock out
switches and tag them to
prevent injury
Electrical Systems

 Before beginning work on this

equipment, familiarize
yourself with the electrical
schematics, as well as power
requirements
 Prior to disconnecting wires,
verify that all wires and
terminals are properly
labelled to ensure proper
reconnection
Hydraulic Systems

 Hydraulic systems and

components are designed for
specific use in the drilling
industry
 The hydraulic pressure for
this equipment can be as
high as 3,000 psi
 Isolate, lock out, and tag the
hydraulic and electrical
power & controls before
beginning work on any
portion of the hydraulic
system
 Familiarize yourself with the
hydraulic and electrical
schematics
Hydraulic Systems

 Properly discharge all system

accumulators
 Take precautions when
bleeding down residual
system pressure, using bleed
valves or alternative
techniques
 Hydraulic fluids can be
extremely hot and under high
pressure
Hydraulic Systems

 Never check for hydraulic

leaks with your hands
 Oil under pressure and
escaping from a hole can be
nearly invisible and can
penetrate skin causing
serious injury
 Always check for leaks with a
piece of wood or cardboard
Hydraulic Systems

 Collect all residual fluid in a

container to prevent spillage
– for both safety and
environmental reasons
 Take precautions to prevent
hydraulic oil from leaking into
other open electrical or
mechanical components,
such as junction boxes
 PS Specific Safety

 The L-bars are for lifting the

top cover ONLY!
New Photo
 DO NOT lift the Power Slip by
the L-bars
 PS Specific Safety

 The PS should be lifted ONLY

New Photo with the dedicated lifting
eyes
 PS Specific Safety

 After assembly, always lock

New Photo the ram guide assembly with
the lynch pin
PS Specific Safety

 The plate shown warns

personnel against risks and
dangers
 The plate must ALWAYS be
present on the PS 21/30
 The plate is a free-item and
available on request at your
nearest authorized Varco
repair facility
 The best advice - Do Not
Touch the PS!
General Information
Background to Development

 The rig floor can be a

dangerous place
 Especially with new racking
systems, it is not safe to have
personnel moving around on
the rig floor
 In these cases the use of hand
and foot-operated slips is not
recommended
Background to Development

Inert Video from Old Rig Set-Up

 Function

New Photo

The PS 21/30 is designed to clamp

and suspend tubular goods
 General Description

 The PS 21/30 is a
hydraulically operated power
slip which is equipped with
replaceable slip assemblies
and insert carriers to handle
New Photo
various styles and sizes of
tubular
 The PS 21/30 can handle
casing, drill pipe and drill
collars and is used in
combination with the Rotary
Support Table
The PS 21/30 in Operation
 Ratings

PS 21 = 2⅜” – 14” up to 500T

PS 30 = 2⅜” – 20” up to 750T
 System Configurations

The PS 21/30 is Operated in

Combination with the Rotary Table

Like the FMS, it eliminates the need for

work platforms during casing operations
 System Configurations

The PS 21/30 can be installed in a number of

different rotary tables – including Varco’s RST

Example of PS30 in
Emsco 49½” Rotary
Connection & Operation

 Through incorporation of a
hydraulic slip ring in the
Varco RST, hoses do not
need to be disconnected
 The PS 21/30 slips will set or
New Photo raise when a remote
command is given by the
driller
 The status of the slips (set or
up) is determined by the
signal-line pressure
Rotary Tables

PS 21 = 37½”
PS 30 = 49½”
 Back-Up Torque
13.375”
90,000

10.75”
80,000
Maximum Back-Up Torque (ft.lbs)

70,000

60,000

50,000
45,000ft.lbs – PS21 Operational Limit 6.625”
40,000

30,000
5”

20,000

10,000

0
0 10 20 30 40 50 60

Additional Pipe Weight (short tons)

 Back-Up Torque

 The PS 21 can generate a back-up torque up

to 45,000ft.lbs - depending on weight and type
of string
 The PS 30 can generate a back-up torque up
to 55,000ft.lbs - depending on weight and type
of string
Slip Arrangement

 The PS 21/30 allows handling

of all pipe sizes and types
 The slips have a rapid-
change system with no loose
parts
 Two handles on the middle
slip retract and lock the
spring-loaded retaining pin
Insert Carriers

 Insert carriers can be

changed in less than 5
minutes – even with pipe in
the hole
 A special locking mechanism
eliminates the use of
bolts/pins
 Load Rings

Depending on the size of the insert carrier, one or

two ‘load rings’ have been added
 Tubular Sizes

PS 21
Universal Slip with Insert Carriers to Handle Pipe up to Ø10¾”
Universal Ram with Ram Inserts to Centre Pipe up to Ø10¾”
Size Specific Slips to Handle Pipe from Ø10¾” - 14”
Size Specific Rams to Centre Pipe from Ø10¾” - 14”

PS 30
Universal Slip with Insert Carriers to Handle Pipe up to Ø16”
Universal Ram with Ram Inserts to Centre Pipe up to Ø16”
Size Specific Slips to Handle Pipe from Ø16” - 20”
Size Specific Rams to Centre Pipe from Ø16” - 20”
 Centring Device

 When the pipe is hard to one

side (due to rig movement or
heavy directional drilling) a
centring device centres the
pipe prior to setting the slips
 The PS 21 always requires a
New Photo centring device on floating
rigs
 The PS 30 requires a centring
device on all rig-types
Centring Device
 When a centring device is
provided, a ram guide in
each top cover half pushes
the pipe to the centre
 This happens before the slip
cylinders are actuated
– operating in an automatic
sequence with the slips
 No modifications to the
controls is needed to operate
a PS with a centring device
 The ram inserts are pipe size
specific and must be
changed with each slip/insert
carrier change
 Stainless Steel Ram Insert

New Photo

Available for drillpipe sizes 6⅝” and smaller

The guides use a steeper top and bottom lead-in chamfer to
better guide the tool joint through the top guides
The contact area between pipe and ram insert is enlarged
A machined groove is included to indicate
maximum allowable wear
Visual Slips Set Indicator

 An indicator is added to give

New Photo a clear visual feedback of
when the slips are fully set
 Hand Slip Bowls

 The PS 21/30 can be fitted

with insert bowls for use
with hand slips
 Extended hand slip handles
are fitted between the
handle and body to
eliminate clearance
problems with the top cover
New Photo
 Hand Slip Bowls

Number PS Rating Size Range Slip Size

#1 PS 30 150 tons 13⅜” – 11¾” 16”
#2 PS 30 150 tons 10¾” – 9⅝” 16”
#3 PS 30 150 tons 8⅝” – 2⅜” 16”
#3 PS 21/30 100 tons 8⅝” – 2⅜” 10¾”
 Pipe Wipers

When tripping out drillpipe, Varco recommends that a 19"

spirol (helical) wiper be placed below the tool
This wiper can be installed with the tool still in the rotary by
pulling the insert carriers and
lowering the wiper through the slips
Position the wiper UNDERNEATH the tool to
keep mud away from the moving parts of the PS
 General Requirements
General
Tubing & Hoses All hoses connecting the PS to the
power unit/ring main must be ½”
minimum
Minimum Working Pressure 2,300psi (with centring device)
Maximum Working Pressure 3,000psi
Power Unit A closed centre power unit or ring
line with a minimum of 2,500psi
working pressure and 5gpm is
required
A flow rate of 10gpm is
recommended
Maximum Oil Temperature 180°F (82ºC)
Application Filter • An in-line pressure filter in the
hydraulic supply line between the
power unit and the hook-up kit
• An in-line 50µ filter in the
hydraulic signal line on the hook-
up kit manifold
 Pressure Requirements
Pressure Requirements

 Optimum pressure is 2,500psi

 Pressure must not be less than 2,000psi for a
PS without a centring device
 Pressure must not be less than 2,300psi for a
PS with a centring device
 Back-pressure must not exceed 200psi for a
PS with a centring device
 Pressure Requirements
Special Note

The sequence of the ram-guide and slip-cylinders

is automatically controlled by the manifold on the PS
The sequence valve is activated by a pressure difference
between the slips up hose and the slips down hose
The PS will function best when the
activate pressure is 2,300psi and the back-
pressure is no more than 200psi
With these pressure settings, a centring force of 10 tons
is obtained at the ram-guides
Hydraulic Fluid Requirement

Petroleum based hydraulic fluid with properties which provide inhibition,

anti-rust, anti-foam de-aerating and anti-wear properties
Fluid viscosity 150-225 SSU (SEA 10W) at 100°F (38°C) and with a
viscosity index of 90°F minimum

Do NOT use non-petroleum base or fire-resistant fluids

 Grease Requirements

A high quality, multi-purpose, water-resistant,

extreme pressure (EP1 or EP2) grease, with a
minimum dripping point of 300°F (150°C) should be
used

The use of grease with a dripping point

of at least 480°F (250°C) is recommended
 Grease Requirements

Application Brand Type Quantity

Bowl (North Sea) TRIBOL MOLUB ALLOY N/A
968 SF Heavy
Bowl (GOM) TRIBOL MOLUB ALLOY N/A
936 SF Heavy
Cylinder Housing TRIBOL MOLUB ALLOY 50cc (3.2in³)
968 SF Heavy
 Installing
the PS 21/30
 Power Slip Identification

The identification stamp individually identifies the tool

It is therefore very important that, when
contacting Varco for service purposes, to have this
information available
Installing the PS in the Rotary

1. Lift the PS with the special

lifting sling

Add photo of sling

Installing the PS in the Rotary

2. Rotate the locking pins to the

retracted position
Installing the PS in the Rotary

3. Ensure that the manifold block

on the PS 21/30 is on the same
side as the hoses/connections
4. Lower the PS 21/30 into the
rotary table
5. Engage the locks
 Hooking Up the PS
Flushing/Filtering System

An in-line filter is placed between the rig’s pressure ring and

the pressure line to the PS hook up system
A flushing manifold ensures that all return oil flows
directly into the rig’s return ring line and does not
re-enter the hook up kit manifold
 Hooking Up the PS
Mounting Plate Pressure Switches
Junction
Box
New Photo

Pressure
Gauges

Directional
Valve

Accumulator

Manifold
Block
 Hooking Up the PS
Mounting Plate
Driller’s
Hooking Up the PS
Control
Panel

Hook Up Manifold

Slips Up Switch
(1600psi)
Slips Set Switch JB
(1800psi)
Low Pressure Switch
(2000psi)

Accumulator

Manifold Hydraulic
Block Controls
Pressure Control
(2500psi)

Pressure
Filter
PS 21/30
Hooking Up the PS

New Photo
 Hooking Up the PS
PS 30

New Photo

Slips Up

Signal
Slips Set
 Hooking Up the PS
PS 21 – No Centring Device

Slips Up

Signal

Slips Set
 Hooking Up the PS
PS 21 – With Centring Device

Signal
Slips Set

Slips Up
Installation Checklist

 Arrange the hoses on the rig

floor in such a position that the
hazard of cutting or dragging is
minimised
 Before operating, remove air
from the hydraulic circuit by
fully cycling the slips 10 times
(or flush with flushing kit)
 Varco recommends that only
OEM controls be used to operate
the PS – use of other controls
may result in hydraulic circuit
damage
Equipment Set-Up
 Pipe Crushing Loads

1
F = Qyp x A x RK + RK 2

1+ L L

F = Crushing Load (lbs) R = Outside Radius of Pipe (in)

Qyp = Yield Stress of Pipe (psi) L = Length of Slip Contact (in)
A = Sectional Area of Pipe (in2) A = Crushing Factor (Nominally 2.6)
 Opening

Maximum Throat
11⅝

Opening (Slips-
Up)
P/N for Ram
Ram Guides

Guides for PS21 202346-663

with CD
P/N for Fixed
Guide for PS21 202302-913
Without CD
Selecting Slips & Inserts

Guides

Fixed Guide
Fixed

9⅛

Diameter (in) for

PS21 without CD
Qty of Inserts 24B-48
Insert p/n 2632
Slips & Inserts

Insert Carrier
Assembly Less 202273-1
Inserts p/n
Insert Carrier
Assembly p/n
202273-663
Slip Body p/n 202250-1

500T
Pipe Size & Type
Rating
Plain DC (in)

-
Zip DC (in)

-
6⅝
Nominal Size (in)
 Installing the Slip in the PS

Ensure that hydraulic lines are disconnected

before ANY work is carried out on the PS-21/30
Installing the Slip in the PS

Note:
Slip-pin engagement will be easier
with the lifting arms approx. 1/3
down (45°)
Control the slips down and stop the
movement with the ball valve in
the slips-down line
Installing the Slip in the PS

1. Open the top covers using the

lifting hook and a tugger line
2. Grease the ribs on the inner
New Photo bore of the PS 21/30
3. Grease the ribs of the slip
assembly
Installing the Slip in the PS

4. Lower the slip assembly into

the PS 21/30
Installing the Slip in the PS

New Photo
5. Move the slip mounting pins
outward – use the special
handling tool to push the pins
from inside the slotted hole
and LOCK the slip assembly
 Sizing the Inserts
Size inserts for slip body 10¾” for PS-21

The correct insert carrier can be measured with an OD calliper using:

X = 7½” – ( (nominal size clamping diameter) / 2 )
Dressing the Insert Carrier

1. Remove the screws and spring

washers on top of the insert
carrier assembly

DO NOT grease the grooves

Bottom inserts must be Beveled
Dressing the Insert Carrier

2. Dress the slip assembly and

lock it with socket head lock-
New Photo screws and lock-washers

DO NOT forget the yellow SIZING Insert

Installing the Insert Carrier

1. Pick up the insert carrier

assembly with the lifting hook
2. Grease the back of the lock
trigger and the big dovetail
3. Place the insert carrier with the
dove tail on the insert carrier
retainer in the slip and push
the latch back with the insert
carrier

Lift the insert carrier with the insert carrier lifting hook
DO NOT grease the back of the insert carrier!
Installing the Insert Carrier

New Photo 4. Lower the insert carrier

Installing the Insert Carrier

5. The latch will engage

automatically
New Photo 6. Connect the hydraulic hoses to
the PS 21/30
 Removing the Slips
1. Raise the slips
2. Close the ball-valve in the slips
down hose
3. Operate the controls to set the
slips
4. Slightly open the ball-valve and
lower the slips just enough to
have slack on the slip quick-
New Photo release pins
With Pogo
5. Close the ball-valve and
disconnect the hoses
6. Connect a 2-way lifting sling to
the lifting eyes on the right and
left slip segments
7. Gently raise the slips until the
quick release slip pins can be
retracted
 Removing the Slips

8. Disconnect the slip quick-

New Photo
release pins
 Disconnecting Hoses

Hoses could be disconnected:

 To allow the tool to be lifted out of the rotary table
 To allow the PS and rotary table to be rotated
Hoses must be disconnected:
 To prevent unwanted slip movement – especially when
someone has to work on the PS

Be careful when disconnecting hydraulic hoses

Ensure that pressure is off the hoses and
that string weight cannot generate pressure
 Disconnecting Hoses
With Slips UP
1. Raise the slips
2. Close the ball-valve in the
slips-set hose
3. Operate the controls to set the
slips
4. Disconnect the quick-connects
- keep the controls in the slip-
New Photo down position and keep the
ball-valve closed
5. Reconnect the quick-connects
6. Operate the controls to raise
the slips
7. Open the ball-valve in the
slips-down hose
 Disconnecting Hoses
With Slips SET

1. Set the slips

2. Close the ball-valve
3. Disconnect the quick-connects
– keep the controls in the
slips-down position and keep
New Photo
the valves closed
4. Re-connect the quick-connects
5. Open the ball-valve
Operation
 Operating the PS 21/30
Remember….

 Be aware of the limited back-up for torque

 Check that the slips/carriers are set on the correct section of
the pipe
 The PS must be set before releasing the elevator (preferably
using an interlock)
 The PS is properly set when the ‘slips down’ signal comes on
 When the rotary table and the PS have to be rotated, always
decouple the quick disconnects on the PS prior to rotation
(except for RST) - not doing so may cause severe damage to
the PS, hydraulic hoses or controls
Operating the PS21/30

With the string held in the

PS, make-up or break the
ALWAYS
Connect
Install
upper pick
the
stand allup
PS
hydraulic
the
in the
weight
ALWAYS Setorthe
joint and
slips
of the
equipment
rotary
pipeusing
string
&it
all
check
with
4 x the
beforehandle
releasing the
elevator
lifting
correct
BEFORE
eyestooland
function
raising
4-waythe
Never raise elevator
the slips whilst
lifting
slipssling
the pipe load is suspended in
the slips
 Operating the PS 21/30
Recommendations….

 It is recommended that the PS be operated by the driller

 It is recommended that the pipe is lowered slightly with the
elevators whilst setting the slips
 It is recommended that the pipe is raised slightly with the
elevators whilst releasing the slips
 The rotary locks on the PS may only be needed on floating
rigs or while floating in pipe – in case the PS is pushed out of
the rotary
 Removing the PS
With Pipe in the Hole

 BE AWARE of loose parts while lifting

 DO NOT lift the PS using the L-bars on the cover
 Lift the PS out of the rotary table ONLY using the 4-way lifting
sling with curved spreader beam – use ALL 4 hoist swivel rings
 Beware of pinching fingers between the body and the door
 NEVER place hands anywhere else than on the top of the door
 Removing the PS
With Pipe in the Hole

Disengage
Raise the top
slipscover
and lock
Disconnect
Lift the PS the
& pin
on the
disengage
door
Remove and
thethe
gently
rotary
hinge open
Hydraulic
Swing the Hoses
door open
the
table
toplocks
cover
 Handling Tools
Hand-Slip Bowl Handling Tool

Lock
1. Locate the tool
2. Lock the tool
3. Pull backward and lift the bowl
4. Remove the bowl with a tugger
line
 Handling Tools
Slip Handle Operating Tool
 Handling Tools
Slip Assembly Lifting Tool
 Routine
Maintenance
 Daily Inspection
Daily Inspection
1. Check for worn and damaged parts
2. Check for loose and missing parts
3. Check correct sizes of slips, insert carrier and top guide/ram
4. Check correct installation of these parts
5. Check hoses for sign of cracks, wear or abrasion
6. Inspect hoist ring parts. Never use hoist ring that shows:
• signs of corrosion
• wear
• damage
7. Check if bail is bent or elongated
8. Check and clean rotary table
9. Check locking of:
• bolts and nuts
• safety wire
• slotted nuts & cotter pins
• bent lock tabs, safety latch pins & lock bars
• roll and dowel pins
• snap rings
• cotter pins
 Functional Inspection

Functional Inspection
1. Connect the PS 21/30 to the control manifold and check:
• Correct function of tool
• Slips Up: Slips raise then centring rams go out
• Slips Set: Centring rams go in first then slips set
• Check hydraulic pressure
2. Check Slip Signals:
• Check slips down signal is on when slips are set:
• Check slips down signal is off when slips are up
• Check slips up signal is on when slips are up
• Check slips up signal is off when slips are down
3. If the PS door was open on installation, check that the removable hinge-pin has been re-installed
4. Check correct engagement of slip and insert carrier quick release mechanism
5. Check correct installation and locking of centring rams/ram inserts
6. Engage the top cover lock after inspection
7. Always keep top cover lock engaged during operation
 Lubrication

Do NOT apply grease:

 To the back-side of the insert carriers (except for the
dovetail slot)
 To the inner bore of the slips
 To the dovetail slots retaining the inserts
 The back-side of inserts

NEVER use tool-joint compound (pipe dope)

for lubrication purposes
 Lubrication

Lubricate the PS 21/30:

 After every 25 joints (average) run
 Prior to cementing
 When loads will be hanging for more than 1 hour
 Prior to storage
 Lubrication

Action Nipples Method

1 Flushing and filtering system - After every connection
2 Grease the cylinder levers 4

Apply grease manually or use a

grease gun until grease is seen
3 Grease the nipples on the outside of
2
the top cover

exiting the bores

4 Grease the nipples on the inside of the
2
top cover (ram guides)
5 Grease the nipples on the top cover
2
hinge pins
6 Grease the nipples on the knuckle pins
2

7 Grease the hinge pins 4

8 Grease the door hinge pins -
 Lubrication
Flushing & Filtration System
 Lubrication
Grease the Cylinder Levers
 Lubrication
Grease the Nipples on the Outside of the Top Cover

New Photo
 Lubrication
Grease the Nipples on the Inside of the Top Cover (Ram Guides)
 Lubrication
Grease the Nipples on the Hinge Bosses
 Lubrication
Grease the Nipples on the Knuckle Pins
 Lubrication
Grease the Top Cover Hinge Pins

New Photo
 Lubrication
Grease the Door Hinge Pins
 Lubrication

Lubricate the Insert Carrier/Slip Set:

 Prior to installation
 Prior to storage
 Lubrication
Insert Carrier/Slip Set

Action Method
1 Grease the back of the slips
2 Grease the lock trigger Apply with a brush
3 Grease the dovetail of the insert carriers
 Lubrication
Grease the Back of the Slips

New Photo
 Lubrication
Grease the Lock Trigger

New Photo
 Lubrication
Grease the Dovetail Slot

New Photo
 Lubrication
Weekly Lubrication

Action Method
1 Grease the slot in the ram guides
2 Grease the cover plate lock Apply with a brush
3 Grease the sliding mechanism
 Lubrication
Grease the Ram Guide Slot
 Lubrication
Grease the Top Cover Lock
 Lubrication
Grease the Sliding Mechanism

New Photo
 Automated Flushing

The performance of the PS 21/30 is heavily influenced by

the cleanliness of the oil in the hydraulic system
Varco has therefore developed a flushing/filtration kit that
allows the PS unit to be flushed with oil before start up especially
after reconnecting the tool
 Flushing & Filtration

New Photo

Flushing
Handle
 Automated Slip Greasing

The performance of the PS power slip is related directly to

the greasing of the back of the slips
Varco has developed an automatic greasing system which uses
standard grease buckets
The system greases the backside of the slip
 Automated Slip Greasing

The system uses the slips set pressure switch signal

to count the slip cycles and, at a preset number of cycles
the grease pump starts to pump grease from
the bucket
The grease is divided using a directional control valve

Directional
Control Valve
Automated Slip Greasing

Port ‘A’ Ports ‘B’ & ‘C’

Centre Slip Left/Right Slip

 Automated Lubrication

Using a dedicated PLC, greasing frequency and quantity can be

adjusted to meet job specific requirements

Siemens PLC
 Automated Lubrication

Light on top of JB

Manual
Grease Cycle
Questions?

?
End of Day’s Programme

Thank You!
 Day 2
Maintenance
Safety Analysis
Dropped Pipe Analysis

Ram Insert
Not Installed
Lynch Pin Not Used OR
Ram Insert
OR Fallen Out
Lynch Pin Not
Properly Fastened
 Dropped Pipe Analysis
Rig Movement
(Floaters)
OR
Heavy
Directional Drilling
AND
No
Malfunctioning Centring Device
Hydraulic Hinge Pin
OR Malfunctioning
Centring Device
No Ram Insert OR

Top Cover Open

Cylinder Mounting
Plate Loose
Knuckle Centring
Device Loose

Knuckle Pin Lost

 Dropped Pipe Analysis

No Insert Carriers

Opening (Slips Set)

Inserts Too Small OR
Is Too Big

Worn Inserts

Malfunctioning
Hydraulics

Dropped Pipe
Slip Actuator
Defective
Slips Not
OR OR
Fully Down
Pipe String Tilted

Sticking Slips

Malfunctioning
Interlock
 PS Releasing from RST
Rotary Table
Lock Not In
Rotary Table
OR
Not Functioning
Rotary Table
Locks Broken
Buoyancy While AND
Running Casing
BX Pulling Up
Interlock
AND OR
Malfunctioning
PS Slips Set

Sticking Slips
Set Slips
OR
Don’t Release
Malfunctioning PS Releases
Hydraulics From RST
AND

Rig Movement
Upward
OR
Pipe Movements
Kicks
Hydraulic Systems
Applying Electrical Power

SYSTEM POWER
PRESSURE LOW

SIGNAL PS 30 SIGNAL PS 30
OPEN CLOSED

Power

SLIPS
SLIPS OPEN CLOSED
 Applying Electrical Power

31

41 9
42
43
44 10
45
46 1
47
48
P 49
50
51
52
Power
53 1
1
O 54 2
2
55
3
3
56 4
4
57 5
5
58 11 6
6
59 7
7
60
8
12
30

13
 Applying Hydraulic Power

ACCU

To/From Grease/Flushing Kit To Hook-Up Kit

P B
 Low Pressure Alarm

E12

3 2 1
PS1

P T
Low Pressure Alarm

E14
9E2 1
1
10E2
2
11E3
E9 3
12E3
4
13E3
5
E10 9E3
6
2
10E3
7
11E2 8
12E2 9
E11 13E2
10
9E1 11 3
E12 10E1 4
12
13
12E1 14 6
13E1 7
E13 15
11E1
16
5
14E4
17
18
19
14E1
20
8
 Low Pressure Alarm

31

41 9
42
43
44 10
45
46 1
47
48
P 49
50
51
52
Power
53 1
1
O 54 2
2
55
3
3
56 4
4
57 5
5
58 11 6
6
59 7
7
60
8
12
30

13
 Low Pressure Alarm

SYSTEM POWER
PRESSURE LOW

SIGNAL PS 30 SIGNAL PS 30
OPEN CLOSED

Power

SLIPS
SLIPS OPEN CLOSED
 Setting the Slips

SYSTEM POWER
PRESSURE LOW

SIGNAL PS 30 SIGNAL PS 30
OPEN CLOSED

Power

SLIPS
SLIPS OPEN CLOSED
 Setting the Slips

31

41 9
42
43
44 10
45
46 1
47
48
P 49
50
51
52
Power
53 1
1
O 54 2
2
55
3
3
56 4
4
57 5
5
58 11 6
6
59 7
7
60
8
12
30

13
Setting the Slips

E14
9E2 1
1
10E2
2
11E3
E9 3
12E3
4
13E3
5
E10 9E3
6
2
10E3
7
11E2 8
12E2 9
E11 13E2
10
9E1 11 3
E12 10E1 4
12
13
12E1 14 6
13E1 7
E13 15
11E1
16
5
14E4
17
18
19
14E1
20
8
 Setting the Slips

E10
E9

3 2 1 1 2 3

B1 T P A1
 Setting the Slips

S1
B1
A1

To/From Grease/Flushing Kit To Hook-Up Kit

P T
Setting the Slips

B1 A1 S1
 Setting the Slips

E11

3 2 1
PS2

B1
SV1

S1
Setting the Slips

E14
9E2 1
1
10E2
2
11E3
E9 3
12E3
4
13E3
5
E10 9E3
6
2
10E3
7
11E2 8
12E2 9
E11 13E2
10
9E1 11 3
E12 10E1 4
12
13
12E1 14 6
13E1 7
E13 15
11E1
16
5
14E4
17
18
19
14E1
20
8
 Setting the Slips

31

41 9
42
43
44 10
45
46 1
47
48
P 49
50
51
52
Power
53 1
1
O 54 2
2
55
3
3
56 4
4
57 5
5
58 11 6
6
59 7
7
60
8
12
30

13
 Setting the Slips

SYSTEM POWER
PRESSURE LOW

SIGNAL PS 30 SIGNAL PS 30
OPEN CLOSED

Power

SLIPS
SLIPS OPEN CLOSED
 Raising the Slips

SYSTEM POWER
PRESSURE LOW

SIGNAL PS 30 SIGNAL PS 30
OPEN CLOSED

Power

SLIPS
SLIPS OPEN CLOSED
 Raising the Slips

31

41 9
42
43
44 10
45
46 1
47
48
P 49
50
51
52
Power
53 1
1
O 54 2
2
55
3
3
56 4
4
57 5
5
58 11 6
6
59 7
7
60
8
12
30

13
Raising the Slips

E14
9E2 1
1
10E2
2
11E3
E9 3
12E3
4
13E3
5
E10 9E3
6
2
10E3
7
11E2 8
12E2 9
E11 13E2
10
9E1 11 3
E12 10E1 4
12
13
12E1 14 6
13E1 7
E13 15
11E1
16
5
14E4
17
18
19
14E1
20
8
 Raising the Slips

E10
E9

3 2 1 1 2 3

B1 T P A1
 Raising the Slips

S1
B1
A1

To/From Grease/Flushing Kit To Hook-Up Kit

P T
Raising the Slips

B1 A1 S1
 Raising the Slips

E13

3 2 1
PS3

A1
SV2

S1
Setting the Slips

E14
9E2 1
1
10E2
2
11E3
E9 3
12E3
4
13E3
5
E10 9E3
6
2
10E3
7
11E2 8
12E2 9
E11 13E2
10
9E1 11 3
E12 10E1 4
12
13
12E1 14 6
13E1 7
E13 15
11E1
16
5
14E4
17
18
19
14E1
20
8
 Raising the Slips

31

41 9
42
43
44 10
45
46 1
47
48
P 49
50
51
52
Power
53 1
1
O 54 2
2
55
3
3
56 4
4
57 5
5
58 11 6
6
59 7
7
60
8
12
30

13
 Raising the Slips

SYSTEM POWER
PRESSURE LOW

SIGNAL PS 30 SIGNAL PS 30
OPEN CLOSED

Power

SLIPS
SLIPS OPEN CLOSED
 Functions

ACC Minimizes Pressure Fluctuations and Assures

Pressure for Torque Back-Up Feature
CV 1 Check Valve Protects Against Unloading of
Accumulator
PC 1 Pressure Reducing Valve for a Constant Pressure
Set @ 2500psi
PG 1 Pressure Gauge to Check System Pressure
DV 1 Operates Slips
PS 1 Low Pressure Indicator
PS 2 Pressure Switch for Signal Slip Set
PS 3 Pressure Switch for Signal Slip Up
 Functions

SV 1 Controls “Slip Down" Signal

SV 2 Controls “Slip Up" Signal
CV 2 Protection Against Switching P&T Line
PS 1,2,3 Pressure Switches
F1 to F5 Filters
PG 2 Pressure Gauge to Check Slips Set Signal
PG 3 Pressure Gauge to Check Slips Up Signal
 Functions

PC 1
 The control manifold can be connected to a closed
centre power supply with working pressure between
2,500 and 3,000psi
 Because the PS has a maximum working pressure of
2,500psi, PC 1 is set at 2,500psi to protect the PS
against overloading
ACC, CV 1 & PS 1
 The accumulator ACC and check valve CV 1 reduce
pressure fluctuations in the power supply and maintain
the back-up feature
 Should the pressure in the accumulator drop below
2,000psi, PS 1 gives a signal that the back-up feature is
no longer valid
 Functions

DV 1
 This directional control valve operates the slips
SV 1 & SV 2
 When the slips are set, the PS gives a hydraulic signal
back to the control manifold
 SV 1 transfers this signal to the pressure switch PS 2,
eliminating a false signal in the slips up position
PRV 1 & FC 1
 PRV 1 (pressure relief valve) controls the slips power up
force whilst FC 1 (flow control) controls slip speed
Automated Lubrication
 Automated Lubrication
Siemens PLC system

By using the buttons on the front of the SIEMENS LOGO, the

parameters for the timer can be set and changed
Three settings are important;
1. The time the solenoid is operated to accomplish a full
pump stroke (B20 and B22)
The higher the viscosity the longer it takes to make a full pump stroke
A is the centre slip whilst B and C are the left hand and right hand slips

2. The time a greasing sequence is taking (B08 and B09)

The type of grease and the viscosity determines these parameters

3. B06 is the number of slips sets after which a grease cycle

starts
This depends on the grease properties and field conditions
 Automated Lubrication
Siemens PLC system

The SIEMENS LOGO is brought up on the module by pressing

the "ESC" and "OK" buttons simultaneously
The following message appears on the display:
 Automated Lubrication
Siemens PLC system

By using the scroll buttons, select "Set Param" option and

press "OK"
By using the scroll buttons, select the function block required
 Automated Lubrication
Siemens PLC system

If you want to change the parameters, select the function

block and press "OK"
The following message appears on the display;

B3 : T
T =00.50s
Ta =00.00s
 Automated Lubrication
Siemens PLC system

 B03 is the function block

 T for the set value
 Ta is the actual value

To close the parameter module press "ESC" twice

Regular Inspections
 Six-Monthly Inspection

Inspection Tasks

1 Clean tool thoroughly

2 Check that all grease restrictors are open

3 Check that all grease nipples are present and functional

4 Check condition of in-line filters in manifold block

5 Check condition of in-line filters in hook-up manifold

6 Check condition of hoist swivel rings (6 off) – replace if necessary

7 Grease tool according to normal procedures

8 Use paper test to check PS 21/30 body v slip fit

 Annual Inspection

Inspection Tasks
1 Replace top cover hinge pin seals

Remove hydraulic cylinders from body – check for:

• Rust
2 • Denting
• Cracks
• Damage

3 Replace all seals

5 Check piston is still fixed on rod
6 Apply new grease to gear
7 Assemble cylinders and check barrel bolts for correct torque
8 Carry out magnetic particle inspection against relevant drawing
Part Replacement
Centring Device Ram Inserts

1. Close the ball valve

2. Disengage the top cover lock
and open the top covers
3. Remove the lynch pin clip that
locks the ram insert into the
universal ram guide
Centring Device Ram Inserts

4. Replace the ram insert – 2 x

threaded holes for lifting eyes
are provided in each ram insert
to ease handling
5. Lock the new ram insert with
the lynch pin clip
6. Close and lock the top covers
7. Open ball valve
Centring Device Ram Guides

1. Close the ball valve

2. Disengage the top cover lock
and open the top covers
Centring Device Ram Guides

3. Remove the ram hinge pin

Centring Device Ram Guides

4. Remove the knuckle pin

5. Replace the ram
6. Re-assemble the pins and the
pin retainers – lock-wire the
bolts on the pin retainers
7. Open the ball valve
 Fixed Guides
PS 21 without Centring Device

1. Open the top covers

2. Disconnect the lynch pin from
pin on guide half
 Fixed Guides
PS 21 without Centring Device

3. Change out ram guide halves

4. Re-assemble lynch pin
5. Close & lock top covers
Troubleshooting
 PC-POL Rules

Check that Pressure to the hook-up

P manifold is 2300psi min

Check that all hoses and quick-

C connects are properly Connected
and the ball valve is open

Check that electrical Power is

P available at the control panel

Check for Oil leakage at the

O manifold block, hook-up kit, quick-
connects and hoses

L Check Lubrication of the PS

Pipe Slipping through Inserts

Are teeth Yes

on inserts worn? Replace Inserts

No

Wrong Yes Check/Change-Out

Insert Carriers? Insert Carriers

No

Yes Check/Change-Out
Wrong Inserts?
Inserts

No
Pipe Slipping through Inserts

Slips Not Yes Lack of Grease or

Setting Correctly? Dirt in Slip Cylinder

No

Lack of Slip Yes Check Pressure &

Down-Force? Accumulator
 Slips are Cocking

Wrong Yes Check/Change-Out

Insert Carriers Insert Carriers

No

Yes Check/Change-Out
Wrong Inserts?
Inserts

No

Radial Yes Rotate PS with

Force centre slip toward
On Door Side? deviation

Install Centring
No Device on PS21
 Slips are Cocking

Wrong
Ram Inserts Yes Check/Change-Out
In Centering Ram Inserts
Device?

No

Slips Not Yes 1. Lack of Grease

Setting Properly? 2. Slip Hinge Pins not Greased,
Broken or Badly Assembled
3. Accumulator Faulty
4. Incorrect Ram Sequencing – check
pressure differential
5. Dirt in PS Manifold – flush or clean
6. Incorrect pressure setting on
sequencing valve – 1900psi
7. Dirt in slip cylinder – inspect and
repair as necessary
Slips are Not Fully Retracting

Dirt
between Yes Remove slip and
body and clean slip/body
slips?

No

Excessive Yes
Friction Grease Hinge Pins
on Hinge Pins?

Check
No Torsion Springs
on Hinge Pins

Slip
Cylinder Piston Yes Dirty cylinder
Not Stroking – Inspect & Repair
Fully?

Piston is Loose
No –Inspect & Repair
Slips are Not Fully Retracting

Incorrect Yes Check Pressure

Hydraulic Pressure? From Power Supply
to Hook-Up Kit

Check
In-Line Filters

No
Check
Quick-Connects

Lack of Yes
Lubrication? Grease Slips/Body

Ensure Correct
Grease Distribution
No

Check Grease
System & Outlets
Slips are Not Fully Retracting

Malfunctioning Yes Dirt in

Directional Valve? Hydraulic System

Back-Pressure
Too High
Slips Do Not Move Up or Down

No/Low Yes Set Correct

Hydraulic Pressure? Slips-Up Pressure

Back-Pressure
Too High

Check
Connections

Check
Ball Valve
Slips Sagging when Isolated

Worn
Left Hand Cylinder
Yes Replace
Seals? Piston Seals

No

Malfunctioing Yes Check for Dirt in

Pilot Check Valve? Pilot Check Valve

Defective Valve
– Inspect & Repair
 Inappropriate Signals

HUK
Manifold not Yes 1. Check Quick-Connects
Getting Signal 2. Check Accumulator
From PS? 3. Check In-Line Filters
4. Check Middle Barrel Port on RH
Cylinder
5. Check Piston Seals in RH Cylinder
No – replace if necessary

No Signal
from HUK Yes 1. Dirt in HUK Manifold
Manifold to Pressure 2. Incorrect Setting of SV1 & SV2 –
Switch? Should be 1500psi
3. Back-Pressure on SV1 & SV2 Too
High

No

Malfunction of 1. Dirt Inside Pressure Switch

Pressure Switches
Yes
2. Incorrect Setting Pressure
on HUK?
Switches
3. Incorrect Wiring of Pressure
Switches
 Slip Travel Too Slow

Insufficient Yes 1. Check for Blocked Filter(s)

Hydraulic Pressure? 2. Check Accumulator
3. Check Operation of Sequencing
Valves
4. Dirt in PS Manifold
5. Check Pressure Setting of
No Sequencing Valve – 1900psi
6. Check Pressure to HUK Manifold –
2300psi

Insufficient Yes 1. Check Quick-Connects

Hydraulic Flow? 2. Check Ball-Valve in Slips-Set Hose
3. Check Flow in HUK Pressure Line –
5gpm Min to 10gpm Max
Top Cover Ram Malfunction

Piston Not Yes Check for Dirt

Fully Stroking? In Cylinder

No

Knuckle
on Cylinder Yes Check Assembly
Rod Not of Knuckle
Connected?

No

Leak
From Top Cover
Yes Disassemble &
Hinges? Check Condition
 Insert Carriers Slipping

Insert 1. Dirt Under latches

Carriers Improperly
Yes
2. Lifting Hook Not Seating Properly
Latched?
3. Dirt on Top of Slip
 Difficulty Installing Slips

Center Slip 1. Check for Dirt in Sliding Hole

Mounting Pins
Yes
Inside Centre Slip
Stuck?
2. Check Drain Hole in Sliding Hole
3. Check Greasing of Mounting Pins
4. Check that Pins are Not Bent
5. Check Assembly Procedure
6. Check Function of Ball-Valve in
No Slips-Set Hose

Handles Check Orientation

Preventing
Yes
Of Mounting Pin
Full Retract? Handles
 Insert Carrier Assembly

Yes 1. Clean Carriers Outer Contour and

Build-Up of Dirt? Retainer Slot
2. Clean Slip Inner Contour and
Retainer

No

Bad Fit 1. Remove Burrs from Both

Between Carrier
Yes
Components
& Slip?
2. Check Condition of Slip’s Carrier
Retainer & Replace if Necessary

No

Malfunction of Yes 1. Check Function of Latches on Top

Quick Release? of Slip
2. Check that Lifting Eye on Top of
Carrier Can Move Freely
Inserts Cracking or Breaking

Yes Ensure Inserts

Wrong Inserts? Are Original
Varco Supply

No

Yes 1. Check Sizing of Ram Inserts

Pipe Impact?
2. Check that Bevelled Inserts are
Installed in Bottom Row
 Breaking Lifting Eyes

Have Lifting Eyes Yes 1. Never lift PS with Top Cover ‘L-
Been Overloaded? Bars’
2. Only Use the Dedicated Lifting
Sling
3. Replace the Lifting Eyes
No

Have Lifting Eyes Yes 1. Only Use the Lifting Eyes For
Been Side-Loaded? Hoisting Purposes
2. Replace the Lifting Eyes
 Internal Tubing Leaks

Is Tubing Moving Yes 1. Slip Cylinders May Not Be Properly

During Operation? Attached
2. The PS Manifold May Not Be
Properly Attached to the Body
3. The Top Cover Hinge Blocks May
Not be Properly Attached to the
PS Body
Inspection
 Safety!

Ensure that all hydraulic lines are disconnected

before ANY work is carried out on the PS-21/30
 Welding!

You MUST
NOT weld on the PS
21/30 body or any of its components
 Hinge Pin Wear

PS 21 PS 30
New Bore Max Ø 2.380” 3.005”
New Pin Max Ø 2.365” 2.990”
Worn Bore Max Ø 2.405” 3.030”
Total Clearance ‘A’ 0.050” 0.050”

Bore
Wear
Bore Wear – Paper Test

Full Contact
Determine bore by making a paper
print:
1. Connect the PS to the power unit
2. Dress the PS with NON-WORN slips
and clean NON-WORN inserts
3. Wrap waterproof paper around the
clean insert mark free section of
pipe
4. Clamp the slips using 2500psi
Top Contact

power down pressure

 Bore Wear - Evaluation

Full Insert Contact?

Yes PS & Slips
Are Good

No

Insert Yes Replace Slip

Contact on Top? & Re-Test

No

Full Contact?
Yes Return Slips
to Service

No

Remove Slips
PS Bowl is Worn
From Service
Repair
 Disassembly

Prior to disassembly of the PS, thoroughly

clean the unit with a steam-cleaner in order to
prevent the disassembled parts from becoming
contaminated with dirt, mud etc
Disassembling the Cylinders

1. Disengage the top cover lock

and open the top covers
Disassembling the Cylinders

2. Ensure that the Lift Levers are

at approx. 45º
3. Disconnect all 3 x hydraulic
tubes from the right hand
cylinder – do not remove this
tubing from the manifold block
Disassembling the Cylinders

4. Remove all 4 bolts that

connect the cylinder barrel to
the cylinder gear box
Disassembling the Cylinders

5. Gently slide the barrel up until

the barrel parts from the piston
 No excessive force should be
needed to remove the barrel
 Turning the barrel while sliding
up should help ease
disassembly
Disassembling the Cylinders
Bevelled

6. Check the configuration of the

barrel
 If the barrel has an internal
bevelled shoulder, the cylinder
gear box does not have to be
removed from the PS body in
order to re-assemble the
Square barrel later
 If the barrel has an internal
square shoulder, the cylinder
must be removed from the PS
body in order to reassemble
the barrel
 Replacing the Piston

1. Check if the existing piston is

secured to the piston rod by
means of a set screw
2. Loosen this set screw if
applicable
3. Unwind the piston from the
piston rod
4. Assemble the new piston
New Photo
5. Secure the piston to the rod by
means of the set screw –
inserting a nylon pellet below
the set screw
6. Insert the NPT plug on top of
the set screw
7. Check that the NPT plug is
below the piston contour
 Replacing the Seals

1. Inspect the seals for any

damage and/or scoring
2. Warm the 2 x white outer rings
in hydraulic oil (65°C)
3. Assemble the 2 x half moon
rings (delivered together with
replacement seals) in the top
seal groove
New Photo
4. Assemble the O-ring and white
outer ring – the outer ring
needs to be stretched gently
BY HAND over the taper on the
piston and into the bottom seal
groove
5. Remove the 2 x half moon
rings and assemble the top
seal
Reassembling the Barrel

1. Always fit the barrel BY HAND –

never tap the barrel down with
a hammer as this will damage
the seals
2. Turning the barrel fitting will
help to ease assembly
3. A special piston assembly
bushing is required in the case
that the barrel has an internal
square shoulder
4. Secure the barrel to the
cylinder gear box by means of
the 4 x bolts – assemble and
torque the bolts and lockwire
 Assembling the Levers

Ensure that the V-mark on the levers is lined up with

the V-mark on the cylinder spline shaft
Installing the Cylinders

1. Install the hydraulic cylinders

without tightening the bolts
Installing the Cylinders

2. Slide the synchronisation shaft

through both cylinders
Installing the Cylinders

3. Assemble the 4 x bolts and

washers in the back
4. Torque to 185ft.lbs (250Nm)
 Installing the Cylinders

After bolts are tight, check

alignment of the 2 x cylinders by tapping
the synchronisation shaft with a rubber
mallet
The shaft must be tight but not clamped
Assembly of Hoisting Rings

Loads may slip or fall if improper hoist ring assembly

and lifting procedures are employed
A falling load may cause serious injury or death
Ensure that spacers (washers) are NOT used
between the flange and mounting surface
Always be sure threads on shank and holes are
clean, not damaged and fit properly

New Photo
Assembly of Hoisting Rings

APPLY LOCTITE NO. 243 TO THE THREADS

Torque: 2500lbs SWL hoist ring = 28 ft.lbs
Torque: 5000lbs SWL hoist ring = 100 ft.lbs
After installing, always ensure that the bail
is free to pivot 180º and swivel 360º

New Photo
Assembly of the Manifold Block

1. Put the manifold in position

 PS 30 – Use liquid gasket
 PS21 – Use an o-ring

2. Torque and lock-wire the

securing bolts
Assembly of Cover Hinge Pins

It is of utmost importance that the

cover plate hinge pins are properly assembled to ensure
proper functioning of the centring device
Clean the pin and hinge boss hole and
remove any sharp burrs that might damage the
seals during assembly
Clean the seals
Assembly of Cover Hinge Pins

1. Apply a grease coating to all

pin surfaces
2. Assemble the o-rings, backup
rings, lip seals and spacer rings
 Assembly of Cover Hinge Pins

3. Apply a coating of grease to all

hinge boss holes
4. Carefully insert the pin – taking
care not to damage the seals

New Photo
 Assembly of the CD Cylinder

1. Ensure a 0.125" clearance

between the knuckle and the
piston rod shoulder

New Photo
Questions?

?
End of Training Programme

Thank You!