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Blohm + Voss Oil Tools, LLC 9PU-7200 HYDRAULIC POWER UNITTechnical Documentation
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GENERAL INFORMATION
Warnings and Notes
WARNING: A “WARNING” INDICATES A DEFINITE RISK OF EQUIPMENT DAMAGE OR DANGER TO PERSONNEL. FAILURE TO OBSERVE AND FOLLOW PROPER PROCEDURES COULD RESULT IN SERIOUS OR FATAL INJURY TO PERSONNEL, SIGNIFICANT PROPERTY LOSS, OR SIGNIFICANT EQUIPMENT DAMAGE.
NOTE: A “NOTE” indicates that additional information is provided about the current topics.
Intended use of this manual
WARNING: THIS TECHNICAL DOCUMENTATION CONTAINS INSTRUCTIONS ON SAFETY, INSTALLATION, OPERATION AND MAINTENANCE. IT MUST BE STUDIED BEFORE WORKING WITH THE TOOL.
CE Marking
The tool complies with the Machinery Directive 2006/42/EC and the Directive 94/9/EG “Equipment and protective systems in potentially explosive atmospheres”The marking is as follows:CE Ex II 2G T5
Patents
The following patent numbers apply:U.S. 11/404,317U.S. 11/890,582U.S. 11/732,813
Limited Warranty
The warranty provided will be void if the HPU is:
1. Repaired or serviced by a service facility which was not authorized by Blohm + Voss Oil Tools, LLC.
2. Replacement parts not manufactured by Blohm + Voss Oil Tools, LLC are used.
3. Modifications were made to the Hydraulic Power Unit which were not approved by Blohm + Voss Oil Tools, LLC.
Manufacturer & Agents World Wide
This manual is intended for use by field service, engineering, installation, operation, and repair personnel. Every effort has been made to ensure the accuracy of the information contained herein. Blohm + Voss Oil Tools, LLC, will not be held liable for errors in this material, or for consequences arising from misuse of this material.Anyone using service procedures or tools, whether or not recommended by Blohm + Voss Oil Tools, LLC, must be satisfied that neither personal safety nor equipment safety will be jeopardized.
Intellectual property
All rights retained. No part of this document may be reproduced in any form (print, photocopy, microfilm or any other procedure) or be processed using an electronic system without written approval of Blohm + Voss Oil Tools, LLC
All information contained in this manual is based upon the latest product
information available at the time of printing. Dependent on ongoing technical improvements (ISO 9001) “Blohm + Voss Oil Tools, LLC” reserves the right to change the design and specifications without announcement. The values specified in this manual represent the nominal values of a unit produced in series. Slight deviations in the case of the individual devices are possible.
General remarks
As with all rig equipment, the HPU must be operated in accordance with accepted rig safety practices and procedures. All operators should be familiar with all safety precautions and recommended installation and operating procedures, including the information provided in this manual and any other safety publications by Blohm + Voss Oil Tools, LLC Listed on the next page are safety considerations and warnings found throughout this manual.
Blohm + Voss Oil ToolsHermann-Blohm-Straße 220457 Hamburg, Germany
Phone: +49(0)40/3119-1826/1162 Fax: +49(0)40/[email protected]
Premier Sea & Land Pte. Ltd.Shaw Centre 1 Scotts Road #19-12
228208 Singapore Republic of Singapore
Phone: +65-6734-7177Fax: +65-6734-9115
Blohm + Voss Oil Tools, LLC7670 Woodway, Suite 266
Houston, Texas 77063United States of America
Phone: +1-713-952-0266Fax: +1-713-952-2807
[email protected] www.blohmvoss-oiltools.com
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Safety issues
WARNING: ONE SHOULD AVOID CREATING IGNITION SOURCES, LIKE HEAT, AS A RESULT OF THE USE OF THE TOOL WITH OTHER TOOLS OR EQUIPMENT.
WARNING: THE WARNING PLATES, SIGNS AND LABELS MUST BE PRESENT ON THE TOOL. DO NOT REMOVE THE LABELS. IF THEY ARE MISSING, REPLACING IS MANDATORY.
WARNING: ALL WARNING PLATES, SIGNS AND LABELS ATTACHED TO THE EQUIPMENT MUST BE OBSERVED.
WARNING: DO NOT USE THE TOOL FOR ANY OTHER PURPOSE THAN MAKING UP AND BRAKING OUT WITHIN ITS SPECIFICATION.
NOT RE-USE THEM. ALWAYS REPLACE THEM WITH NEW SAFETY ELEMENTS.
WARNING: KEEP HANDS AND ARMS CLEAR OF ALL MOVING PARTS WHEN CONNECTING, DISCONNECTING OR OPERATING THE UNIT.
WARNING: ALWAYS WEAR PROTECTIVE GEAR FOR EYES, HEAD, HANDS AND FEET.
WARNING: WHEN SERVICING UNIT, BE SURE ALL POWER IS OFF AND SUPPLY LINES ARE DISCONNECTED AND INTERNAL PRESSURE IS BLED FROM THE TOOL.
WARNING: LUBRICATE UNIT ONLY WHEN SUPPLY LINES ARE DISCONNECTED. VERIFY THAT SYSTEM PRESSURE IS -0- PSI.
WARNING: ALWAYS USE LIFTING APPARATUS (SLINGS, CABLES, SHACKLES AND THE LIKE) THAT HAVE BEEN INSPECTED AND ARE IN GOOD CONDITION AND ARE PROPERLY SIZED. ENSURE THAT ALL RIGGING AND LIFTING PROCEDURES ARE IN ACCORDANCE WITH ACCEPTED OILFIELD PRACTICES AND STANDARDS.
WARNING: ALWAYS CHECK THE UNIT FOR LOOSE FASTENERS AND HYDRAULIC CONNECTIONS AS WELL AS ANY OTHER DAMAGE PRIOR TO TURNING ON THE POWER UNIT.
WARNING: FAILURE TO CONDUCT ROUTINE MAINTENANCE COULD RESULT IN EQUIPMENT DAMAGE OR INJURY TO PERSONNEL.
WARNING: THE TOOL MUST ONLY BE SERVICED BY TRAINED BLOHM + VOSS PERSONNEL OR BY AUTHORIZED PERSONNEL.
WARNING: WEAR PERSONAL PROTECTION EQUIPMENT WHILE WORKING WITH THE EQUIPMENT.
WARNING: IF ANY SAFETY ELEMENTS (LIKE SAFETY ROPES, WIRE, SAFETY SHEETS, PLATES OR WASHERS) WERE DISASSEMBLED DUE TO MAINTENANCE WORK, DO
Revision History TableREV. SECTION SUB-SEC. PARA. CHANGE REQUEST # DATE AUTHORIZED BY
Draft All All All N/A 10/01/10 KJ
0 All All All N/A 03/19/12 KJ
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TABLE OF CONTENTS
Revision History Table 3
TABLE OF CONTENTS 4DESCRIPTION 6General Components 7Motor 7Hydraulics 7Tank 7Filters 7Cooler/Heater 8Explosion Proof Box 8Location of Identification Tag 8Frame 8Controls 8Specifications 9Hydraulic Specifications 9Shipping Data 9
COMMISSIONING 10FloorHand Commissioning Procedure 12
INSTALLATION 15Lifting 16Electrical 16Attaching the Hydraulic Lines 17Filling the Reservoir 17
OPERATIONS 18The Pumps 19Start-Up Procedure 20Troubleshooting 22HPU will not power up. 22HPU powers up, but will not build pressure. 23
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MAINTENANCE & INSPECTION 24Electric Motor 25Reservoir 25Filters 25Hydraulic Oil Quality 26Primary Hydraulic Oil 26Frequency 27Inspection 27Lubrication 27Hydraulic System Inspection 27Dismantling Inspection 27
SPARE PARTS 28Recommended Spare Parts for One Year Operation 29
DRAWINGS 30HYDRAULIC POWER UNIT 9PU7200 31MOTOR 9PU-8023 32TEMPERATURE SWITCH 9PU-8018 33ELECTRICAL BOX 9PU7210 34COOLER 9PU-8020 35SUCTION LINES 36FILTRATION 37FLOORHAND COMPLETE HYDRAULIC SCHEMATIC 38ELECTRICAL SCHEMATIC 39HYDRAULIC SCHEMATIC 40
INDEX 41
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DESCRIPTION
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General Components All components of the Hydraulic Power Unit are mounted within a rugged but lightweight frame. The components are mounted with consideration for easy access during operation, maintenance and repair.
The Hydraulic Power Unit utilizes a pressure compensated hydraulic pump close-coupled to an electric motor. When the Hydraulic Power Unit is in operation, it supplies a constant pressure but varies the flow rate depending on the requirements of the FloorHand. Attached to the end of the pump is a separate circulation pump, which constantly circulates tank oil through the cooler and return filter.
Temperature control is factory set depending on the operating environment and the requirements of the customer. Typically, for use with moderate to high ambient temperature environments, a radiator type cooler with a thermostatically controlled fan is installed. For use in cold weather environments, an anode type heater with integral thermostat is installed.
MotorThe motor on the 9PU7200 Hydraulic Power Unit is a TEFC (totally enclosed, fan cooled), 3 Phase Motor, explosion proof motor. This power required would be 50 amps, 440 volt, 3 phase. The motor provides 40hp at 60 Hz.
HydraulicsThe hydraulic system on the power unit has an operating flow of 2,500 psi (175.81 kg/cm) with a maximum operating pressure of 3,400 psi (239.10 kg/cm). The flow is 26 GPM or 98.42 LPM.
TankCapacity of the tank is 100 gallons. The power unit is equipped with a level sensing switch in the reservoir. If the level gets too low, the switch will cause the hydraulic power unit to shut off. Conventional petroleum based hydraulic fluid is usually specified but care should be taken to ensure that it is compatible with the environment it will be operated in, particu-larly the ambient temperature range.
FiltersBecause of the vital importance of CLEAN, FILTERED HYDRAULIC OIL to the operation and longevity of all components in the FloorHand System, the hydraulic power unit utilizes
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suction strainers as well as pressure and return filters.
Cooler/HeaterDepending on your location, Blohm+Voss will have either an oil cooler or a heater built into the unit.
Explosion Proof BoxThe electical system on the hydraulic power unit is a self contained and requires only a power connection between the motorstarter box and the rig generator house or other appropriate electric power source.
Location of Identification TagAn Identification tag can be located on the base near the front left forklift slot.
FrameThe frame of the Power unit is an Oilfield skid with a crash frame & lift eyes.
ControlsThe controls are hosed in a Remote Start/Stop Station With Lights,
Figure 1
Figure 2
Figure 3
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SpecificationsHydraulic SpecificationsHydraulic pressure:Operating: 2,500 PSI (17,236 kPa)Maximum: 3,400 PSI (23,443 kPa)
Hydraulic flow: Operating: 26 GPM (98.42 Liters) Pressure Line Connection: 1” Male JICReturn Line Connection: 1 1/4” Male JICElectrical Horsepower: 40 HP @ 60 HzElectrical power required: 50 amps, 440 volt, 3 Phase
Pressure and Return Filters: 10 Micron
Shipping DataHeight (without flanges) 60 inches (152.4 cmWidth 50 inches (127 cm)Depth 60 inches (152.4 cm)Weight 2174 lbs (988.18 Kgs)
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COMMISSIONING
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Document Front Page
0 11/04/2010 FloorHand Shop Test/ Commisioning Procedure DT CT MT
Draft 10/28/1020 Issued DT CH MT
Rev./Status Date Description Made by Checked By: Approved:
Suppiler References:
Procurement References:
TAG No:
Date: Signature: SDRL Code: Area: System: Pages: Encl:
Company: Document Title/ Equipment:
Commissioning Check Sheet for FloorHand (Iron Roughneck)
Rig/Vessle/Customer Order: Equipment Serial No:
Supplier:
Blohm + Voss Oil Tools, LLCDocument No:
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FloorHand Commissioning ProcedureThis test procedure is to be performed by authorized B+V personnel only!
Note: When performing the following steps, appropriate PPE will be used and standard safety practices must be followed at all times.
Note: When commissioning, H.P.U Commissioning must be completed prior to FloorHand commissioning. If installing FloorHand to customer supplied hydraulics, hoses must be flushed completely before connecting to FloorHand.
1. ___ConnectFloorHand(usingflowmeter)toHydraulicpowersourceof2,500-2,800psiand25-28gpm.Ifpressureisabove2,800psi,aPressureReleaseValve(PRV)shouldbeused._____Ifflowrateisabove28gpm,apressurecompensatedflowcontrol should be used.______
2. ___H.P.Ushouldbepoweredupaminimumof20minutesbeforemovingtonextstep, to bring all oil to required operating oil temperature, record oil temp._________
Note: Throughout entire test, observe FloorHand for leaks, and or malfunctions, repair as necessary.
3. ___ Run spinner motors in make direction for 20 seconds, check that rotation of all fourrollersarecorrect,checkforleaks.Monitorflowmeter,recordmaxflow.________See step 1.
4. ___ Run spinner motors in break direction for 20 seconds, check for leaks. Note: After making fresh hydraulic connections, or a rig move, it is best to always run the spinner before anything else. The spinner is the only system that is close to a direct system. For example, there are no PRV’s, check valves, shuttle valves, diverter valves, pilot operated check valves, etc. in the spinner motor system, only a flow divider. This means, by running the spinner first, any small trash or contaminants that may be in the lines, will be flushed through with minimal to no damage. If there were trash in the lines, and the torque, or clamp system were operated first, there is a chance of contaminants getting lodged in a small orifice, in one or more of the many valves in the other systems.
5. ___Withoutpipe,clampandunclamplowerwrench10times,checkthatdieblocksextendandretractevenly,checkforleaks.
Note: This helps to remove air from the lower clamp system so that the flow divider may work correctly.
6. ___Withoutpipe,clamplowerwrench.7. ___Clampandunclampupperwrench10times,checkthatdieblocksextendand
retract evenly, check for leaks.8. ___Unclamplowerwrench.9. ___ Without pipe, clamp and unclamp spinner 10 times, check for leaks. Note: spinner may, or may not close evenly, this is normal.
10. ___Backtorqueadjustmentknoboutcompletely,thenturnin(clockwise)4turns,Blohm + Voss Oil Tools, LLC.
11. ___ Actuate torque cylinder 10 complete strokes in each direction and check for leaks.
12. ___Adjustmakeupspeedflowcontrolfora5secondstroke.Verifyduringcommissioning.
13. ___Installtestgaugeonlowerclampcylinderoutboardtestport.14. ___Clamplowerwrench.15. ___Observethetestgaugeonlowerwrenchclampcylinder,andPressureRelease
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Valve (PRV) if applicable.16. ___SetPressureReleaseValve(PRV)outputtoobtain600psiatlowerclamp
cylinder. Verify during commissioning.17. ___Clampupperwrench,ensurethatsystempressureisnowpresentonlower
clampcylindersalso(PRVreadingshouldnotchange),unclampupperwrench,unclamplowerwrench.
18. ___Mockuptestpipe,withtorque,atendofstroke,checkthatgaugedumpvalvefunctions correctly.
19. ___Stallspinnerinmakedirectionandholdfor5secondsandcheckforleaks.20. ___Stallspinnerinbreakdirectionandholdfor5secondsandcheckforleaks.21. ___Operatemanipulator/liftcylinderfullup&down10timestoremoveallairfrom
cylinderandcounterbalancevalve,checkforleaks.Ifcommissioning,informrigcrewthatthisshouldbedoneaftereveryrig-up.
22. ___ Raise manipulator / lift cylinder to mid stroke, check that counterbalance valve holds.
23. ___Ifapplicable,extendandretractmanipulatorfulloutandin5times,checkforproper function, check for leaks.
24. ___WARNING:Clamplowerwrench,verifythatmanipulatorfunctionsdonotoperate.
25. ___Unclamplowerwrench.26. ___ Connect test gauge to return system test port, run spinner motors and hold
whilecheckingpressurefilterbypassindicator(ifapplicable),andmonitoringsystembackpressure,nottoexceed250psi.Recordbackpressure________
27. ___ If applicable, check shutoff valve for proper function.28. ___ Remove test gauges, and reattach the cap ports.29. ___ Install any panels / covers removed for test.30. ___ Ensure rig personnel fully understand all functions and basic maintenance of
the FloorHand, including but not limited to: Importance of keeping fresh dies installed, propermakeuptorqueadjustment,properbreakoutprocedure.Demonstratehowtoremoveandinstallthefollowing:Dies,dieblocks,anddriverollers.
Tech: ________________________________________Signature: ____________________________________Date: ________________________________________
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Name: Areas of Training:
(Lubrication/Frequency/PM,etc.)
Signature: Date:
My signature above indicates that I have read and understand the opening instructions and have been trained to use the above machine by Blohm + Voss Oil Tools, LLC Technicians.
Technician:
Signature:
Date:
Record of Training
AcknowledgementofRigSuperintendant/ToolPusher Date
Name Signature
My signature above indicates acceptance of commissioning and the above personnel training.
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INSTALLATION
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LiftingThe Hydraulic Power Unit frame incorporates lifting lugs on the uppermost corners of the frame. The unit should always be lifted using a four point sling with equal length legs, one leg of the bridle attached to each of the brackets.
The hose basket and lifting frame is designed to support hoses and cables with a combined weight not to exceed 250 lbs.
ElectricalThe electrical system on the Hydraulic Power Unit is self contained and requires only a power connection between the motor starter box and the rig generator house or other appropriate electrical power source.
Figure 3
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Figure 4
Before connecting the Hydraulic Power Unit to the electrical power source, it is imperative that the supply voltage be verified to be compatible with the electrical motor on the hydraulic power unit.
All electrical connections should be made by a licensed electrician in accordance with the appropriate electrical codes and standard industrial safety practices.
Attaching the Hydraulic LinesRemove cap or plug and ensure that mating parts of the hydraulic connection are clean and free from dirt or other contaminants. Carefully thread the connection together and tighten appropriately.
Filling the ReservoirThe reservoir is filled via the breather connection on the top of the reservoir. Conventional petroleum based hydraulic fluid is usually specified but care should be taken to ensure that it is compatible with the environment it will be operated in, particularly for the ambient temperature range.
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OPERATIONS
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The PumpsThere are two pumps incorporated with the Hydraulic Power Unit.
The first pump is a large pressure compensated hydraulic pump. Essentially, it is one that senses outlet pressure and adjusts displacement accordingly. The pump has a 3/4” case drain with no restriction. The pump has its own bypass-able, inlet strainer and ball valve. This pump has a pressure filter downstream of the pump outlet. After the filter, there is a check valve. Both the filter and the check valve are inline before reaching the power unit bulkhead. FloorHand oil is strained, pumped, filtered, used, cooled, then filtered again, prior to returning to the tank.
The second pump (a circulation gear pump) is a small gear type pump that also has its own suction strainer and valve and uses the meshing of gears to pump fluid by displacement. The strainer on this pump is also bypass-able. The sole purpose of this pump is to circulate oil through the cooler and return filter even when the FloorHand is not being used. The small pump strains fluid from the tank and then sends the fluid to the cooler. From the cooler the fluid is then pumped through a return line filter and back to the tank.
There is a small amount of oil that is not filtered prior to returning to the tank. This is oil that is taken from a small port on the outside of the cooler to flow over the temperature probe. The fluid is not run through the filter as to not cause any restriction. There is a free flow of fluid over the probe then to the tank to keep an accurate temperature readingThe explosion proof temp switches will vary slightly, they normally turn the fan on between 123 and 130 °F (50.5 and 54.4 °C) and then they cool the oil for a drop of 15-20 °F (-9.4 to -6.6 °C) before turning off.
Figure 5
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Start-Up ProcedureVerify that the main suction inlet ball valve and circulation pump inlet ball valve are in the open position.
Verify that the compensator control ball valve is in open position. Verify that the main pump case is filled with oil. The Hydraulic Power unit has been operated, tested and adjusted at the factory for use with the FloorHand Wrench and Spinning Tool. Transportation require-ments are such that the pump must be drained. Once the unit has been delivered, The pump will always need to be primed.
Loosen a fitting in the main hydraulic pump discharge line to allow the air to be bled during the priming procedure. When oil is present at the loosened coupling, and the line is free of air, the coupling may be retightened.
Remove the plastic cover that shields the motor coupling.
Jog the motor once (DO NOT ALLOW THE PUMP TO RUN AT THIS TIME) and verify that the direction of the rotation of the motor is consistent with the directional arrow tags on the motor. If the direction is incorrect, have the electrician correct the motor wiring and recheck.
Replace the plastic cover that shields the motor coupling.
Jog the motor three to six more times to ensure priming of the pump.
Start the motor and allow the pump to run with the compensator control ball valve in the open position for several minutes. Once the unit has been unloaded, inspect the unit for leaks and correct as needed.
Slowly close the compensator control valve and verify that system pressure is 2,650 PSI.
While running the FloorHand spinner motors, check the pressure filter indicator and the return line filter indicator to ensure that they are not operating in the “BYPASS” mode. Replace the filter elements as required.
After the FloorHand and the manipulator have been cycled to ensure that the entire system is filled with fluid, top off the reservoir to the correct operating level.
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Note: Pressure and return filters are 10 micron. Both filter housings are equipped with filter cleanliness/bypass indicators. The power unit incorporates a low oil level shut off switch, with sight glass (maximum capacity, 110 gallons). DO NOT FILL COMPLETELY.
WARNING: MANUALLY OVERRIDING THE LOW OIL LEVEL SHUT OFF SWITCH BY HOLDING IN THE CONTACTOR WILL BURN-OUT THE CONTACTOR, THUS VOIDING ANY WARRANTY ON ELECTRICAL COMPONENTS.
The Hydraulic Power Unit is equipped with an explosion proof remote start/stop station to be located within easy reach of the driller. After the initial installation/start-up procedure, the Hydraulic Power Unit is normally started and stopped using the buttons on the remote start/stop station.
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Is the Power Supply to the HPU on?
Have a licensed electrician bypass the
low oil level shut off and test. Replace if necessary. Does
the problem persist?
Check the HPU oil level. Is the unit showing
atleast 3/4 full in the sight glass?
HPU is equipped with a low oil shut off
switch.SEE WARNING.
Continue Operation.
Check that the cords are connected and turn on the
breaker.
Fill the HPU to minimum 3/4 up the sight glass.
Have a licensed electrician troubleshoot the main contactor or
contact Blohm + Voss Oil Tools LLC.
Yes
NoNo
Yes
Yes
START
HPU will not power up.
No
Troubleshooting
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Is HPU CompensatorValve closed?
Close the compensator valve. Is the pressure required
present?
With HPU Lines capped and HPU
running alone, is pressure required Present at
HPU?
Is the HPU connected to any
equipment with open centered valving?
Isolate hpu from the rest of the system and run
independently.
Disconnect HPU from any open centered equipment
and cap lines.
The problem is downstream of HPU. Pressure is being lost through equipment.
Suction strainers inside tank should be replaced prior to any pump / compensator service. Other filters should be checked for
serviceability.
It is possible that the pump is worn out, or trash is clogging one or more ports in the
compensator. Please contact Blohm + Voss service for further Instructions.
Yes
Yes
Yes
Yes
START
HPU powers up, but will not build pressure.
No
No
No
No
Continue Operation.
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MAINTENANCE & INSPECTION
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Electric MotorThe Electric motor should be lubricated as indicated by the motor manufacturer. Grease zerks are installed, do not over lubricate.
ReservoirThe fluid level in the reservoir should be checked. If the level is low, return fluid to its normal operating range. The fluid should be changed after the initial 10 hours of operation and every 100 HOURS thereafter.
FiltersThe Hydraulic Power Unit is equipped with two suction strain-ers and one low pressure return filter as well as a high pres-sure filter. Each filter is equipped with a visual indicator, the element should be changed when the indicator shows that the filter is approaching “BYPASS” mode. Low pressure strainers without visual indicators should be changed after the initial 10 hours of operation and every 100 hours thereafter.
Note: It is recommended that the filters and strainer elements be changed whenever the FloorHand is put back into service after overhaul.
Note: It is important to monitor the filters during the initial start-up and during the break-in period.
Note: Indicators must be checked while Spinner motors are running.
Figure 8
Figure 7
Figure 6
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Hydraulic Oil QualityBVOT recommends a mineral based hydraulic oil, ISO 68 or equivalent for primary use in temperature ranges between 65° - 95° F (18° - 35° C). For environments above or below this range, consult the chart below to select an appropriate substitute.
Primary Hydraulic OilChevron Regal® R&o ISO 220-ISO 680Shell Tellus® Oil Premium 68
Multipurpose grease, e.g.:Retinax Grease LX2 Shell Alvania RL 3Aviaticon XRF NLGI 0
Alternatively; use EP gear lubricating grease for greasing ”non-oil tight gear trains”NESSOS SF0NLGI 0DIN 51 826 GPOF-25DIN 51 502 GPOF-25
Figure 9
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WARNING: ALWAYS TURN OFF THE HYDRAULIC POWER UNIT; DISCONNECT THE HYDRAULIC LINES AND TAG OUT THE H.P.U CONTROL BEFORE LUBRICATING THE FLOORHAND. FAILURE TO DO SO MAY CAUSE INJURY TO PERSONNEL OR DAMAGE TO THE EQUIPMENT.
FrequencyInspectionA thorough inspection should be carried out periodically (every 3 months) or as special circumstances may require. Before starting an inspection disconnect hydraulic system and remove all foreign materials (dirt, paint, grease, oil, scale, etc) from surface by a suitable method. After a field inspection, it is advisable to record the extent of testing and testing results. A periodic load inspection may be conducted in the field. If cracks, excessive wear etc are recognized, contact Blohm + Voss Oil Tools, LLC or an authorized service company.
LubricationThe 9PU7200 Hydraulic Power Unit should be inspected and greased each week. For higher ambient temperature up to 86° Fahrenheit (30° Celsius) we recommend to use NLGI grade 2. (See Figure 57).
Hydraulic System InspectionCheck for leakage every day. If an internal or external leakage reaches an unacceptable level, contact Blohm + Voss Oil Tools, LLC or an authorized service company.
Dismantling InspectionGenerally, when the equipment returns to base, warehouse, etc carry out the tool inspection, immediately. Furthermore, repair it if necessary prior to it being sent on the next job. The tool should be dismantled and inspected in a suitably equipped facility for excessive wear, cracks, flaws or deformations. Corrections should be made in accordance with recommendations which can be obtained from Blohm + Voss Oil Tools, LLC.
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SPARE PARTS
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Part number Description Qty.9PU-8006 DRIVE COUPLING 1
9FH-01152-7 HPU MAIN SUCTION STRAINER 2
9FH-01152-8 HPU CIRCULATING SUCTION STRAINER 2
9FH-01152-6 HPU RETURN FILTER ELEMENT 2
9FH-01152-4 HPU PRESSURE FILTER ELEMENT 2
9PU-8003 GAUGE 1
9PU-8005 COVER 1
9PU-7220 HPU HOSE & FITTING KIT 1
Recommended Spare Parts for One Year Operation
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DRAWINGS
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HYDRAULIC POWER UNIT 9PU7200
Item Part number Description Qty.1 N/A SUCTION LINES 12 N/A FILTRATION 13 9PU-8023 MOTOR 14 9PU-8018 TEMPERATURE SWITCH 15 9PU7210 ELECTRICAL BOX 16 9PU-8020 COOLER 1
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Item Part number Description Qty.21 9PU-8023 EXPLOSION PROOF MOTOR 122 9PU-8004 PUMP MOTOR ADAPTER 123 9BN0115311 HEX HEAD CAP SCREW 424 9BN1133897 SPLIT LOCKWASHER 425 9PU-8006 DRIVE COUPLING 126 9PU-8016 PRESSURE COMPENSATED HYD PUMP 127 9BN0115210 HEX HEAD CAP SCREW 428 9BN1133895 SPLIT LOCKWASHER 430 9BN0115107 HEX HEAD CAP SCREW 231 9BN1133893 SPLIT LOCKWASHER 232 9PU-8003 GAUGE 133 9PU-8005 COVER 134 9BN0115315 HEX HEAD CAP SCREW 435 9BN1133897 SPLIT LOCKWASHER 436 9BN1133819 SAE FLAT WASHER 451 9FH-01018-11 FLOORHAND S/N TAG 152 9BN41203 RIVET 4
Figure 12
MOTOR 9PU-8023
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SFigure 13
Item Part number Description Qty.41 9FH-01402 HPU TEMP SWITCH MOUNT BRACKET 142 9PU-8018 EXPLOSION PROOF TEMP SWITCH 143 9FH-01401 HPU TEMP SWITCH MANIFOLD 144 9BN0115005 HEX HEAD CAP SCREW 345 9BN1133857 FLAT WASHER 646 9BN1137183 NYLON LOCK NUT 3
TEMPERATURE SWITCH 9PU-8018
34
DR
AW
ING
S Figure 14
Item Part number Description Qty.55 9PU-7210 EXPLOSION PROOF 156 9BN0115211 HEX HEAD CAP SCREW 457 9BN1133861 FLAT WASHER 458 9BN1137187 NYLON LOCK NUT 4
ELECTRICAL BOX 9PU7210
35
DR
AW
ING
S
Figure 15
Item Part number Description Qty.37 9PU-8020 EXPLOSION PROOF COOLER 138 9BN0115107 HEX HEAD CAP SCREW 639 9BN1133815 SAE WASHER 1240 9BN1137185 NYLON LOCK NUT 6
COOLER 9PU-8020
36
DR
AW
ING
S
Figure 10
Item Part number Description Qty.1 9PU-7100FRM HYDRAULIC POWER UNIT FRAME 12 9AF3X2B BUSHING 13 9AF2XCLN CLOSE NIPPLE 14 9FH-01152-7 HPU MAIN SUCTION STRAINER 15 9AF1X34B BUSHING 16 9AF34X2N NIPPLE 17 9FH-01152-8 HPU CIRCULATING SUCTION STRAINER 18 9AF2XCLN CLOSE NIPPLE 19 9AF2S90 STREET 90° 110 9PU-8008 BALL VALVE 111 9PU-8009 BALL VALVE 112 9HC12HHP COUNTERSUNK PLUG 113 9PU-8019 EXPLOSION PROOF LEVEL SWITCH 1SP3 9FH-01152-7 HPU MAIN SUCTION STRAINER 2SP4 9FH-01152-8 HPU CIRCULATING SUCTION STRAINER 2
SUCTION LINES
37
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Figure 11
Item Part number Description Qty.14 9PU-8021 EXPLOSION PROOF SIGHT GLASS 115 9PU-8017 OIL PROBE THERMOMETER 116 9PU-8010 FILTER BREATHER 117 9PU-8002 RETURN FILTER AND HOUSING 118 9BN0115003 HEX HEAD CAP SCREW 2819 9BN1133857 FLAT WASHER 2820 9PU-8013 BALL VALVE COMPENSTOR 129 9PU-8007 SECONDARY GEAR PUMP 137 9PU-8020 EXPLOSION PROOF COOLER 147 9PU-8012 PRESSURE FILTER AND HOUSING 148 9BN1123419 SOCKET HEAD CAP SCREW 449 9BN1133861 FLAT WASHER 450 9BN1137187 NYLON LOCK NUT 453 9PU-8015 CHECK VALVE 154 9PU-8090 TANK LID SEAL 13SP1 9FH-01152-4 HPU PRESSURE FILTER ELEMENT 2SP2 9FH-01152-6 HPU RETURN FILTER ELEMENT 2
FILTRATION
38
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Figure 16
FLOORHAND COMPLETE HYDRAULIC SCHEMATIC
9FH-01142-1SPINNER DRIVE MOTORS
TORQUE CONTROL VALVE
MAKEUP SPEED CONTROL
9FH-01151TORQUE MANIFOLD
UPPER CLAMP CYLINDERS9FH-0174-2
SHUTTLE VALVE9FH-01149-9
DIVERTER VALVE CARTRIDGE
9FH-01149-11
LOWER CLAMP CYLINDERS
9FH-01074-2
LOWER CLAMP FLOW DIVIDER9FH-01152-1
PRESSURE REDUCING VALVE SET TO 600 psi
9FH-01149-8
TO INLET SUPPLY OF MANIPULATOR OR LIFT
VALVE
UPPER CLAMP FLOW DIVERTER
VALVE MANIFOLD9FH01150
FILE: FH-HS-10017.DWGDATE: 17JUL2011
UPPER WRENCH CLAMP VALVE
LOWER WRENCH CLAMP VALVE
SYSTEM PRESSURE GAGUGE9FH-01152-10
HYDRAULIC RETURNHYDRAULIC SUPPLY
RELIEF VALVE IS PART OF MAIN CONTROL
VALVE9FH-01149-1
MAIN CONTROL VALVE RELIEF VALVE
SET TO 2500 psi
GAUGE DUMP VALVE(SEE NOTE)
NOTE: ALL RETURN LINES CONNECT TO RETURN MANIFOLD
FIXED.031" DIA.
TORQUE CONTROL ADJUSTMENT
DUMP VALVE
SPINNER CONTROL VALVES ARE PART OF MAIN CONTROL VALVE
9FH-01149-1
TORQUE CONTROL VALVE IS PART OF MAIN CONTROL VALVE
CONTROL VALVES ARE PART OF MAIN CONTROL VALVE
9FH-01149-1
SPINNER VALVE
SPINNERCLAMP VALVE
9HCSMK2004TEST PORT
9HCSMK2008TEST PORT
9HCSMK201/4TEST PORT
9HCSMK2004TEST PORT
9HCSMK2008TEST PORT
SU
PP
LY T
O S
TAB
BE
R
CO
NT
RO
L VA
LVE
(PLU
G I
F N
OT
NE
ED
ED
)
9HCSMK2004TEST PORT
9HCSMK2004TEST PORT
9FH-01149-10SHUTTLE VALVE
CA
SE
DR
AIN
9FH-01149-46FLOW DIVIDER
9FH-01152-11ACCUMALATOR
1600 psi PRECHARGE
PART OF COMBINATION MANIFOLD9FH-01539
PART OF COMBINATION
MANIFOLD9FH-01539
PART OF COMBINATION
MANIFOLD9FH-01539
TORQUE CYLINDER9FH-01152-2
TORQUE GAUGE 9FH-01152-2
9FH-01074-1SPINNER CLAMP
CYLINDER
9FH-01149-19PO CHECK VALVE
CARTRIDGE
SPINNER CONTROL CIRCUIT
3 2
SCU SCC
TPC
SCVA
SCVB
LCA
1LC
B1
LCA
2LC
B2
FT
1
1
32
ACC
VA CA CA
TPB
TPA
CB
CB P
G1 1
12
3
2
ECA
ECBRCA/RCB
EX
RET
2
3
FT
VB
T
TORQUE CONTROL VALVE CIRCUIT
WRENCH CLAMP CIRCUIT
B+V FLOORHAND GEN II HYDRAULIC SCHEMATIC
39
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AW
ING
S
Figure 17
ELECTRICAL SCHEMATIC
40
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AW
ING
S
Figure 18
HYDRAULIC SCHEMATIC
41
IND
EX
INDEX
42
IND
EX
9AF1X34B 319AF2S90 319AF2XCLN 319AF3X2B 319AF34X2N 319BN41203 339BN0115003 329BN0115005 349BN0115107 33, 369BN0115210 339BN0115211 359BN0115311 339BN0115315 339BN1123419 329BN1133815 369BN1133819 339BN1133857 32, 349BN1133861 32, 359BN1133893 339BN1133895 339BN1133897 339BN1137183 349BN1137185 369BN1137187 32, 359FH-01018-11 339FH-01152-4 299FH-01152-6 299FH-01152-7 29, 319FH-01152-8 29, 319FH-01401 349FH-01402 349HC12HHP 319PU-7100FRM 319PU-7220 29
43
IND
EX
9PU-8000 359PU-8002 329PU-8003 29, 339PU-8004 339PU-8005 29, 339PU-8006 29, 339PU-8007 329PU-8008 319PU-8009 319PU-8010 329PU-8012 329PU-8013 329PU-8015 329PU-8016 339PU-8017 329PU-8018 349PU-8019 319PU-8020 32, 369PU-8021 329PU-8023 33
AB
BALL VALVE 31, 32BALL VALVE COMPENSTOR 32BUSHING 31
CCHECK VALVE 32, 37CLOSE NIPPLE 31COUNTERSUNK PLUG 31COVER 29, 33
DDRIVE COUPLING 29, 33
EEXPLOSION PROOF COOLER 32, 36EXPLOSION PROOF LEVEL SWITCH 31EXPLOSION PROOF MOTOR 33
44
IND
EX
EXPLOSION PROOF SIGHT GLASS 32EXPLOSION PROOF TEMP SWITCH 34
FFILTER BREATHER 32Filters 7, 9, 25FLAT WASHER 32, 33, 34, 35FLOORHAND COMPLETE HYDRAULIC SCHEMATIC
37
FLOORHAND S/N TAG 33
GGAUGE 29, 33, 37
HHEX HEAD CAP SCREW 32, 33, 34, 35, 36HPU CIRCULATING SUCTION STRAINER 29, 31HPU HOSE & FITTING KIT 29HPU MAIN SUCTION STRAINER 29, 31HPU PRESSURE FILTER ELEMENT 29HPU RETURN FILTER ELEMENT 29HPU TEMP SWITCH MANIFOLD 34HPU TEMP SWITCH MOUNT BRACKET 34Hydraulic Oil Quality 26HYDRAULIC POWER UNIT FRAME 31
IJ
J&L ELECTRIC - EXPLOSION PROOF 35
KLMN
NIPPLE 31NYLON LOCK NUT 32, 34, 35, 36
OOIL PROBE THERMOMETER 32
PPRESSURE COMPENSATED HYD PUMP 33
45
IND
EX
PRESSURE FILTER AND HOUSING 32Primary Hydraulic Oil 26PUMP MOTOR ADAPTER 33
QR
RELIEF VALVE 37Reservoir 17, 25RETURN FILTER AND HOUSING 32RETURN MANIFOLD 37RIVET 33
SSAE FLAT WASHER 33SAE WASHER 36SECONDARY GEAR PUMP 32SOCKET HEAD CAP SCREW 32SPINNER CONTROL CIRCUIT 37SPLIT LOCKWASHER 33STREET 90 31
TTAG 11TORQUE CONTROL VALVE CIRCUIT 37TORQUE GAUGE 37Troubleshooting 22
UVW
WRENCH CLAMP CIRCUIT 37
XYZ
Manufacturer & Agents World WideBlohm + Voss Oil ToolsHermann-Blohm-Straße 220457 Hamburg, Germany
Phone: +49(0)40/3119-1826/1162 Fax: +49(0)40/[email protected]
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Blohm + Voss Oil Tools, LLC7670 Woodway, Suite 266
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