Knight Oil Tools EPCM 7625

Warning: This information is controlled and any printed version, unless suitably endorsed by a controlling authority, is deemed as uncontrolled and should be compared with the source information at time of use to ensure no revisions have been implemented.

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Operation and Maintenance Manual

EPCM-7625 R2/R3

Customer: Location: Job #: Local Rep: Rep Phone # Document #

Knight Oil Tools, Manufacturing 700 E Texas Ave. Rayne, LA 70578 Phone: (337) 334‐6969 Fax: (337) 365‐6565 www.knightmanufacturinginc.com


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Table of Contents Introduction .................................................................................................................................................... 4 Safety ................................................................................................................................................................. 3

Safety Features Include: ......................................................................................................................... 5 Machine Specifications ................................................................................................................................ 6

Standard Features .................................................................................................................................... 6 Optional Features.................................................................................................................................... 6 Specifications ........................................................................................................................................... 6 Pipe Plant Requirements ........................................................................................................................ 6

Machine Setup ............................................................................................................................................... 7 Controls ............................................................................................................................................................ 8 Process Setup .................................................................................................................................................. 9

Brush Housing Adjustment ................................................................................................................... 9 Automatic Lance Support Adjustment ................................................................................................ 9

Automatic Lance Support Adjustment ................................................................................................. 10

Sensor Adjustment ................................................................................................................................ 10 Startup............................................................................................................................................................. 11 Process ............................................................................................................................................................ 12 Preventative Maintenance Procedure .................................................................................................... 14

Daily ........................................................................................................................................................ 14 Weekly .................................................................................................................................................... 15 Annual Maintenance ............................................................................................................................. 15

Parts List ........................................................................................................................................................ 15

Paddle Loader ........................................................................................................................................ 16 Brush Housing Assembly .................................................................................................................... 17 Drive Station .......................................................................................................................................... 18 Idler Station............................................................................................................................................ 19 Rear lance Assembly ............................................................................................................................. 20 Front Lance Assembly ......................................................................................................................... 21 Auxiliary Cylinder Assist ...................................................................................................................... 22 Secondary Cylinder (Assist) ................................................................................................................. 23


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Recommended Spare Parts ...................................................................................................................... 24 Electrical Schematics ................................................................................................................................. 25

480V Electrical Schematics .................................................................................................................. 25 PLC Output Schematic ........................................................................................................................ 26 Relay Schematic ..................................................................................................................................... 27 PLC Input Schematic ........................................................................................................................... 28

Hydraulic Schematic .................................................................................................................................. 28


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Introduction

EPCM7625 Enclosed Pipe Cleaning Machine For environments that noise and dust control are required or desired, Knight Manufacturing’s EPCM is an excellent choice. The EPCM effectively cleans tubing, pipe and casing while virtually eliminating dust emissions and reducing noise output to below 100 dB. The standard dual brush housing cleans most pipe in one pass, increasing productivity. The net result is more production, in a cleaner, safer plant environment.


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Safety

Knight has provided operating procedures and other information on labels to ensure the safety of both the operator, and equipment.

This entire operating manual is filled with important safety information - please read it thoroughly.

Safety Features Include:

Mechanically active components are painted a high visibility yellow. Enclosure designed to reduce sound and dust. Low oil level indicator protects machinery in the case of a hydraulic line rupture and limits

environmental impact. Low voltage operator interface (24vdc) Electronic collar stop on the load side designed to protect enclosure from impact. Equipment safety labels. Adjustable control station allows the operator to position themselves in the best location

for the task while keeping a safe distance from the work area Totally enclosed for dust & noise reduction Mechanical enter-locks deter access to machine hazards Interior Table lighting for operator visibility

DO NOT ATTEMPT TO DEFEAT ANY OF THE INSTALLED SAFETY FEATURES ON THIS

MACHINERY


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Machine Specifications

Standard Features

Dual wire brush for outside diameter cleaning Lance for inside diameter cleaning Debris belt conveyor Bag house dust collection system Dual hydraulic power supply

o One hydraulic pump for conveyor motors & auxiliary equipment o One for wire brushes

Range 2 pipe Left or right hand pipe loading configuration

Optional Features

Electrical enter-locks Outside diameter descaler Automatic Lance Supports Grip enhancer Range 3

o Accommodates pipe lengths up to 46’ o 24’ added to overall length of machine

Specifications

Pipe capacity o Tubing min. OD 2- 3/8” o Drill pipe max. OD 6- 5/8” o Casing max. OD 7- 5/8”

Overall length 84’ Width 30” Height 7’ Drive station spacing 6’ Weight 10,000 lbs. (Max Gross Weight)

Pipe Plant Requirements

Electrical 230/480V, 3 Phase, 60 Hz (Others available upon request)

Compressed air 100 PSI Plant Air System Required @ 150 CFM Rack height 36”- 44”


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Machine Setup For proper operation, the machine must be installed straight and coplanar horizontally level.

1. Remove the lance if it is installed on the machine.

2. Position frame components and loosely bolt them together.

3. Level the machine in the Z direction. To do this, establish a base line from a stationary object (such as installed pipe racks) and adjust the frame elevation of the load / unload side of the machine. The other frame components elevation is adjusted via the jack screws mounted to the feet. The elevation tolerance from the reference is + 1/8”.

4. Align the frame components in the X direction. Alignment tolerance is Y + 1/8” as measured from the machines axial center line through the length of the entire machine at the component joints and perpendicular to the pipe racks.

5. Anchor bolt the feet to the foundation. The minimum foundation thickness is 4” concrete. The anchor bolts may be left loose and tightened after full testing.

6. Verify that the machine is straight (along the X axis), within the elevation tolerance (the Z axis) and reasonably flat to the X-Y plane.

7. Tighten the frame connector bolts without disturbing the alignment. Torque the bolts to 120 ft.-lb..

8. Tighten the machine feet to the torque value recommended by the anchor bolt manufacturer.

9. Proceed with electrical and hydraulic installation. (See pages 28-31 for electrical and hydraulic schematics.)

10. Install duct collection system according to the manufacturer’s procedures manual. |------------------Load/Unload----------------------|----Table----|----------------------Lance Side----------------------|


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Controls Standard EPCM 7625 Layout

(Changes may occur on atypical machine designs.)

Function Description / Comments 1 Emergency Stop Push to stop, twist to disengage

2 Machine (on/off) Switch 2 position detented

3 Operation Switch 2 position detented

4 Pipe Speed Potentiometer Controls the drive wheels and axial speed of the pipe during the process

5 Table Lights Switch 2 position detented

6 Dust Collector Switch 2 position detented

7 Belt Conveyor Switch 2 position momentary. The default is AUTO. When turned to CYCLE, the Dust Conveyor will run for 60 seconds. This will remove all debris from the conveyor belt.

8 Hood Controls Switch 3 position detended. Determines what side(s) the “hood joystick” will control.

9 Hood (up/down) Joystick 2 position momentarty joystick. Opens and closes the hood(s) which is determined by the Hood Controls Switch (8)

10 Brush motor Switch 2 position detented. Turns on both Brush Housing Motors

11 Pipe Flow Directional Control Joystick 4 position momentary joystick. INDEX LOAD selection simultaneously loads a new pipe while offloading a processed pipe. LEFT/RIGHT conveys the pipe

12 Rattler Motor Joystick 1 position momentary joystick. Activates the rattler motor.

13 OD Scraper Joystick 1 position momentary joystick. Lowers the OD scraper

14 Preloader Joystick 2 position momentary joystick. Operates the preloader racks.

15 Automatic Lance Support Mode Switch 2 position detented. The default is AUTO. When MANUAL is selected, the photo eyes are ignored and the lance supports are controlled with switches 16 & 17.

16 Lance #1 (up/down) Switch Manual control of first Lance Support (closest to the Table Section). Lance Supports Control (15) must be in MANUAL mode for this switch to work.

17 Lance #2 (up/down) Switch Manual control of the second Lance Support. Lance Support Control (15) must be in Manual mode for this switch to work.

18 Front Brush Housing Switch 2 position detented. Variable height adjustment for the rear brush housing

19 Rear Brush Housing Switch 2 position detented. Variable height adjustment for the front brush housing

20 Brush Housing #1 Joystick 1 position momentary joystick. Manual control of the first brush.

21 Brush Housing #2 Joystick 1 position momentary joystick. Manual control of the second brush.

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1 2 3 4 5 6 7

8 10 15 16

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18 19

11 12 13 14 20 22


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Process Setup

Prior to operating this machine, ensure that the front and rear brush housing adjustments are positioned to effectively process the pipe. Failure to do so could result in damage to the machinery or decrease in efficiency.

Brush Housing Adjustment

1. When loading the first pipe, or changing pipe

sizes, the brush housing will need to be adjusted accordingly.

2. Move the joint under the brush, and then move the sensor so that it is 1 inch away from the joint directly along the axial center.

3. Move the body of the pipe so that it is below the brush housing and put the bushes in that down position.

a. Then move the front brush housing jack screw and rear brush housing cylinder so that the frame is level when contacting the pipe.

Automatic Lance Support Adjustment

The Automatic Lance Supports are designed to support the lance at an elevation that allows the ID Scraper to enter the pipe without damaging the pipe.

THE AUTOMATIC LANCE SUPPORTS CAN OPERATE WITH THE HYDRAULIC POWER SUPPLY DISABLED. WHEN WORKING AROUND THE AUTOMATIC LANCE SUPPORTS, ENSURE THAT: THE POWER TO THE MACHINE IS

LOCKED OUT/ TAGGED OUT THE AIR IS DISCONNECTED FROM THE

MACHINERY


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Automatic Lance Support Adjustment With the support roller in the position shown, adjust the length of the threaded rod so that the ID Scraper enters the pipe along the center line of the pipe. Adjustment is achieved through the use of the adjustment nuts as shown.

Sensor Adjustment

1. Place the machine in MANUAL MODE (via control #3) with the lance in the up position. 2. Release both of the allen screws attached to the sensor until the sensor is able to pivot. 3. Pivot the sensor towards the lance until the indicator light turns orange signifying that the

photo eye identifies the lance. 4. Once the sensor’s indicator is orange, reposition the sensor away from the lance until it

turns green indicating that it no longer senses the lance. 5. Check that the photo eye is between .25”-.50” away from the lance and tighten the allen

screw.


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Startup

1. Before starting, ensure that all daily maintenance is completed. 2. Install appropriate rattler motor and cleaning head. 3. Turn the Machine Control ON (via control #1). 4. Turn the Dust Collector Control ON (via control #6). 5. Choose MANUAL/AUTO mode for the Lance Support Control (via control #15). 6. Ensure that the Rattler Motor Control (control #12) is in the OFF position. 7. Ensure that the OD Scraper Control (control #13) is in the UP position. 8. Ensure that the Brush Housing Controls (control #20/22) are in the UP position. 9. Load the first joint of pipe onto the machine. 10. Locate collar stop pins so that only one joint is picked up from paddles. 11. Move the joint of pipe under the first brush, then move the brush sensor so that it is 1 inch

away from the tool joint. 12. Repeat for 2nd brush. 13. Move the body of the pipe so that it is below the Front/Rear Brush Housing Controls

(control #18/19) and that they are in the DOWN positions. Then move the front brush housing jack screw and rear brush housing cylinder so that the frame is level when contacting the pipe.

14. Turn the Brush Motors Button ON (via control #10).

Note: Reference page 3 for control panel layout.


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Process

1. With the pipe on the rack, ACTUATE the Pipe Index Load (control #11). This will load the pipe onto the machine.

PRIOR TO LOADING OR OFFLOADING PIPE, ENSURE THAT THERE ARE NO PERSONEL

OR EQUIPMENT IN THE PIPES PATH

2. Using the Motor Directional Control (control #11), CONVEY the pipe toward the Table Section.

3. Adjust the drive motor speed as required with the Pipe Speed Control (control #4). 4. If required, LOWER the OD Scraper (control #9), after the pipe is under the Scraper

Head. 5. After the pipe is under the Brush Housing Assembly, the Brush Housing can be placed in

the DOWN position (via control #20/22). 6. Turn the Rattler Motor ON (via control #12) after the rattler motor is inside the pipe.


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Process, continued

7. If the pipe has traveled beyond the Brush Housing Assembly, ensure that the Brush Housing is in the UP position (via control #20/22), prior to conveying the pipe back toward it.

8. If the pipe has traveled beyond the OD Scraper, ensure that the OD Scraper head is in the UP position, (control #13) prior to conveying the pipe back toward it.

9. Using the Motor Directional Control, (Control #11), CONVEY the pipe toward the Table Section.

STAY AWAY FROM ALL YELLOW MECHANICAL PARTS WHILE THE MACHINE IS ON. THEY CAN

MOVE WITHOUT WARNING CAUSING SEVERE INJURY

10. If required, LOWER the OD Scraper via (control #13), after the pipe is under the Scraper

Head. 11. After the pipe is under the Brush Housing Assembly, the Brush Housing can be placed in

the DOWN position (via control #20/22). 12. Turn the Rattler Motor OFF (via control #12), prior to the ID Scraper exiting the pipe. 13. After the pipe has been processed, convey the pipe back to the load side of the machine. 14. Be sure to properly collar the pipe prior to offloading. 15. After the pipe has been properly collared, ACTUATE the Pipe Index Load

(control #11). This will offload the processed pipe, and load the next pipe onto the machine.

16. Repeat when changing pipe size.

PRIOR TO LOADING OR OFFLOADING PIPE, INSURE THAT THERE ARE NO PERSONEL OR EQUIPMENT IN THE

PIPES PATH


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Preventative Maintenance Procedure

DO NOT ATTEMPT MAINTENANCE OR REPAIR ON THIS MACHINERY UNLESS IT IS LOCKED OUT/ TAGGED OUT

NEVER PUT YOUR HEAD UNDER THE HOOD WITHOUT HOOD BRACES IN PLACE.

Daily

1. Clean the outside and inside windows on table so that the components in the housing

are visible to the operator. 2. Check indicator panel on dust collector. See maintenance section in filtration manual

for further instructions. 3. Check trays and belt, empty if necessary. 4. Inspect drive and idler wheels for excessive wear. Replace wheels as required. The

recommended minimum diameter of the wheels is 6”. a. Once replaced, check to see that the idler wheel is torqued appropriately and

freely rotating. 5. Check brush housing support cylinder oil lubricator bowls, located on the front of the

table and on the rear lance assembly. Make sure airline lubricator containers are full (3). Recommended dial setting is around (2-4).

a. Refill with oil (SAE Grade 20, viscosity index 46 or equivalent). 6. Inspect hydraulic hoses for signs of leaks. Repair as required. 7. Inspect all sensors. Clean with a soft cloth to remove dust and debris. 8. Inspect brush wheels for excessive wear. It is recommended to replace the brush

wheels if the OD if more than 50% of the wire is missing. 9. Check hydraulic reservoir return filter pressure gauge daily while conveyor motors and

brush motors are engaged. 10. The following items should be greased daily with synthetic heavy duty grease (NLGI

#2, GC/LB or equivalent): a. Idler wheel bearings b. Brush shaft bearings

11. Inspect dust conveyor belt for damage, metal inclusions, and excessive buildup.


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Preventative Maintenance Procedure, continued

Weekly

1. The following items should be greased once a week with synthetic heavy duty grease (NLGI #2, GC/LB or equivalent):

a. Brush housing pivot bearings b. Load / Unload assemblies

Annual Maintenance

Knight manufacturing has a great service team and it is recommended that the following items be serviced by the knight team to ensure that everything on your pipe cleaning machine is running at its maximum efficiency.

1. Hydraulic reservoir should be drained and cleaned with a suitable solvent every 2 years. When the tank is drained, remove the suction strainer and clean with solvent.

2. Change hydraulic and air filters on machine. 3. The operator control box should be opened and wires should be cleaned and inspected

thoroughly. a. *This should not be done unless the machine is off and properly lockout and

tagged out. 4. Machine should be level and realigned if necessary. 5. All electrical boxes should be inspected for frays in the wire and tightened to ensure

that connections are not loose.


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Parts List

Paddle Loader

Item # Part # Description Quantity 1 13606 PADDLE FAB ASSY 1 2 13592 PADDLE WEAR PAD 1 3 14645 BEARING, SPHERICAL BRG 2 4 13609 BRG BLOCK 2 5 16086 GREASE FITG, .125 NPT 2 6 17234 RING, EXT, .75” 2 7 22033 DRAG LINK/CYLINDER PIN 2 8 17053 RING, EXT, 1.25” BLACK OXIDE 2 9 17649 WASHER, FLAT, .50” 4 10 14140 WASHER, LOCK, .50” 4 11 14361 BOLT, HHCS, .50” X 3.50” NC 4 12 14460 BOLT, SHCS, .50”-13 X 2 4 13 14124 NUT, HEX, .50”-13NC 4 14 16522 NUT, JAM, .50” NC 2


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Parts List

Brush Housing Assembly

Item # Part # Description Quantity

1 13570 MOUNT, B11582 BEARING MOUNT 1

2 14613 BEARING 2

3 16016 FRAME, BRUSH HOUSING 1

4 14588 BEARING REG 1

5 14589 BEARING CUT MACHINED 1

6 16383 MOTOR 1

7 15012 HUB, L-JAW 1

8 15027 SPIDER 1

9 13909 SHAFT, BRUSH 1

10 14683 WHEEL, WIRE 6

11 13915 SPACER, 2.375” X .375” SCH40 5

12 14680 NUT, MOTOFIED FOR BRUSH SHAFT 1

13 13651 COVER, BRUSH HOUSING 1

14 14145 WASHER, LOCK, .375” 14

15 17656 WASHER, FLAT, .375” 6

16 14124 NUT, HEX, .50”-13 NC 2

17 14140 WASHER, LOCK, .50” 2

18 16531 NUT, LOCK, .375” NC 6

19 15742 FITG, HYD, 2062-16-16 MODIFIED 1

20 15595 FITG, HYD, 2062-16-16 1

21 15580 FITG, HYD, 2023-2-4 1

22 16298 KEY, MACHINE, .25” X 1.25” 2

23 14307 BOLT, HHCS, .375” X 1.50” NC 4

24 14132 BOLT, HHCS, .375” X 1” NC 4

25 14321 BOLT, HHCS, .375” X 2” NC 6

26 14310 BOLT, HHCS, .50” X 1.50” NC 2 27 17272 COLLAR, 1” SPLIT 2


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Parts List

Drive Station

Item # Part Description Quantity 1 17719 WHEEL, NBR, GROOVED 1 2 14134 WASHER, FLAT, .75” CAST IRON 1 3 13566 DRIVE HUB 1 4 16391 MOTOR 1 5 15790 FITG, HYD 1 6 15739 FITG, HYD 1 7 15612 FITG, HYD 1 8 15235 KEY, WOODRUFF, .25”W X 1” 808 1 9 17160 SET SCREW, .3125”-18 X .3125” KNURLED 2 10 14133 WASHER, LOCK, .75” 1 11 14332 BOLT, HHCS, .75” X 1.50” NC 1


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Parts List

Idler Station

Item # Part Description Quantity1 13979 WASHER, FLAT, 1” X 2” X .125” BRASS 22 17718 WHEEL, SMOOTH 13 14435 BOLT, SHOULDER, 1” X 2.50” 14 17776 GREASE FITG, .25”-28 15 17652 WASHER, FLAT, 1” 16 17653 WASHER, FLAT, .75” 17 16485 NUT, HEX, .75” NC 18 13610 RACER, BRG 19 14641 BEARING, NEEDLE, 1” X 1-3/8 X 2” 1


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Parts List

Rear lance Assembly

Item # Part # Description Quantity1 13604 PERFORATED TUBE ASSY (REAR) 12 13602 ELEVATION ADJ COVER (REAR) 13 13972 KNOB, .375” 14 13596 ADJUSTMENT SCREW FOR LANCE 15 22246 WASHER, FLAT, .375” FW-3 26 17649 WASHER, FLAT, .50” 47 15288 PIN, ROLL, .125” X .75” 18 14312 BOLT, HHCS, .50” X 2” NC 29 14140 WASHER, LOCK, .50” 210 14124 NUT, HEX, .50”-13 NC 2


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Parts List

Front Lance Assembly

Item # Part # Description Quantity1 13603 ELEVATION ADK COVER (FRONT) 12 21207 FRONT LANCE BOLT ON PERFORATED ASSY 13 22246 WASHER, FLAT, .375” FW-3 24 13596 ADJUSTMENT SCREW FOR LANCE 15 13972 KNOB, .375” 16 15288 PIN, ROLL, .125” X .75” 1


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Parts List

Auxiliary Cylinder Assist

Item # Part # Description Quantity

1 20563 GUIDE, ADAPTER GUIDE 12 14142 NIPPLE, .125” X 10” BLK PIPE 13 13959 BEARING, TF4 ROD END + EYE ASSY 14 15580 FITG, HYD 15 15607 FITG, HYD 16 1403 FITG, HYD 1


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Parts List

Secondary Cylinder (Assist)

Item # Part # Description Quantity1 14629 BEARING, .50” ROD END 12 15098 CYLINDER, AIR 2” X 4” MODIFIED MILLER 13 21724 ROD, EXTENSION 1” 14 14513 RUBBER, BOOT 15 13568 ANCHER, BOOT 16 13569 SPACER, ROD 17 16335 COUPLING, ALLIGNMENT 18 15582 FITG, HYD, 2024-6-4 29 16511 NUT, HEX, .50” NF 110 14504 BOLT, SHCS, .25”-20 X 1.75” 111 17650 WASHER, FLAT .25” 212 14138 WAHSER, LOCK, .25” 213 16483 NUT, HEX, .25” NC 214 17681 WASHER, SPRING, .375” 115 14135 NUT, JAM, 1” NF 116 17649 WASHER, FLAT, .50” 217 14140 WASHER, LOCK, .50” 1


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Recommended Spare Parts

Part Quantity SAP #

OD Brushes 8 13959

Lenz Fitting 2 14037

Chrome Rod 2 14683

Photo Eye (400mm) 1 17202

Induction Sensor 1 17207

Drive Wheels 10 17719

Idler Shoulder Bolt 6 14435

Needle Bearing 3 14641

1” Brass Washer 6 6 13979

Paddle Wear Pad 4 4 13592

HI Torque Charlynn Motor 1 16391

Hydraulic Power Unit Filter 2 21011

Idler Wheels 6 17718

Washer, Flat, 1” X 2” X .125” BRASS 8 13979

Washer, Flat, 1” 4 17652

Washer, Flat, .75” 4 17653

Nut, Hex, .75” NC 2 16485

Bearing, Needle 1” X 1-3/8 X 2” 2 14641


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Electrical Schematics

480V Electrical Schematics


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PLC Output Schematic


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Relay Schematic


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PLC Input Schematic


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Hydraulic & Pneumatic Schematics

Documents

Knight Oil Tools EPCM 7625