Knight Oil Tools PCM 5000

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Operation and Maintenance Manual

PCM-5000 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 .................................................................................................................................................... 3 Safety ................................................................................................................................................................. 3

Safety Features Include: ......................................................................................................................... 4 Machine Specifications ................................................................................................................................ 5

Standard Features .................................................................................................................................... 5 Optional Features.................................................................................................................................... 5 Specifications ........................................................................................................................................... 5 Pipe Plant Requirements ........................................................................................................................ 5

Machine Setup ............................................................................................................................................... 6 Controls ............................................................................................................................................................ 7 Process Setup .................................................................................................................................................. 7

Brush Housing Adjustment ................................................................................................................... 8 Automatic Lance Support Adjustment ................................................................................................ 9

Automatic Lance Support Adjustment ................................................................................................... 9

Sensor Adjustment ................................................................................................................................ 10 Startup............................................................................................................................................................. 10 Process ............................................................................................................................................................ 11 Preventative Maintenance Procedure .................................................................................................... 13

Daily ........................................................................................................................................................ 13 Weekly .................................................................................................................................................... 13 Annual Maintenance ............................................................................................................................. 14

Parts List ........................................................................................................................................................ 14

Paddle Loader ........................................................................................................................................ 15 Brush Housing Assembly .................................................................................................................... 16 Drive Station .......................................................................................................................................... 17 Idler Station............................................................................................................................................ 18 Rear lance Assembly ............................................................................................................................. 19 Front Lance Assembly ......................................................................................................................... 20 Auxiliary Cylinder Assist ...................................................................................................................... 21 Secondary Cylinder (Assist) ................................................................................................................. 22

Recommended Spare Parts ...................................................................................................................... 23 Electrical Schematics ................................................................................................................................. 24

480V Electrical Schematics .................................................................................................................. 24 Relay Schematic ................................................................................ Error! Bookmark not defined.

Hydraulic Schematic .................................................................................................................................. 25


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Introduction

PCM 5000 Pipe Cleaning Machine The PCM5000 is designed to meet the pipe cleaning needs of today’s oil and gas industry. The unit can clean the inside diameter and outside diameter of pipe prepping it for other operations such as coating and inspection. Its features make it well adapted for most cleaning situations and configurable for nearly all pipe plants. It includes user friendly controls and safety features that make it easy to operate. The PCM5000 is customizable to meet any need.


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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. • Low oil level indicator protects machinery in the case of a hydraulic line rupture and limits

environmental impact. • Low voltage operator interface (24vdc) • Equipment safety labels.

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

MACHINERY


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Machine Specifications

Standard Features

• Single wire brush for outside diameter cleaning • Lance for inside diameter cleaning • 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

• Outside diameter descaler • Automatic Lance Supports • Grip enhancer • Range 3

o Accommodates pipe lengths up to 48’ o 24’ added to overall length of machine

Specifications

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

• Overall length 84’ • Width 30” • Height 7’ • Drive station spacing 6’ • Weight 7,000 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----------------------|----Operator---|----------------------Lance Side-------------------|


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Controls Standard Layout

(typical machine layout, custom units may vary.)

Process Setup

Function 1 Emergency Stop 2 Machine Stop

3 Machine Start

4 Dust Collector Switch

5 Conveyor Wheel Speed Control

6 Conveyor Wheel Dirction

7 Load/Unload Paddles

8 Brush Motor Off/On

9 Brush Engage/Disengage

10 Ratter Motor Off/ON

11 Brush Frame Pressure Regulator

1

2 3

5

4

6 7 8 9 10

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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 housing frame, engage the brush and adjust the adjustment

handle (1) and rear pin (2) so that the brush housing frame is level when contacting the pipe.

a. 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 efficiency.

2

1


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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.

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.

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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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. .

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 #3). 4. Turn the Dust Collector Control ON (via control #4). 5. Ensure that the Rattler Motor Control (control #10) is in the OFF position. 6. Ensure that the Brush Housing Controls (control #9) are in the disengaged position. 7. Load the first joint of pipe onto the machine (control #7). 8. Locate collar stop pins so that only one joint is picked up with the paddles. 9. Adjust brush frame so that it is level when brush is engaging pipe. 10. Turn the Brush Motors Button ON (via control #8).

Note: Reference page 8 for control panel layout.


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Process

1. With the pipe on the rack, ACTUATE the Pipe Index Load (control #7). 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. Turn Brush Motor on (control #8). 3. Using the Motor Directional Control (control #6), CONVEY the pipe toward the Table

Section. 4. Adjust the drive motor speed as required with the Pipe Speed Control (control #5). 5. If equipped, LOWER the OD Scraper, after the pipe is under the Scraper Head. 6. After the pipe is under the Brush Housing Assembly, the Brush Housing can be placed in

the engaged position (via control #9). 7. Turn the Rattler Motor ON (via control #10) after the rattler motor is inside the pipe.


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Process, continued

8. If the pipe has traveled beyond the Brush Housing Assembly, ensure that the Brush Housing is in the UP position (via control #9), prior to conveying the pipe back toward it.

9. If the pipe has traveled beyond the OD Scraper, ensure that the OD Scraper head is in the UP position, prior to conveying the pipe back toward it.

10. Using the Motor Directional Control, (Control #6), CONVEY the pipe toward the Load Section.

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

MOVE WITHOUT WARNING CAUSING SEVERE INJURY

11. If required, LOWER the OD Scraper, after the pipe is under the Scraper Head. 12. After the pipe is under the Brush Housing Assembly, the Brush Housing can be placed in

the engaged position (via control #9). 13. Turn the Rattler Motor OFF (via control #10), prior to the ID Scraper exiting the pipe. 14. After the pipe has been processed, convey the pipe back to the load side of the machine. 15. Be sure to properly collar the pipe prior to offloading. 16. After the pipe has been properly collared, ACTUATE the Pipe Index Load

(control #7). This will offload the processed pipe, and load the next pipe onto the machine.

17. Repeat as required.

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. Check debris level on dust collector, and empty as necessary. 2. 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. 3. 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 between two and four.

a. Refill with oil (SAE Grade 20, viscosity index 46 or equivalent). 4. Inspect hydraulic hoses for signs of leaks. Repair as required. 5. 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. 6. Check hydraulic reservoir return filter pressure gauge daily while conveyor motors and

brush motors are engaged. 7. 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

Preventative Maintenance Procedure, continued

Weekly


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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. All electrical control boxes should be opened and wires should be inspected thoroughly.

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

4. Machine alignment should be verified and realigned if necessary.


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Parts List

Paddle Loader

Item # Part # Description Quantity 1 13606 PADDLE FAB ASSY (customer to specify left or right hand) 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

Parts List

Item # Part Description Quantity 1 17719 WHEEL, NBR, GROOVED 1 2 14134 WASHER, FLAT, .75” CAST IRON 1 3 13566 DRIVE HUB 1 4 16392 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 14131 BOLT, HHCS, .75” X 1.25” NC 1


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Idler Station

Item # Part Description Quantity 1 13979 WASHER, FLAT, 1” X 2” X .125” BRASS 2 2 17718 WHEEL, SMOOTH 1 3 14435 BOLT, SHOULDER, 1” X 2.50” 1 4 17776 GREASE FITG, .25”-28 1 5 17652 WASHER, FLAT, 1” 1 6 17653 WASHER, FLAT, .75” 1 7 16485 NUT, HEX, .75” NC 1 8 13610 RACER, BRG 1 9 14641 BEARING, NEEDLE, 1” X 1-3/8 X 2” 1


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Parts List

Rear lance Assembly

Item # Part # Description Quantity 1 13604 PERFORATED TUBE ASSY (REAR) 1 2 13602 ELEVATION ADJ COVER (REAR) 1 3 13972 KNOB, .375” 1 4 13596 ADJUSTMENT SCREW FOR LANCE 1 5 22246 WASHER, FLAT, .375” FW-3 2 6 17649 WASHER, FLAT, .50” 4 7 15288 PIN, ROLL, .125” X .75” 1 8 14312 BOLT, HHCS, .50” X 2” NC 2 9 14140 WASHER, LOCK, .50” 2 10 14124 NUT, HEX, .50”-13 NC 2


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Parts List

Front Lance Assembly

Parts List

Item # Part # Description Quantity 1 13603 ELEVATION ADK COVER (FRONT) 1 2 21207 FRONT LANCE BOLT ON PERFORATED ASSY 1 3 22246 WASHER, FLAT, .375” FW-3 2 4 13596 ADJUSTMENT SCREW FOR LANCE 1 5 13972 KNOB, .375” 1 6 15288 PIN, ROLL, .125” X .75” 1


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Auxiliary Cylinder Assist

Item # Part # Description Quantity

1 20563 GUIDE, ADAPTER GUIDE 1 2 14142 NIPPLE, .125” X 10” BLK PIPE 1 3 13959 BEARING, TF4 ROD END + EYE ASSY 1 4 15580 FITG, HYD 1 5 15607 FITG, HYD 1 6 1403 FITG, HYD 1


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Parts List

Secondary Cylinder (Assist)

Item # Part # Description Quantity 1 14629 BEARING, .50” ROD END 1 2 15098 CYLINDER, AIR 2” X 4” MODIFIED MILLER 1 3 21724 ROD, EXTENSION 1” 1 4 14513 RUBBER, BOOT 1 5 13568 ANCHER, BOOT 1 6 13569 SPACER, ROD 1 7 16335 COUPLING, ALLIGNMENT 1 8 15582 FITG, HYD, 2024-6-4 2 9 16511 NUT, HEX, .50” NF 1 10 14504 BOLT, SHCS, .25”-20 X 1.75” 1 11 17650 WASHER, FLAT .25” 2 12 14138 WAHSER, LOCK, .25” 2 13 16483 NUT, HEX, .25” NC 2 14 17681 WASHER, SPRING, .375” 1 15 14135 NUT, JAM, 1” NF 1 16 17649 WASHER, FLAT, .50” 2 17 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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Hydraulic & Pneumatic Schematics

Documents

Knight Oil Tools PCM 5000