User Manual No.: T8354-Z-MA-001, Rev.

0
Equipment: Catwalk Machine
Page: 10of 12

CHAPTER 6

MAINTENANCE

Chapter 6: Maintenance

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 User Manual No.: T8354-Z-MA-001, Rev. 0
Equipment: Catwalk Machine
Page: 20f12

TABLE OF CONTENTS

6 MAINTENANGCE .......cootitriitrisscsessstss
s s ss b s as bbb 3
6.1 Safety SUMMAIY ... 4
6.2 Routine Inspections
6.3 Periodic Maintenance Schedule.
6.3.1 Follow-up of Inspections.
6.3.2 Weekly Maintenance ROULINE .........ccuvuerviirirerieieeeeecseesee e 6
6.3.3 2-weekly Maintenance ROULINE .........cccoveiririerieineenisieeceee
e6
6.3.4 Monthly Maintenance ROULINE ............cccccoiiiiriiiiiinicccccc
e6
6.3.5 Annual Maintenance Routine
6.4 Periodic Maintenance Procedures 8
6.4.1 Lubrication
6.5 Corrections and MiNOT REPAIIS ........ccoceierieiaineririrerie et 8
6.5.1 Venting the Hydraulic SYStem .........cccceviiririreinerereer e 8
6.5.2 Replacing Hydraulic HOSES ...........ccccoiiiiiiiiiiiiiiccccccccccce 8
6.6 Major Repairs and Modifications............ccoiiiiiiiiiiiiiiiiicc
s9
6.6.1 Maintenance Not Normally Done by User
6.7 Fault Finding ..
6.8 Storage and Preservation . .
6.9 SPECIAI TOOIS ..ottt
ettt a et s e 11
6.10 Attachment: Lubrication Chart................ccooiiiiiiiiiiiiiccc
e 12

Chapter 6: Maintenance

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 User Manual No.: T8354-Z-MA-001, Rev. 0
Equipment: Catwalk Machine
Page: 3of12

MAINTENANCE

It is recommended that a Maintenance Log be established for this equipment. All

maintenance, abnormal observations and repairs should be logged. Upon request,
the log should be made available to supplier’s service personnel.

Chapter 6: Maintenance

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 User Manual No.: T8354-Z-MA-001, Rev. 0
Equipment: Catwalk Machine
Page: 40f12

6.1 Safety Summary

The following types of safety message may appear in various sections of this
chapter:

WARNING: Must be observed to prevent serious injury.

CAUTION: Must be observed to prevent damage of equipment and/or loss of
operating effectiveness.
NOTE: Must be observed for correct and efficient operation.

It is the responsibility and duty of all personnel involved in the operation and
maintenance of this equipment to fully understand the SAFETY measures, by which
hazards are reduced or eliminated. Personnel must familiarize themselves with all
aspects of safety and operation of the equipment before starting any operation or
maintenance.

The following points summarize the safety aspects related to maintenance:

Only qualified personnel are allowed to carry out maintenance and fault finding.
Only the prescribed maintenance may be carried out by user. Anything else
must be approved by supplier’s service department before being carried out.
A maintenance warning sign should be placed in driller's cabin before
maintenance is carried out.
Keep clear of the equipment’'s many moving parts during (test) operation by the
local hydraulic controls. Only well trained personnel should use these controls.
The equipment is powered by high-pressure hydraulic oil. The pressure must be
thoroughly vented before hydraulic pipes/hoses or filter bowls are unscrewed.
Hydraulic oil and lubricants may contain toxic additives that by repeated skin
contact or inhalation can be dangerous to your health. Study the safety data
sheets of the different compounds, and protect yourself as required.
Beware of the risk of pipe/hose burst. If anyone gets hydraulic oil into the eyes
or open wounds, wash at once with lots of fresh water. Refer the material safety
data sheet for product specific first aid instructions regarding oil in use.
Be especially aware of the danger involved with oil under pressure. It can be
injected under the skin without the victim being aware.
In the case of a fire, be aware that hydraulic oil is flammable. The combustion
point is ca. 200 Deg. C. Oil fog is highly flammable!
Adjustable valves that have been set and sealed by supplier are not to be
adjusted by user without approval and guidelines from supplier.
No welding of lugs, brackets etc. must take place on the equipment.
Heat or excessive force must not be used to move a part, unless beyond repair.
Only original spare parts ordered through National Oilwell Varco must be used,
as modifications may have been performed by NOV on standard parts. Non-
modified parts may interfere with the original performance. Use of non-modified
parts will also influence the terms of warranty.

Chapter 6: Maintenance

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 User Manual No.: T8354-Z-MA-001, Rev. 0
Equipment: Catwalk Machine
Page: 50f12

6.2 Routine Inspections

The inspection part of routine maintenance is covered by the points below, and
should be carried out monthly. All abnormal observations should be reported to the
maintenance supervisor at once, and also recorded in the maintenance log.

Ask the operator if any abnormalities have been observed. All such observations
must be logged for follow-up.
Inspect the overall equipment for wear, deformation and loose bolts.
Inspect the skate’s rack & pinion drive.
Check visually all hydraulic hoses for wear, damage and sharp bends.
Inspect the hydraulic system for leaks.
Inspect the hydraulic pressure filter's pop-up indicator. If the indicator has
popped up, the filter element is likely to be clogged and needs to be changed.
Ensure that the dust caps for the electric and hydraulic quick couplings are in
place.
Inspect the moped (whether it is stored or on the trolley) to verify that it is in
good working order and that its four securing bolts are in place.
Verify that the two rail ramps (if unused) are stored in the brackets at the rear
end of the skate (at the outside of the skate walls).

Chapter 6: Maintenance

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 User Manual No.: T8354-Z-MA-001, Rev. 0
Equipment: Catwalk Machine
Page: 6of 12

6.3 Periodic Maintenance Schedule

6.3.1 Follow-up of Inspections

If the routine inspection revealed any abnormal conditions, these must be followed
up. How fast depends on the nature of the abnormality.

6.3.2 Weekly Maintenance Routine

e Carry out the weekly lubrication maintenance described in the Lubrication Chart.

6.3.3 2-weekly Maintenance Routine

e Carry out the 2-weekly lubrication maintenance described in the Lubrication

Chart.

6.3.4 Monthly Maintenance Routine

* Keep the equipment clean.

e Carry out the monthly lubrication maintenance described in the Lubrication
Chart.
e Check tension on the trolley drive chains, and tighten the chains if necessary.
When the strokes of the chain tighteners are used, it will be necessary to
remove links from the chains. After links have been removed three times it is
recommended to replace the chains.
e Stroke all catwalk cylinders fully out and in a couple of times to lubricate the
cylinder rods. Leave the cylinders in stroked-in position.
o Verify that the skate and trolley are moving easily.

Chapter 6: Maintenance

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 User Manual No.: T8354-Z-MA-001, Rev. 0
Equipment: Catwalk Machine
Page: 7of12

6.3.5 Annual Maintenance Routine

Wash the catwalk thoroughly and allow it to dry.

Have the entire (lifting appliance) equipment inspected by an “Enterprise of
Competence” to verify that it is suited for another year of operation. (Enterprise
of Competence: Person or unit within the operator’s organization, another
company or institution with adequate competence (theoretical knowledge and
practical experience) to understand the design, calculations and operation of
lifting appliances, and with ability to carry out necessary examinations and
tests.) A signed copy of the inspection report must be filed in the maintenance
log, and the remarks must be followed up.
Carry out the yearly lubrication maintenance specified in the lubrication chart.
Change the element of the hydraulic pressure filter (if the element has not been
changed the last year, due to clogging).
Check/retighten all terminal blocks and other electrical connection points,
including earthing.
Check for moisture inside all outdoor junction boxes. Add or replace drying
agent as required.
Check the condition of the oily Denso tape fitted to protect the hydraulic tubing
fittings against corrosion. If the tape is drying out, soak it with new hydraulic oil
to maintain the corrosion preventing effect.
Touch up all paint damage.

Chapter 6: Maintenance

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 User Manual No.: T8354-Z-MA-001, Rev. 0
Equipment: Catwalk Machine
Page: 8of12

6.4 Periodic Maintenance Procedures

6.4.1 Lubrication

Lubricate the equipment according to the attached lubrication chart. The chart
shows intervals, where to lubricate and what kind of lubricant to use. The intervals
are repeated in the above maintenance schedule.

6.5 Corrections and Minor Repairs

6.5.1 Venting the Hydraulic System

Air trapped in the hydraulic system may cause jerky/spasmodic cylinder behaviour.
The remedy is to vent the hydraulic system by running the cylinders slowly between
the end positions several times. This forces the oil/air mixture back to the hydraulic
tank, where the air will be separated from the oil.

6.5.2 Replacing Hydraulic Hoses

If a hydraulic hose becomes worn or damaged, it must be replaced by a new hose

of the original type as follows.

e Clean the old hose and the area around to prevent impurities from entering the
hydraulic system.
o Clean the new hose by flushing it to the NAS 1638 class 8.
¢ Close the isolation valve to the hydraulic ringline (upstream of the pressure
filter), and attach a Maintenance Warning sign to the valve.
e Vent the hydraulic pressure by operating the controls until there is no response.
Confirm pressure ventilation by applying a test gauge to the nearest test point
(see the hydraulic flow diagram).
e Place a bucket under the hose and carefully unscrew the old hose.
e Install the new hose. Avoid twisting of the hose during assembly. A twisted hose
is subject to stress that eventually may work the connection loose.
¢ Re-open the isolation valve and remove the warning sign.
e Vent trapped air from the hydraulic system as described in the section above.

WARNING:
DO NOT UNSCREW HYDRAULIC HOSES BEFORE THE PRESSURE HAS BEEN
THOROUGHLY VENTED!

Chapter 6: Maintenance

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 User Manual No.: T8354-Z-MA-001, Rev. 0
Equipment: Catwalk Machine
Page: 9of12

6.6 Major Repairs and Modifications

All major repairs and modifications must be discussed with and approved by the
supplier's service department before the work can start. The service department will
involve supplier's design engineers as necessary, and a conclusive report and
proposal will be issued.

6.6.1 Maintenance Not Normally Done by User

The repair/modification work listed below shall specifically not be carried out by user
without approval and instructions from supplier’s service department. The list is not
exhaustive, and the general rule is still that maintenance/repair not described in the
Maintenance chapter requires supplier approval before being carried out.

e Adjustments, repairs and replacements of parts belonging to the main hydraulic

system.
* Adjustments, repairs and replacements of mechanical, electrical, or hydraulic
components with load carrying or safety functions.
« Dismantling hydraulic motors, gearboxes and brakes.
« Adjustments, repairs and replacements of components sealed by the supplier.
e Reprogramming of the PLC

Chapter 6: Maintenance

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