Blohm + Voss Oil Tools 9PU-7200 Guide

1
Manual Rev 000, October 2011.
Blohm + Voss Oil Tools, LLC
Hydraulic Power Unit 9PU-7200
Technical Documentation

2
Manufacturer & Agents World Wide
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.
This manual is intended
for use by eld 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 satised 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, microlm
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 specications without
announcement.
The values specied in
this manual represent the
nominal values of a unit
produced in series. Slight
deviations in the case of
the individual devices are
possible.
Limited Warranty
The warranty provided will
be void if the GraySpin 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. Modications were made
to the FloorHand which
were not approved by
Blohm + Voss Oil Tools,
LLC.
General remarks
As with all rig equipment,
the GraySpin 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.
NOTE: In the event of
problems that cannot be
solved with the aid of this
manual, please contact
one of the addresses listed
below.
Blohm + Voss Oil Tools
Hermann-Blohm-Straße 2
20457 Hamburg, Germany
Phone: [phone]/1162
Fax: [phone]
[e-mail]
www.blohmvoss-oiltools.com
Premier Sea & Land Pte. Ltd.
Shaw Centre
1, Scotts Road #19-12
228208 Singapore
Republic of Singapore
Phone: [phone]
Fax: [phone]
[e-mail]
Blohm + Voss Oil Tools, LLC
7670 Woodway, Suite 266 Houston, Texas
77063
United States of America
Phone: [phone]
Fax: [phone]
[e-mail]
www.blohmvoss-oiltools.com

3
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.
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
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.
Revision History Table
REV. 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

4
DESCRIPTION COMMISSIONING INSTALLATION OPERATIONS SPARE PARTS
MAINTENANCE
& INSPECTION DRAWINGS
TABLE OF CONTENTS
TABLE
OF CONTENTS
TABLE OF CONTENTS 4
DESCRIPTION 5
General Components 6
Motor 6
Hydraulics 6
Tank 6
Filters 6
Cooler/Heater 7
Explosion Proof Box 7
Specications 7
Location of Identication Tag 7
Hydraulic Specications 8
Shipping Data 8
COMMISSIONING 9
FloorHand Commissioning Procedure 11
Record of Training 13
INSTALLATION 14
Lifting 15
Electrical 15
Attaching the Hydraulic Lines 16
Filling the Reservoir 16
OPERATIONS 17
Start-up procedure 18
HPU will not power up. 20
HPU powers up, but will not build pressure. 21
MAINTENANCE & INSPECTION 22
Electric Motors 23
Reservoir 23
Filters 23
SPARE PARTS 24
Recommended Spare Parts for One Year Operation 25

5
DESCRIPTION
DESCRIPTION

6
DESCRIPTION
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 ow 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 lter.
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.
Motor
The motor on the hydraulic power unit is a 40hp explosion proof motor. This power required
would be 50 amps, 480 volt, 3 phase. The motor provides 40hp at 60 Hz.
Hydraulics
The hydraulic system on the power unit has an operating ow of 2500 psi (175.81 kg/cm)
with a maximum operating pressure of 3,400 psi (239.10 kg/cm). The ow is 26 GPM or
98.42 LPM.
Tank
Capacity of the tank is 95 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 uid is usually specied but care should be
taken to ensure that it is compatible with the environment it will be operated in, particularly
the ambient temperature range.
Filters
Because 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
suction strainers as well as pressure and return lters.

7
DESCRIPTION
Cooler/Heater
Depending on your location, Blohm+Voss will have
either an oil cooler or a heater built into the unit.
Explosion Proof Box
The 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.
Specications
The FloorHand is equipped with a Closed Center
Hydraulic System. The unit should only be operated
in coordination with a pressure compensated
variable displacement Hydraulic Power Source.
Depending on the environment, as well as customer requirements, the electrical
specications may vary.
Location of Identication Tag
An Identication tag can be located on the base near the front left forklift slot.
Figure 1
WARNING: USE OF A CONSTANT DISPLACEMENT PUMP
WILL RESULT IN DAMAGE AND/OR FAILURE THUS VOIDING
WARRANTY.

8
DESCRIPTION
Hydraulic Specications
Hydraulic pressure:
Operating: 2,500 PSI (17,236 kPa)
Maximum: 3,400 PSI (23,443 kPa)
Hydraulic ow:
Operating: 26 GPM (98.42 Liters)
Pressure Line Connection: 1” Male JIC
Return Line Connection: 1 1/4” Male JIC
Electrical Horsepower: 40 HP @ 60 Hz
Electrical power required: 50 amps, 440 volt, 3 Phase
Pressure and Return Filters: 10 Micron
Shipping Data
Height (without anges) 60 inches (152.4 cm
Width 50 inches (127 cm)
Depth 60 inches (152.4 cm)
Weight 2174 lbs (988.18 Kgs)
Figure 2

9
COMMISSIONING
COMMISSIONING

10
COMMISSIONING
Document Front Page
011/04/2010 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, LLC
Document No:

11
COMMISSIONING
FloorHand Commissioning Procedure
This 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 ushed completely before connecting to FloorHand.
1. ___ Connect FloorHand (using ow meter) to Hydraulic power source of 2,500-2,800
psi and 25-28 gpm. If pressure is above 2,800 psi, a Pressure Release Valve (PRV)
should be used. _____If ow rate is above 28 gpm, a pressure compensated ow
control should be used.______
2. ___ H.P.U should be powered up a minimum of 20 minutes before moving to next
step, 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
four rollers are correct, check for leaks. Monitor ow meter, record max ow. ________
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. ___ Without pipe, clamp and unclamp lower wrench 10 times, check that die blocks
extend and retract evenly, check for leaks.
Note: This helps to remove air from the lower clamp system so that the flow divider may work correctly.
6. ___ Without pipe, clamp lower wrench.
7. ___ Clamp and unclamp upper wrench 10 times, check that die blocks extend and
retract evenly, check for leaks.
8. ___ Unclamp lower wrench.
9. ___ Without pipe, clamp and unclamp spinner 10 times, check for leaks.
Note: spinner may, or may not close evenly, this is normal.
10. ___ Back torque adjustment knob out completely, then turn in (clockwise) 4 turns,
Blohm + Voss Oil Tools, LLC.
11. ___ Actuate torque cylinder 10 complete strokes in each direction and check for
leaks.
12. ___ Adjust make up speed ow control for a 5 second stroke. Verify during
commissioning.
13. ___ Install test gauge on lower clamp cylinder outboard test port.
14. ___ Clamp lower wrench.
15. ___ Observe the test gauge on lower wrench clamp cylinder, and Pressure Release
Valve (PRV) if applicable.
16. ___ Set Pressure Release Valve (PRV) output to obtain 600 psi at lower clamp

12
COMMISSIONING
cylinder. Verify during commissioning.
17. ___ Clamp upper wrench, ensure that system pressure is now present on lower
clamp cylinders also (PRV reading should not change), unclamp upper wrench, unclamp
lower wrench.
18. ___ Mock up test pipe, with torque, at end of stroke, check that gauge dump valve
functions correctly.
19. ___ Stall spinner in make direction and hold for 5 seconds and check for leaks.
20. ___ Stall spinner in break direction and hold for 5 seconds and check for leaks.
21. ___ Operate manipulator / lift cylinder full up & down 10 times to remove all air from
cylinder and counterbalance valve, check for leaks. If commissioning, inform rig crew
that this should be done after every rig-up.
22. ___ Raise manipulator / lift cylinder to mid stroke, check that counterbalance valve
holds.
23. ___ If applicable, extend and retract manipulator full out and in 5 times, check for
proper function, check for leaks.
24. ___ WARNING: Clamp lower wrench, verify that manipulator functions do not
operate.
25. ___ Unclamp lower wrench.
26. ___ Connect test gauge to return system test port, run spinner motors and hold
while checking pressure lter bypass indicator (if applicable), and monitoring system
back pressure, not to exceed 250 psi. Record back pressure ________
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,
proper make up torque adjustment, proper breakout procedure. Demonstrate how to
remove and install the following: Dies, die blocks, and drive rollers.
Tech: ________________________________________
Signature: ____________________________________
Date: ________________________________________

13
COMMISSIONING
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
Acknowledgement of Rig Superintendant / Tool Pusher Date
Name Signature
My signature above indicates acceptance of commissioning and the above personnel training.

14
INSTALLATION
INSTALLATION

15
INSTALLATION
Lifting
The 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.
Electrical
The 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 ap-
propriate electrical power source.
Before connecting the Hydraulic Power Unit to the electrical power source, it is imperative
that the supply voltage be veried to be compatible with the electrical motor on the hydrau-
lic power unit.
All electrical connections should be made by a licensed electrician in accordance with the
appropriate electrical codes and standard industrial safety practices.
Figure 3

16
INSTALLATION
Attaching the Hydraulic Lines
Remove 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 Reservoir
The reservoir is lled via the breather connection on the top of the reservoir. Conventional
petroleum based hydraulic uid is usually specied but care should be taken to ensure that
it is compatible with the environment it will be operated in, particularly for the ambient tem-
perature range.
Note: The compensator should be open, (unloaded) for all
cold starts, only closing once oil has warmed up.
Note: The Hydraulic Power Unit is factory set for the correct
operating pressure for proper operation of the FloorHand and
should not need to be adjusted. For troubleshooting or to
correct unauthorized tampering, a factory instruction sheet
is included at the end of this section for the Parker P2 series
pump. Any adjustments other than P-Max will void warranty.
Figure 4

OPERATIONS
17
OPERATIONS

OPERATIONS
18
There are two pumps incorporated with the
Hydraulic Power Unit.
The rst 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
lter downstream of the pump outlet. After
the lter, there is a check valve. Both the
lter and the check valve are inline before reaching the power unit bulkhead. FloorHand oil
is strained, pumped, ltered, used, cooled, then ltered 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 uid 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 lter even when the FloorHand is not being used. The
small pump strains uid from the tank and then sends the uid to the cooler. From the
cooler the uid is then pumped through a return line lter and back to the tank.
There is a small amount of oil that is not ltered prior to returning to the tank. This is oil that
is taken from a small port on the outside of the cooler to ow over the temperature probe.
The uid is not run through the lter as to not cause any restriction. There is a free ow of
uid over the probe then to the tank to keep an accurate temperature reading
The 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.
Start-up procedure
Verify 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 lled 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.
Figure 5

OPERATIONS
19
Loosen a tting 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 lter indicator and the
return line lter indicator to ensure that they are not operating in the “BYPASS” mode.
Replace the lter elements as required.
After the FloorHand and the manipulator have been cycled to ensure that the entire system
is lled with uid, top off the reservoir to the correct operating level.
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.
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.

OPERATIONS
20
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
No
No
Yes
Yes
START
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.
HPU will not power up.
No