7-5.8 std tong

4225 Highway 90, EastBroussard, Louisiana 70518

Phone: (337) 837-8847Fax: (337) 837-8839

www.superior-manf.com

TECHNICAL MANUAL

7 5/8" CLINCHER STD TONG

COVERS TONG MODEL

CLES7625

Published 08/2007


Phone: (337) 837-8847Fax: (337) 837-8839


TECHNICAL MANUAL


COVERS TONG MODEL

CLE7625

Published 08/2007

© Copyright, 2007, SUPERIOR Manufacturing & Hydraulics, Inc. All rights reserved. This document is the property of SUPERIOR Manufacturing & Hydraulics, Inc. It is supplied as reference information to users of our products. This document is considered confidential and is not to be disclosed, copied or reproduced, transmitted, transcribed in any form or stored in any type of system without the express written consent of SUPERIOR Manufacturing & Hydraulics, Inc. CLINCHER, CHROMEMASTER, LOCKJAW, HYTOPS, Drillmaster, Grit Face, Grit Faced Die or Insert & Low-Friction are trademarks of SUPERIOR Manufacturing & Hydraulics, Inc. The products described in this manual are covered by U.S. and foreign Patents and/or pending Patent Applications.

This manual is not a controlled document and is subject to revision without notice. To receive updates and insure you have access to the latest information concerning the 7 5/8" CLINCHER STD Tong, we request you complete this form and return the lower half to SUPERIOR Manufacturing and Hydraulics by mail or facsimile. Access to our manuals can also be acquired through our web site www.superior-manf.com. Select the tab ‘CLINCHER Products’, select the equipment from the list to get Specs page, select the tab ‘Download Manual’. Name: Company: Address: Address: City: State: Postal Code: Country: Telephone: Fax: Tong Model No.: Serial No.: Assembly Date:

7 5/8" CLINCHER STD Tong Technical Manual Registration Form

Name:

Company:

Address:

Address:

City:

Postal Code: Country:

Telephone: Fax:

Tong Model No.: Serial No.:

Assembly Date:

Return To: SUPERIOR Mfg. & Hyd. 4225 Hwy. 90 East Broussard, LA 70518 USA Telephone: 337-837-8847 Facsimile: 337-837-8839 Web Site: www.superior-manf.com

TABLE OF CONTENTS

Hazard Warnings 1

Description, Features, & Specifications 2

Jaws, Adapters, & Die Information 3

Assembly Torque Requirements Lubrication Specifications 4

Operational Instructions 5

Maintenance Instructions & Trouble Shooting 6

Spare Parts Recommendations 7

Accessories and Options 8

STD TONG Illustrations 9

Lift Cylinder Illustration 10

Load Cell and Torque Gauge 11

Motor Service Manuals 12

Valve Technical Data 13

SUPERIOR Manufacturing & Hydraulics, Inc. 7 5/8" CLINCHER STD Tong Revision: 12/07 Page 0 - 1


REVISION TABLE

Section Page Date Description

9 8 12/07 Revised illustration Drive Assy. 77071.

7 5/8" CLINCHER STD Tong

HAZARD WARNING


Nomenclature used in this manual: WARNING concerns an operating procedure or practice that,

if not strictly observed, can result in injury to personnel or loss of life

Caution concerns an operating procedure or practice that,

if not strictly observed, can result in damage to or destruction of equipment

Note concerns an operating procedure or practice that

needs highlighting CLINCHER Tongs, Backups and Hangers are manufactured to provide a means of making up or breaking out high torque tubular connections. They utilize high pressure hydraulic fluid power which moves Tong, Backup and Hanger components with forces that are capable of causing significant injuries. It is imperative that this manual is read in full, prior to the installation and use of this equipment. WARNING : Tongs and Backups are not to be operated by untrained personnel or personnel with diminished physical or mental capacity. No work of any type, including changing of dies, is to be carried out while the tong and backup are connected to any hydraulic power supply. CLINCHER Tongs and Backups require to be suspended from a suitable point as close to the center of the wellbore as possible, without interfering with drilling equipment operation, to allow the tong to be readily swung into the working position. Vertical position control should be achieved by means of a CLINCHER hydraulically operated lift cylinder/spring hanger. The CLINCHER STD Tong weighs in excess of 1,650 lbs. / 748 kg and will also exert dynamic loads. It is recommended, as a minimum, that this equipment be suspended from a 7/8" (22mm) high strength IWRC wire rope with a minimum breaking strength/load of 31 tons (28.1 tonnes). WARNING : Users must insure the entire suspension system including cables, rig mounting points, lift cylinders, tong lifting brackets/bridles, winches, pulleys, counter weights, etc., are capable of handling the static weight of the tong and backup plus any loads which could be transferred to it during the makeup or breakout process PLUS any shock loads which may be seen during operation, is capable of handling such loads inclusive of a suitable factor of safety. This system must readily allow downward movement equal to a minimum of the thread makeup distance to avoid overloading the suspension system and/or damage to equipment. A 1" (26mm) IWRC minimum diameter wire rope with a 51.7 ton (43.4 tonne) minimum breaking strength or better, should be attached at a 90 degree angle to the tong and at the same level to insure proper readout of torque indicator. A

SNUBBING LINE should always be attached even when an integral backup is in use to provide additional safety in the event of a backup slippage. WARNING : Users must provide a safe system of work unique to their own working environment in order to safely control the Tong and Backup movements in all directions when it is in use. Failure to account for its size, weight, movement and the amount of torque developed could produce significant hazards. CLINCHER Tongs and Backups utilize up to 3000 psi high pressure hydraulic fluids. Portions of the tong and backup, control valves, hydraulic lines and cylinders may contain high pressure fluid even when the power unit is de-energized and the fluid supply hoses are disconnected. During normal operation the temperature of the hydraulic fluids as well as hoses, piping, valves, etc., can rise to a level which could cause burns. WARNING : Personal Protective Equipment (PPE), as a minimum, safety glasses, face visors, protective gloves, hard hats, coveralls and protective footwear, must be worn to minimize residual risks presented by this equipment. Furthermore, ensure that personnel have no loose clothing to prevent entanglement with any moving components. This equipment should only be serviced by competent hydraulic technicians using procedures to safely insure hydraulic pressure is bled from these circuits. The CLINCHER Tong is equipped with a door interlock system which prevents tong rotation whenever the door is open. This system is to be tested before each mobilization and at every shift change by attempting to rotate in low gear at low speed while door is open. Should the interlock system be deemed to be inoperative, the tong is to be removed from service and quarantined until such a time as the interlock is reinstated and thoroughly tested by a competent hydraulic technician. CAUTION: Never try and bypass the interlock system, for whatever reason. As well as exposing personnel to unnecessary risks, operating the tong with the door in the open position could result in severe damage to the equipment and will void all manufacturer warranties. WARNING : Operating the tong with the door open by means of a defective or bypassed door interlock system exposes the operator and nearby personnel to significant risk. No attempt should be made to operate the CLINCHER Tong and Backup for any purpose other than which it is intended. This system is capable of generating very large clamping forces and torsional loads which, if improperly applied or controlled, could result in damage to the tubular, to the tong and backup, or could possibly result in significant risk to personnel. Do not attempt to operate the unit without correct dies and the proper size tubular being in the tong and backup. See Section 3 for more information concerning the selection and use of dies.

7 5/8" CLINCHER STD Tong

HAZARD WARNING


CAUTION: Operating this equipment without the correct size, type, and orientation of dies could cause slippage and result in and ignition source being produced and/or damage to the equipment or tubulars being handled. NOISE SAFETY A CLINCHER 7 5/8" Tong was operated at maximum rotational speed in the centre of a workshop with hard walls, floor and roof. The equipment supplying the hydraulic power supply was not in the workshop. The CLINCHER Tong was stopped and started during the measuring process. The tong jaws were actuated in and out. The tong door assembly was also opened and forcibly closed. Using an AZ Corporation Inc. Digital Sound Meter, Model 8928 with the manufacturer’s original calibration, the following readings were recorded at a distance of 0.5 meters from the CLINCHER’S rotating element:

‘A’ weighted reading of 94 dB 1

‘C’ weighted reading of 95 dB 1 The sound power is 9.4 bel. An ‘A’ weighted reading is an average noise level. The ‘A’ weighted reading above was recorded over a 1 minute period of continuous maximum rotation. A ‘C’ weighted reading is a peak or impact noise level. The ‘C’ weighted reading above occurred when the Tong Door Assembly was forcibly closed. HYDRAULIC POWER PACKS SAFETY It is imperative that CLINCHER Units ARE ONLY USED IN CONJUNCTION WITH HYDRAULIC POWER PACKS THAT ARE FITTED WITH AN EMERGENCY STOP(s) . The onsite risk assessment should be used to determine the location of the Emergency Stop(s). In some cases it will be necessary for an Emergency Stop to be fitted locally to, or even on, the CLINCHER Unit.

1 USA only, maximum continuous exposure without hearing

protection, is 4 hours per day (OSHA 1910.95 b 2).

CONTROL VALVE SAFETY Control Valves may ‘stick’ (spool bind) in the incorrect position due to many factors including contaminated hydraulic fluid. Control Valves may stick due to external factors such as the misapplication of paint, mechanical damage arising from shipping abuse, etc. The measures taken during the manufacture of this equipment, the maintenance regime and other measures detailed in this manual ensure the hydraulic fluid remains free from contamination significantly reduces the prospect of such incidents occurring. If, however, the User notices that a control valve is not returning to neutral, it is reluctant to do so, or the control valve fails to function, the User is to immediately stop using the equipment and isolate the equipment from the hydraulic supply, until such time as a competent hydraulic technician has inspected/repaired the equipment and deemed it safe to use. HYDRAULIC OIL Hydraulic oil must be filtered to a minimum of 25 microns. Filters should be changed regularly. It is recommended that spin-on type filters be changed after 50 hours of initial use and then after every two hundred fifty hours of use. Use of a filter condition indicator is recommended. BASIC HYDRAULIC SYSTEM SAFETY MAINTENANCE On a shift basis, perform visual checks of all accessible hydraulic connections checking for leaks or any obvious signs of damage, chaffing, etc. If you observe a leak, discontinue use of the equipment. As with any hydraulic system, if you are struck by a jet or stream of hydraulic fluid and you think it may have penetrated your skin or contacted your eyes, seek urgent medical attention. If any replacement parts are required always use exact replacements. Always protect valve spools from paint overspray. Faulty quick disconnects can cause high back pressures and potential problems with control Valves and other hydraulic components. See Section 5, HYDRAULIC LINES (B), for quick disconnect cleaning instructions.

DESCRIPTION and APPLICATION


The CLINCHER Tong is an “open-throat” design in which the tong can handle tubulars as small as 4 1/2 inches to as large as 7 5/8 inches in diameter. This system features two (2) jaws in the tong which encircle the pipe. Wrap around jaws and dies, combined with our low friction jaw technology, constant radial load cam system and compensating jaw design provide exceptional gripping capabilities with reduced pipe deformation, stress and marking. Using our non-marking aluminum die system or grit faced dies in the Tong will now allow stainless steel corrosion resistant alloys (CRA) to be run as quickly and easily as a traditional tong runs conventional steel tubulars. WARNING: Due to the possibility of a potential ignition source, aluminum dies are not to be used on carbon steel ferrous tubulars as per European Union regulations.

Notable Features and Benefits Low Friction Jaws increases cam angle efficiency to

allow use of aluminum dies

Splined Die System aligns the die with the tubular and more evenly distributes radial load, essentially wrapping the die around the tube reduces pipe stress, deformation and minimizes marking

Constant Cam Angle insures an adequate radial load is available regardless of relative rotation to enhance performance on undersized pipe

Die Retention Method provides an enhanced method of preventing equipment damage and die loss if the pipe is inadvertently moved while the tong or backup are still gripping the pipe

In addition to these unique features listed above, the CLINCHER Tong is also equipped with numerous standard features including:

Door Interlock prevents tong ring gear rotation whenever the tong door is open but allows control and operation of backup and lift cylinder at all times

Pressure Control Valve adjustable pressure control valves allow the customer to limit the amount of pressure applied and torque developed

The CLINCHER Tong can also be equipped with optional features including:

Encoder Adapter 1accepts customer’s turns encoder to signal to a torque/turn computer

Tong Handles with protects operators hands Closed Covers The features described above are covered by US and foreign patents or pending US and foreign patents. TONG APPLICATION After completing the make-up or break-out cycle, the jaws are opened by reversing the tong motor to drive the ring gear and cam surfaces in the opposite direction until the reversing pin contacts the ring gear shoulder. Springs are used to return the jaws to their fully open position.

1 Please note that for certain use within the European Economic

Area (EEA), there may be a requirement for this equipment to meet with the European ATEX Directive.

DESCRIPTION and APPLICATION


OPERATING TEMPERATURE The Clincher tong is designed to operate in an acceptable working temperature range using ISO68 hydraulic oil which is 130 degrees F (55 degrees C) to 170 degrees F (77 degrees C), in order to maintain proper viscosity of 100 SSU. WARNING: Within the EEA this equipment is certified for use at a maximum temperature of 180 degrees F (82 degrees C).

Furthermore, exceeding this temperature may have a detrimental effect on the life of this equipment. The working temperature of the hydraulic fluid is affected by the tong and backup and its duty cycle, but is affected more by the hydraulic power unit design. Factors such as horse power, flow rate, maximum pressure, reservoir size & shape, pump type (fixed or variable displacement), all play a role in heat generation and dissipation. The use of an oil cooler may be required if hydraulic oil temperatures approach the maximum of 180 degrees F (82 degrees C). OPERATING PRESSURE The Clincher tong hydraulic components and hydraulic systems are designed with a maximum working pressure of 2,400 psi (165.5 bar). WARNING: Whenever a Clincher power tong is connected to a hydraulic power source it is VITAL that the operator knows and confirms that the maximum pressure will not be exceeded (e.g. through the use of relief valves). Failure to confirm this may result in catastrophic failure.

STABILITY The design characteristics built into the Clincher power tongs and integral backups ensure their stability throughout all stages of the equipments life; including handling, traveling, installation and use. All personnel involved in moving, positioning, loading or unloading the power tong and or integral backup should ensure that the characteristics of the supporting surfaces (ground conditions, rig floor gratings, track rails, cargo boxes, containers or other hazards) are taken into account when positioning to ensure the safety of all personnel. In some cases customers may have their own design of cargo baskets or containers, therefore every situation must be assessed correctly before execution of a task.

CLES7625 / 7 5/8" STD CLINCHER TONG SPECIFICATIONS


Maximum Torque High Gear Low Gear

4,100 ft.lbs./ 5,559 Nm 25,000 ft.lbs./33,895 Nm

Maximum Operation Pressure 2,400 psi/165.5 Bar RPM @ 60 GPM/227 LPM: Hydraulically Shifted

(Using A-35 Valve Package) High Low

56 RPM 10 RPM

Handle Length STD Tong 38" / 96.5 cm Overall Length STD Tong 55 3/8" / 140.7 cm Overall Width / STD Tong w/o Handles 30 1/2" / 77.5 cm Overall Height STD Tong Overall Height STD Tong w/ Hanger Bracket

21 3/16" / 53.8 cm 38 1/2" / 97.8 cm

Weight STD Tong (approximate) 1,650 lbs. / 748.4 kg Tong Jaw Capacity 4 1/2" thru 7 5/8"

Operates using Steel Tooth Wrap Around Dies, Grit Faced Wrap Around Dies and Aluminum Wrap Around Dies

Standard Equipment: Optional Equipment: - Door Interlock - Tong Handles - Rigid Hanger Bracket - Two Speed Hydraulic Motor - Electronic Solenoid Dump Valve (Not rated for hazardous svc.) - Shipping Stand, or Skid - Varying Outlets for Torque Turns Computer Sending Units

Handle Length 38"

Overall Length 55-3/8"

4225 HWY. 90 EASTBROUSSARD, LA 70518(318) 837-8847

THIS DOCUMENT IS THE PROPERTY OF SUPERIOR MANUFACTURING &HYDRAULICS AND IS CONSIDERED CONFIDENTIAL. THIS INFORMATIONMAY NOT BE USED, DISCLOSED, COPIED, OR REPRODUCED IN ANYFORM, WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIORMANUFACTURING & HYDRAULICS.

LOG #08/07/07

REV. # DATEREF: P:\Manuals\Equip Manuals\Dwgs\CLES7625\Dimensions.wpg

Page 2 - 4

7 5/8" STANDARD TONGDIMENSIONS

CLINCHER WRAP AROUND DIES


Clincher Wrap Around Dies are available in three types: Fine Toothed Steel Dies: for low to ultra high torque

applications on carbon steel tubulars including tubing, casing, and drill pipe

Smooth Faced Aluminum Dies: for low to moderate torque

applications on corrosion resistant alloy (stainless steel) tubulars. WARNING: Due to the possibi-lity of a potential ignition source, aluminum dies are not to be used on carbon steel ferrous tubulars as per EU regulations.

Grit Faced Dies: for low to high torque applications

on corrosion resistant alloy (stain-less steel) tubulars where the use of steel dies is prohibited as well as on carbon steel tubulars where reduced marking is desired

CLINCHER Dies are designed to match the OD of the tubing, casing, coupling, or accessory being made up or broken out. Each die is stamped on the top or side to identify its size. Using Fine Toothed Steel Dies which are slightly larger than the tubular is acceptable provided the difference in diameters is less than 3/32" (0.093"). Aluminum and Grit Faced Dies should be matched with the specific tubular diameters required. Note: The use of improperly sized dies can result in reduced torque capacity, increased pipe marking, and reduced die life.

CAUTION: Do not attempt to grip tubular diameters which are larger than the dies being used. Failure to observe this precaution can result in damage to the tubular or tong jaws. CLINCHER Wrap Around Dies are manufactured in specific diameters to match standard tubing and casing diameters, API coupling diameters, selected work string connection diameters and certain commonly used premium connection coupling diameters. CLINCHER Wrap Around Dies should not be used on tubulars which are larger than the nominal die size. Steel Toothed Dies can be used on tubulars which are no smaller than 3/32" (0.093") less than the nominal die size. Aluminum and Grit Faced Dies should be matched with the specific tubular diameters required. Note: Fine Toothed Steel Dies are normally stocked in our Broussard, Louisiana facility. A partial listing of commonly manufactured sizes is shown below. Aluminum and Grit Faced Dies are normally made to order although a limited range of sizes and small quantities may be available from stock. Contact SUPERIOR Manufacturing & Hydraulics for information concerning availability of stock and special die sizes.

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Phone: (337) 837-8847Fax: (337) 837-8839


Wrap-Around Die System

Clearance Radial Reaction

Tangential Reaction

Patented Spline & Die

TECH UPDATE

A brief explanation of oil field dies, the evolution of the CLINCHER™ Tong Die, and advances in hydraulic power tong technology.

SUPERIOR’s CLINCHER line of power tongs, backups, and accessories supplies the oil industry with equip-ment used when installing oil field tubing, casing, and drill pipe. These products are hydraulically powered wrenches which grip the exterior surface of the pipe and transmit torque to tighten or loosen the pipe’s threaded connection. Traditionally, tongs employing a series of hardened steel dies with sharp teeth were used to grip oil field tubulars. Early steel die designs were made from strips of flat bar stock. These early dies ranged from approxi-mately 3/4" to 1 1/2" in width and were approximately 4" long. They are known as strip dies because of their long narrow geometry. These dies were in-stalled in a holder, known as a jaw, in sets of 2 or 4 and arranged in a v-block configuration. The jaws holding the strip dies are installed in opposed pairs in a power tong. As the tong is oper-ated, a cam system generates radial loads which force the jaws to close on the pipe and cause the teeth of the die to penetrate the pipe’s surface. (ref. Figure 1)

In high torque applications the pipe is loaded on the leading edges of the jaws while the trailing edges are unloaded. Under these conditions, the strip die can severely mark the pipe because the strip die provides essen-tially only line contact. The limited contact area associated with strip dies can also lead to permanent pipe de-formation under high torque conditions. In an effort to reduce the depth of the marks left by strip dies and increase the contact area, strip dies were modified to provide a contoured sur-face which matched the radius of the pipe. In 1985 Superior introduced the CLINCHER Splined Tong Jaw and Wrap-Around Fine Toothed Steel Die system (ref. Figure 2). This wrap around die replaced the two traditional tong jaws and strip dies resulting in an increase in contact area to approxi-mately 230 degrees or 64% of the circumference.

CLINCHER Wrap-Around Dies are fixed to the jaws by means of a patented spline arrangement which insures proper alignment and uniform distribution of radial loads (ref. Figure 3). This causes the torsional loads to be distributed across the entire die unlike the concentrated loading observed in strip dies. The increased contact area combined with the fine tooth pattern significantly reduces the marking of tubulars under high torque conditions when com-pared to the traditional die system. Simultaneously, the increased contact area reduces the stress in the tubular and the possibility of permanent deformation. In 1987, we introduced the CLINCHER Hydraulic Backup which also uses our Wrap-Around Die. When these dies are installed in CLINCHER Backups, CHROME-MASTERm and LOCKJAWm Tongs having 3 jaws, this contact area is increased to as much as 340 degrees or 94% of the tubular’s circumference.

Published 01/2005

CLINCHER Die Technology (Ver 8.0 01/11/05) Page 2 of 4 e-mail: [email protected]

Page 3 - 4

Figure 4

In the last decade, the use of carbon steel tubulars has declined and the use of exotic stainless steel tubulars has increased. This change is in response to declining reserves of sweet, non-corrosive hydrocarbon reserves and the increase in production from hot, corrosive oil and gas reservoirs. Some of these corrosion resistant alloys (CRA) materials can have their corrosion resistance severely degraded if their surface is damaged and/or contami-nated with small particles of iron or steel (ref. IADC/SPE Paper 36386). The marks left behind by traditional slips and elevators used to handle the tubulars or by the tong dies used to tighten the tubulars can also reduce the mechanical strength and lead to premature fatigue failures. Since these exotic CRA tubulars cannot be used with any type of toothed steel die it became necessary to develop a non-marking die. CLINCHER Non-Marking Wrap-Around Dies are manufactured from a special aluminum alloy and are machined with a smooth face which matches the radius of the tubular. They grip the pipe and transmit torque without penetrating the pipe by using the frictional force developed between the die and the pipe. Standard tongs used by the oil industry do not develop enough radial load to allow non-marking dies to function. CLINCHER developed its CHROMEMASTER to allow non-marking dies to be used with standard tubing and casing tongs. The CHROMEMASTER works by increasing the amount of radial load applied to the pipe. Three wrap-around non-marking aluminum dies virtually

encircle the pipe to reduce deforma-tion and stress levels in the tubular. For more information on the CHROME-MASTER as well as the CLINCHER Hydraulic Power Tong which drives it and our CLINCHER Hydraulic Backup, contact Superior Manufacturing and Hydraulics. For a given radial load, torque values for Non-Marking Dies can vary significantly from tube to tube because they are totally dependent upon the coefficient of friction. The presence of a small amount of varnish, moisture such as dew, or some other type of lubricant can reduce this value sub-stantially. If this occurs, the torque values can be increased by the addi-tion of CLINCHER silicon carbide screen cloth. The particles on this cloth are sized to span the film of lubricant between the pipe and the die to increase the coefficient of friction. CLINCHER GRIT FACEDm Dies were developed to further enhance die torque capabilities for CRA tubulars and eliminate the need to install a new sheet of silicon carbide screen cloth for every connection. The CLINCHER GRIT FACED Dies are available for our CHROMEMASTER, CLINCHER Backups, CLINCHER LOW-FRICTIONm Tong Jaws, CLINCHER LOCKJAW Tongs and CLINCHER Bucking Units. GRIT FACED Dies typically provide at least twice the torque which can be achieved using aluminum dies with silicon carbide screen cloth. CLINCHER GRIT FACED Dies do not leave the tooth marks normally seen with conventional steel dies. Like the aluminum dies, GRIT FACED dies do

not allow steel, iron, or carbon to contact the pipe body. The absence of teeth greatly reduces stress risers and crevices which have been observed to cause premature failures in CRA tubing strings. First proven in critical North Sea applications, the CLINCHER GRIT FACEDm Die is rapidly becoming the standard die used with CRA strings around the world. When properly used GRIT FACED Dies will not leave any significant marks on the pipe. During recent lab tests the maxi-mum depth of marks left after very high torque applications was 0.004 inches. It is our belief these results are considerably better than competitive systems as they are shallower, are in a random pattern which reduces stress risers in the tubulars, and they do not contaminate the CRA tubing with steel, iron, or carbon. GRIT FACED dies provide another major benefit. Running of the tubulars is faster, safer, and less tiring for operators because they do not have to replace six sheets of carbide paper every joint. Instead, we recommend one die be removed every 10 joints and replaced with a die which has been brushed to remove any accumulated dirt or paint. The introduction of the GRIT FACED Die brings the number of tong dies available to three as shown in Figure 4. The aluminum is a non-marking die used on CRA tubulars at low to moderate torques, GRIT FACED Dies for CRA tubulars at low to high torques, and the fine tooth steel die is used in low to ultra high torque applications on carbon steel tubulars.

CLINCHER Die Technology (Ver 8.0 01/11/05) Page 3 of 4 e-mail: [email protected]

Page 3 - 5

Figure 5

Superior Manufacturing & Hydraulics is committed to continually improving our products and expanding our product lines. In early 1997 we intro-duced the CLINCHER LOCKJAW Tong. Like our other tongs, the LOCKJAW tong utilizes our Wrap-Around Die system (ref Figure 2). This is where the similarity with all other tongs ends. The LOCKJAW features a three jaw system which provides more than 300 degrees of die coverage to further reduce pipe mark-ing under high torques. It also features our patented constant cam angle and a load control system which generates the radial loads required to use our Non-Marking Aluminum and GRIT FACED Dies without a CHROMEMASTER. In October 1997, CLINCHER introduced its latest tong innovation to the industry. The CLINCHER LOW-FRICTION Jaw System now allows

Non-Marking Aluminum and GRIT FACED Dies to be used in conven-tional CLINCHER Tongs which are not equipped with CHROMEMASTERS. These innovations now allow a single tong and backup assembly to be used for running normal steel tubulars, drill pipe, or CRA tubulars. Eliminating the need for separate tong systems reduces capital and spare parts re-quirements for service companies using the conventional tongs. These mecha-nical systems will be easier to maintain and less prone to failure than old fashioned hydraulic systems to further reduce operating costs. The simple mechanical system reduces operator training and experience re-quirements when compared to other systems used with CRA tubulars. The CLINCHER LOCKJAW Tong and the CLINCHER Tong dressed with LOW-FRICTION Jaws are significantly

lighter in weight than competitive systems which will reduce operator fatigue and improve safety. GRIT FACED Dies enhance job safety by reducing operator fatigue and elimi-nating the need to reach inside a tong and backup to replace the silicon car-bide screen cloth at every connection. GRIT FACED dies can also reduce overall operating cost by reducing the time required to run casing and tubing strings. CLINCHER GRIT FACED Die tech-nology was recognized at the 1998 Offshore Technology Conference in Houston, Texas, where Superior Manufacturing & Hydraulics was pre-sented with a Special Meritorious Award for Engineering Innovation by editors of Petroleum Engineer International.

GRIT FACED Inserts for Slips, Elevators and Safety Clamps As part of our ongoing program providing tubular handling inno-vations to the oil field, SUPERIOR Manufacturing & Hydraulics is pleased to announce we are now pro-viding inserts for slips, elevators, and safety clamps which feature our GRIT FACE Technology (ref. Figure 5). This technology, field proven in tong applications, now provides the indus-try with handling tool inserts designed to protect CRA tubing and casing strings from the hazards associated with the use of conventional steel toothed inserts. A combination of exotic materials used in these new inserts protect CRA tubulars from contamination associated with con-ventional steel inserts. GRIT FACED inserts are offered to fit almost all types of tubular handling tools. We provide our inserts for manual and power slips/elevators used to handle tubing, casing, drill pipe and drill collars. Safety clamp inserts are available for handling drill collars and downhole tools. Inserts are also avail-able for manual tongs used with tubing, casing, and drill pipe.

US and foreign Patents Pending. CLINCHER, CHROMEMASTER, LOCKJAW, LOW-FRICTION and GRIT FACE are marks of SUPERIOR Manufacturing & Hydraulics. CLINCHER Die Technology (Ver 8.0 01/11/05) Page 4 of 4 e-mail: [email protected]

Page 3 - 6

Figure 6

Two different styles of GRIT FACED inserts are available. One has a cylin-drical surface which has been coated with our grit material. This style insert, known as a “smooth” insert because it doesn’t have any teeth, is used to handle most CRA tubular goods. The “smooth” insert will accommodate tubulars who’s OD is coated with moderate amounts of foreign materials such as pipe mill coatings. Our insert style has “teeth” which are coated with our grit material to protect the tubulars from iron contamination. The mud grooves and recesses between the teeth provide room to accommodate large amounts of foreign materials which are often found on the exterior of tubulars when removed from wells.

To insure maximum effectiveness during use, both types of inserts must be periodically inspected and cleaned of foreign materials using a wire brush. Our in-house laboratory testing, and tests performed by an independent third party have demonstrated the marks left on tubulars by both of our insert styles are almost negligible. While our GRIT FACE insert system is not totally non-marking, the depth of the imprint left on the tubular after the application of very heavy loads is significantly less than the depth of slip marks left by conventional inserts. Smooth style GRIT FACED inserts do not leave aligned “slip marks” which are known to reduce mechanical strength

and lead to premature corrosion or fatigue failures in tubular goods. Figure 6 compares the marks left by “smooth” GRIT FACED inserts with standard toothed inserts. Close exami-nation will show it is almost impossible to distinguish the im-pressions left by the GRIT FACED insert from the normal pipe mill surface imperfections. It is our belief these results are considerably better than competitive systems as they are shallower, are in a random pattern which reduces stress risers in the tubulars, and they do not contaminate the CRA tubing with steel, iron, or carbon. As an additional benefit, our GRIT FACE insert system does not require specially adapted handling tools so it can be used with almost all handling tools in use today.

Typ. Pit Depth 0.0025 – 0.003"

Typ. Pit Depth 0.005 – 0.006"

ASSEMBLY TORQUE REQUIREMENTS


FASTENER LUBRICATION AND MAKE UP TORQUE REQUIREMENTS Most bolts, nuts and other threaded components are to be lubricated with Never-Seez or equivalent before assembly. Certain fasteners are to be assembled using permanent or removable Loctite as indicated in the assembly instructions and drawings. All tapered pipe threads are to be treated with Lok-Tite 542 or equivalent sealing compound to prevent leakage. CAUTION: Do not use Teflon tape. Improper application of Teflon tape can cause joint failures. Teflon tape can release large particles which can plug small passages in hydraulic equipment. All standard fasteners used in CLINCHER products are to be GRADE 8 or better. DO NOT SUBSTITUTE lesser grades of fasteners. All fasteners are to be made up to the torque charted below. Failure to properly assemble these fasteners can result in their loss, product malfunction and ultimately result in situations where personnel can be exposed to dangerous situations.

LUBRICATION STANDARDS Bearings and gears must be lubricated to minimize friction, cool, exclude foreign matter and prevent corrosion. Superior recommends using Texaco Marfak MP 2 or equivalent for all grease zerts, roller bearings and bushings. Gears located within the clutch housing or between the tong plates are to be heavily lubricated using PLUSCO 855 or equivalent. Reference Lubrication Specifications on following page. IMPORTANT NOTE: Grease all zerts located on the top and bottom of the tong. Certain dumbell roller shafts including the brake shaft and the ones located above the tong legs can only be lubricated from one side. Rotate the ring gear and cage plate assembly to visually confirm grease is being displaced on both ends of each dumbell roller assembly.

STD TONG FASTENERS

Size Application Torque 3/8"-16

Set Screws bearing caps, door switch adj. sleeve * 1

3/8"-16 NC encoder hole cover, hyd. shift cyl. to drive mount plate, brake bands & tabs, cage plate spring bolts, ring gear key, door protector flap bolts, tong jaw bolts

38 ft lbs

7/16"-14 NF tong plates 61ft lbs

1/2"-13 NC brg. caps, cage plate bolts, reversing pin, spring plunger plate, motor mounts 93 ft lbs

5/8"-11 NC cage plate spacer bolts, door spacer bolts 180 ft lbs

3/4"-10 NC drive mount plate, spring plunger, hanger bracket 317 ft lbs

7/8"-14 NF cam follower nuts 63 ft lbs

1"-8 NC shift cylinder bearing plate 100 ft lbs

1 1/2"-12 NF idler shaft 1,200 ft lbs

*1 Bearing Caps: Coat with removable Loctite, tighten until screw contacts bearing, back off 1 turn. Door Switch Adj. Sleeve: Coat with removable Loctite, tighten by hand until snug.

LUBRICATION SPECIFICATIONS


Use an EP synthetic grease that meets or exceeds the following specifications:(Used in tong case)

Use an EP synthetic grease that meets or exceeds the following specifications:(Used as bearing grease)

Type High Temp MP Type N/A

NLGI Consistency Grade 1 NLGI Consistency Grade 2

Color Medium Green Color Blue

Lithium Complex Soap, wt% Non Soap Lithium Complex Soap, wt% 14

Serv. Temperature 0 Deg. F – 450 Deg. F Serv. Temperature N/A

Base Oil Viscosity:

@ 100º F @ 200º F

1300 SUS 89 SUS

Base Oil Viscosity: ASTM D 445

@ 40ºC, cSt @ 100ºC, cSt

150 14.5

Viscosity Index 77 Viscosity Index N/A

Penetration, dmm Worked ASTM D 217

325-340 Penetration, dmm Worked, 60X ASTM D 217

280

Dropping Point, ºF ASTM D 566

500 ± Dropping Point, ºF ASTM D 2265

450+

Rust Protection, 5% SSW N/A Rust Protection, 5% SSW ASTM D 5969

Pass

Water Washout %wt loss @ 175ºF

N/A Water Washout %wt loss @ 175ºF ASTM D 1264

6.8

Timken, OK Load, lbs 50 Timken, OK Load, lbs ASTM D 2509

45

Bomb Oxidation 100 hrs @ 210ºF, psi drop

N/A Bomb Oxidation 100 hrs @ 210ºF, psi drop ASTM D 942

5 max

Applications High & Low Speed Bearings, Wheel Bearings, Pumps, Gears, Lubrication

Applications Industrial application where a high temperature/multipurpose extreme pressure grease is needed, Trailers

Use a premium quality hydraulic fluid that meets or exceeds the following specifications:

Humble Hydraulic H 68

ISO Viscosity Grade 68

Base Oil Viscosity: ASTM D 445

cSt @ 40ºC cSt @ 100ºC

65.0 8.5

Viscosity Index – ASTM D 2270 95

Pour Point – ASTM D 97 -9

Flash Point – ASTM D 92 C(ºF) 222 (432)

Demulsibility – ASTM D 1401 41/39/0 (20)

Vickers 104C (IP281) Pass

Vickers M-2950-S Quality Level

Vickers I-286-S Quality Level

TOST – ASTM D 943 2000+

OPERATIONAL INSTRUCTIONS


PERSONNEL TRAINING All personnel installing, operating, repairing or maintaining equipment or those in the vicinity of this equipment should be trained in rig safety, correct tool operation and maintenance as applicable. This measure helps ensure the safety of everyone exposed to the equipment for whatever purpose or reason. During installation, operation or maintenance of this equipment personnel should wear appropriate personnel protective equipment (PPE). SUSPENSION A) CLINCHER Tongs should be hung from a 7/8"

(22 mm) high strength IWRC wire rope with a minimum breaking strength/load of 31 tons (28.1 tonnes). It should be hung as close to the center of the drill rotary without interfering with operation of the drill string and lifting equipment. It is recommended the operator make use of the CLINCHER Lift Cylinder. If this equipment is to be used in the EEA, the CLINCHER Lift Cylinder must be used as a condition of the ‘CE Marking’. The CLINCHER Lift Cylinder incorporates a hydraulic cylinder and manual lift spring. The hydraulic cylinder portion is used to assist in the raising and lowering of the tong and backup while the spring allows for movement during make-up and break-out. WARNING : The suspension system must allow the tong to easily move down a distance equivalent to the thread make-up length. If significant resistance is encountered the suspension system may be subject to load which could cause its failure, damage equipment, or expose personnel to severe or fatal hazards. RIGGING UP LIFT CYLINDER Attach suspension cable to hydraulic rod end of lift cylinder assembly using appropriate shackle. Carefully raise lift cylinder assembly until it is vertical. Position to allow an appropriate shackle to be connected to the tong’s lifting bail or bridle. Connect lift cylinder quick disconnect to quick disconnect on tong valve package.

B) Assure that tong is suspended in level manner. Both tong

and the backup must be level at the point they contact the tubular. Using adjustment screws and slots in rigid hanger assembly, adjust tong so that it hangs level on horizontal axis and is parallel to tubular on vertical axis.

C) Make certain that floor space is adequate to maneuver

tong on and off pipe. The space must be clear of obstructions to allow safe and unrestricted operation.

D) Attach 1" (26mm) IWRC minimum wire rope with a 51.7 ton (43.4 tonne) minimum breaking strength or better, as a tong back up line at 90 degree angle to tong and at same level to insure proper readout of torque indicator. You should always have snubbing line attached. Use of an integral hydraulic backup is safer than manual backup, but operators should maintain additional safety of snubbing line to prevent injury in case of hydraulic failure or the failure of operator to have backup properly applied to tubular. This equipment generates extreme torque and should be used with caution.

JAW AND DIE INSTALLATION A) WARNING: No work of any type, including changing of

dies, is to be carried out while the tong and backup are connected to any hydraulic power supply.

B) Determine O.D. of tubular to be made-up or broken-out.

Use proper dies to bite O.D. of tubular and insert as follows: Remove sliding head jaws (2) from cage plate pockets. Insert one jaw with proper dies into pocket assuring the jaw roller pin faces upward. Repeat procedure for other side.

HYDRAULIC LINES A) See Warning ‘A’ above. B) Always inspect hoses and quick disconnects prior to

installation for abrasions, kinks, and other visible damage. Clean quick disconnects with clean, lint free cloth, approved safety solvent or compressed air as needed to insure no foreign matter is introduced into hydraulic system.

C) Install hydraulic supply hose and hydraulic return hose

between tong and hydraulic power unit. Be advised that the standard installation on Clincher tong calls for 1" Hydraulic Supply hose and 1-1/4" Hydraulic Return hose. The differing hoses eliminate the possibility of attaching the wrong hose to the wrong outlet while at the same time reducing back pressure in your hydraulic system. It is important the operator MUST ALWAYS fit the 1 1/4" return hose first when coupling the power tong to ensure free flow back to the reservoir. The reverse procedure MUST ALWAYS be followed when disconnecting the power tong.



TYPICAL SNUB LINE INSTALLATION

NOTE: SNUB LINE IS PERPENDICULAR TO AXIS OF TONG

TONG OPERATION A. Insure proper dies are installed. Connect hydraulic hoses,

verify reservoir is full of hydraulic fluid and insure suction valve is open.

B. Open bypass valve to hydraulic system, then check to make sure all hose connections are secure and hydraulic system is free of leaks.

C. Be certain door is completely closed before operation to insure safe operation. The Clincher Tong is equipped with a optional door switch, which prevents operation of the tong when door is even partially open.

D. Use power unit start up procedure as outlined in your owners manual supplied by the manufacturer.

E. In the event hoses are not tightened securely, possible failures to hydraulic system can occur.

1) If pressure supply hoses are restricted or flow is blocked, pressure will increase in the hydraulic power unit, resulting in increased RPM in the power unit.

2) If return line hoses are restricted or flow is blocked, pressure will increase in the hydraulic power unit and the hydraulic system to the tong itself, resulting in the tong motor increasing to maximum pressure and possible motor seal failure.

F. After completion of A through E restart the power unit and allow engine to idle for approximately 10 minutes. Slowly close bypass valve to allow circulation of hydraulic oil through tong and hoses. Place in low gear position and rotate ring gear several times. Repeat in reverse. If correct jaw-die combination is installed, the unit is now ready to run pipe.

G. Adjust height of tong to a safe working height using the clearly marked Lift Cylinder Lift/Lower control.

H. Stand facing the Tong Door (the normal operators position), insert the locking pin into the rear cage plate hole (opposite the operators side). This pin allows ring gear to rotate clockwise (make-up) and engage the cam to close jaws on pipe.

I. Swing tong onto tubing.

J. Rotate ring gear clockwise until jaws lock on pipe and continue to rotate until desired amount or torque is applied.

K. After correct amount of torque specific to that connection has been applied, release tong jaws until throat in cage plate is aligned with door opening. Open door.

L. High and low gear is adjusted by use of the valve section

marked ‘Shift’, located on the far right side of the valve package. Push the lever forward for High and pull the lever for Low. Modes are shown on the tag located on the valve section.

DEPRESSURIZATION PROCEDURE A. Rotate tong to open throat position, fully retract backup

and pusher cylinders, fully extend lift cylinder.

B. De-energize hydraulic power unit.

C. Repeatedly actuate tong motor control valve fully in both directions while tong door is closed to dissipate any stored hydraulic pressure.

D. Remove HPU supply hose quick disconnect at tong.

E. Repeatedly actuate all control valve levers fully in both directions while the tong door is closed.

F. Remove HPU return hose quick disconnect at tong.

G. Disconnect any other hoses such as case drains or load sense if they are utilized.



TYPICAL TONG INSTALLATION

NOTE: TONG IS PERPENDICULAR TO TUBING

LIFT CYLINDERLIFT CYLINDERLIFT CYLINDERLIFT CYLINDER

LIFTLIFTLIFTLIFT

LOWERLOWERLOWERLOWER

SHIFTSHIFTSHIFTSHIFT

HIGHHIGHHIGHHIGH

LOWLOWLOWLOW

TONGTONGTONGTONG

MAKEMAKEMAKEMAKE

BREAKBREAKBREAKBREAK

LIFT CYLINDERLIFT CYLINDERLIFT CYLINDERLIFT CYLINDER

LOWERLOWERLOWERLOWER

LIFTLIFTLIFTLIFT

PUSHERPUSHERPUSHERPUSHER

FWDFWDFWDFWD

REVREVREVREV

OR

INTENSIFIERINTENSIFIERINTENSIFIERINTENSIFIER

EXTENDEXTENDEXTENDEXTEND

RETRACTRETRACTRETRACTRETRACT

CHROMEMASTERCHROMEMASTERCHROMEMASTERCHROMEMASTER

OPTIONAL

OPTIONAL OPTIONALSTD STD

BACKUPBACKUPBACKUPBACKUP

CLAMPCLAMPCLAMPCLAMP

RELEASERELEASERELEASERELEASE

OPTIONALSTD

OPERATIONAL HEIGHT It is important that all operators of power tongs maintain a safe working height for each operation. The safe working height is determined by ensuring that the operator has a clear unobstructed line of sight to the control valves and can operate all system controls with ease. If this is not the case, we suggest the use of approved work platforms or scaffolding. Individual companies or location will require the operator to first carry out an assessment of the risks involved and take these into account prior to starting an operation and throughout the duration of the task at hand.

CONTROL LEVER FACE PLATES

MAINTENANCE INSTRUCTIONS


Superior recommends that owners of Clincher Hydraulic Power Tongs, Backups, Chromemasters and accessories adapt a regularly scheduled maintenance program. Implementation of this type of program offers several benefits. First you decrease the possibility of anyone being harmed by the equipment. Second, you increase the life of your equipment. And third, you may find a problem before it escalates to a costly repair or down time on the job. A major inspection (described at the end of this section) should be carried out if equipment is suspected to have been damaged during transit, has suffered some form of significant overloading / impact during operation, or is to be mobilized to a remote location where maintenance operations are difficult to carry out. It is strongly recommended that the CLINCHER Tong, Backup and Hydraulic Power Unit be fully function tested upon installation, prior to being put into service. HYDRAULIC SYSTEMS AND COMPONENTS Hydraulic systems and components are designed for specific use in the oil and gas industry. The hydraulic pressure rating for this equipment can be as high as 3000 psi. Therefore, it is VITALLY IMPORTANT that prior to carrying out any work on any portion of the hydraulic system that you familiarize yourself with the hydraulic schematics. WARNING: No work of any type is to be carried out while the tong and backup are connected to any hydraulic power supply. It is recommended that you fully disconnect all hydraulic lines supplying power to the hydraulic system and utilize a method of isolation or lockouts on the control systems. Always take precautions when bleeding down any residual system pressure by ensuring the return (1 1/4") hydraulic line is disconnected last and that all control levers are in the neutral or open center position. While residual fluids will be minimal in quantity, it is VITALLY IMPORTANT that all residual fluids are secured in a suitable container taking the necessary precautions to safeguard and protect against potential environmental contamination. ROUTINE MAINTENANCE Cleaning - Upon return from each and every job: A) Pre-wash unit to remove majority of dirt and grease build

up as to allow removal of dies, and inspection of overall condition of unit.

B) Remove and inspect dies from tong and backup. Note any missing or damaged die retainers, and or die retainer bolts.

C) Remove side jaws from tong and inspect side jaw for missing or broken parts, damaged splines, broken ears (locking hooks on front portion of side jaws.)

D) Clean and inspect side jaws, jaw pins, jaw rollers for damage or excessive wear (cracks, breakage, and uneven wear patterns). Reassemble jaw sections replacing any damaged parts. Lubricate pins, and rollers and reinstall in tong.

E) Clean and inspect backup operating cylinder. Insure spline area is free from damage and any rust or dirt is removed. Replace any missing or damaged die retainer clips and die retainer bolts.

F) Inspect all hoses for wear, replace as necessary, or as per manufacturers recommendations.

G) Inspect hanger assembly to assure all parts are returned and in operating condition. (i.e. H-Plates, spring, leg springs, leg spring caps and pins.)

H) Replace jaw, pins and rollers in tong.

I) Lubricate tong’s cam followers (upper and lower), Idler and Pinion gear assemblies are installed with sealed bearings. There are no provisions to grease these bearings. Re-pack tong body cavity.

J) Install dies of a size needed for testing purposes, and attach hydraulic power unit to tong. Before energizing power unit make certain no one is working on tong or backup and all tools and parts are removed from the tong and backup.

K) Insert test mandrel of the exact same size as the dies which are installed in the tong and backup. Caution: Testing the function of the backup without the proper size dies installed and/or without the proper sized mandrel in place, you risk serious damage to the backup cylinder.

L) After power unit has reached operating R.P.M. and temperature, operate the backup control valve and close backup around test mandrel using sufficient flow and pressure to clamp mandrel and maintain pressure to backup. (Recommended operating pressure of 2,500 psi / 172 bar) Backup pressure gauge should match system operating pressure. After release of control valve you may experience a slight drop in backup pressure (up to 300 psi / 21 bar) this is normal. If backup pressure drops more than 300 psi within 2 minutes, you may be experiencing a hydraulic leak.



M) While maintaining pressure on backup visually inspect hoses, stainless steel lines, fittings, etc., for seepage of hydraulic fluid. Repair or replace parts causing leaks. If you see no visible external leaks and your backup is still losing pressure, there may be an internal leak in the operating cylinder or load holding valve allowing fluid to bypass the piston. It is recommended that the backup be returned to the manufacturer for repair.

N) If at this time your backup is functioning correctly, open and close unit several time to insure consistent operation.

O) With the proper dies installed in the tong and backup, and test mandrel locked in the backup, place reversing pin into the make-up position, set tong into low gear and operate tong through several cycles of locking, biting and torquing to required torque. Change reversing pin to break-out position and repeat. Repeat same procedure in high gear. Note: Torque developed in high gear is considerably less than torque developed in low gear.

P) WARNING: This test must be performed in low gear. Test door interlock system by opening door slightly with tong rotating. (Remove test mandrel for this procedure.) The tongs rotation should stop. If tong rotation fails to stop, close door, cease rotation, deactivate power unit, and inspect door interlock switch for damage. Insure that adjustment collar is oriented to allow wheel of door switch to fit into recess on collar. WARNING : If door switch system is not functioning properly tong must not be used.

Q) Re-inspect tong and backup hydraulic system for leaks.

R) If at this time the unit is functioning as intended, replace all covers and grease splines in tong and backup (side jaws and back jaws), tape or grease spools on control valves (to prevent paint from adhering to polished spool surface), prime and paint unit for storage.

DEPRESSURIZATION PROCEDURE A. Rotate tong to open throat position, fully retract backup

and pusher cylinders, fully extend lift cylinder.

B. De-energize hydraulic power unit.

C. Repeatedly actuate tong motor control valve fully in both directions while tong door is closed to dissipate any stored hydraulic pressure.

D. Remove HPU supply hose quick disconnect at tong.

E. Repeatedly actuate all control valve levers fully in both directions while the tong door is closed.

F. Remove HPU return hose quick disconnect at tong.

G. Disconnect any other hoses such as case drains or load sense if they are utilized.

RECOMMENDED LUBRICATION SCHEDULE PERFORMED AFTER COMPLETION OF EACH JOB Hydraulic Tong A) Cam followers: upper and lower (all) B) Re-pack tong cavity C) Idler and Pinion gear shafts (if sealed bearings have been

replaced by non-sealed bearings) D) Jaw rollers and pins: Remove jaw pins and rollers, clean

and lubricate with gear grease E) Inspect hydraulic fluid for foreign material and contami-

nants. Filter or replace. You must filter or replace entire system including power unit tank and lines along with tong to insure all contaminants are removed.

ANNUAL MAJOR MAINTENANCE Inspection and repair Routine preventative maintenance will reduce risks to personnel, significantly extend the operating life of your equipment, reduce operating cost and avoid downtime. Superior recommends a program of frequent routine inspection, and if equipment is suspected to have been damaged during transit, has suffered some form of significant overloading/impact during operation, or is to be mobilized to a remote location where maintenance operations are difficult to carry out, perform the following: A) Visually inspect components on power tong or backup

which could possibly have been damaged either during operation or transit. i.e. Damage to hanger assembly, hydraulic backup, mounting legs, or hydraulic valve assembly.

B) Check test date. Ensure that a load test and inspection was carried out within the last 9 months (as per AUWED 95/63/Ec (LOLER) in the EEA).

C) Check ring gear. Check for any signs of damage or wear.

D) Remove motor and valve assembly from the tong body.

E) Check motor seal. Apply hydraulic power, run motor and visually check motor seal for any signs of leakage.

F) Check drive gear, high and low pinion gears. Check for excessive sign of wear on motor gear.

G) Check condition of control valve spools. Activate valves and check for any sign of wear, pitting, or scoring of the chrome surface of spools. If spool is damaged in any way, the complete section must be changed out. Spools are not interchangeable.



H) Check gear selector and shaft. Visually inspect the shifting shaft for alignment and straightness.

I) Check Hi/Low Gear assembly. Visually inspect high and low clutch and gears for any sign of chipped, broken, or worn teeth.

J) Check dumbell rollers, shafts and bushings. Check for excess movement on either bearings, bushings, shafts or dumbells.

K) Check idler gears and center pinion shaft gears and bearings. Check that there are no signs of worn, chipped, or broken teeth on idler and center pinion shaft gears.

L) Check door bearings. Visually check excess movement on bearings at door assembly. If excess movement is found door must be removed making careful note of bearing washers positions for reassembly.

M) Check door switch system. Visually check that door switch valve has sufficient strength to hold door in closed position. If this is not the case, then repairs are required.

N) Check door safety device. Functionally check tong door safety switch. Engage low gear, open tong door and push rotor control lever forward as if to rotate rotor. If safety device is operational then the rotor will not rotate.

O) Check lifting hanger test date. Check lifting hanger for damage. Ensure that a load test and inspection was carried out within the last 9 months (as per AUWED 95/63/Ec (LOLER) in the EEA).

P) Check condition of all hydraulic hoses and fittings. Visually inspect all hydraulic hoses fitted to the tong and in the backup for any signs of leaks, cuts, or wear.

Q) Reinstall all parts which were removed for inspection and/or damage. Connect to hydraulic power supply and function test operation of tong in high, low, forward, and reverse. Torque test utilizing appropriate dies and test mandrel. Test operation of lift cylinder.

R) Inspect power unit system according to manufactures specifications.

S) Lubricate tong and backup according to maintenance schedule preceding this section.

T) Paint, remembering to mask off surfaces not intending to paint with grease or masking tape.

U) Complete dated inspection report giving details of all duties performed along with complete list of items replaced.

DU�� BEARING DRY WEAR PROCESS

1. 2. 3.

1. Running-in completed. Low wear rate starts when up to 10% of the bronze is exposed.

2. Typical surface appearance when DU� bearing approaches its half life with 40% to 50% of the bronze exposed.

3. Bronze is beginning to smear near the end of DU’s useful life as a dry bearing.

Over 75% of the bronze is visible at the surface. For additional information about DU bearings, please contact

Garlock Bearings Inc, 700 Mid Atlantic Parkway, Thorofare, New Jersey 08086.

(609) 848-3200 FAX: (609) 848-5115

TROUBLESHOOTING


HYDRAULIC SYSTEM

Hydraulic Pump Making Excessive Noise:

Problem Solution

A) Restricted or clogged intake line Clean line, check for contamination.

B) Contaminated fluid Flush system, change fluid.

C) Restricted vent Clean or replace air vent.

D) Air in fluid Check for leaks and be certain fluid suction in tank is well below hydraulic fluid in reservoir.

E) Damaged or worn parts Repair or replace damaged parts, check fluid for contamination.

F) Excessive RPM Check PTO, gears, and recommended speed to assure proper pump is installed for operation.

G) Increased friction Make sure pump has been assembled using correct torque values.

H) Damaged or worn relief valve. Replace relief valve.

I) Damaged or worn check valve. Replace check valve.

J) Restricted discharge Check to make sure relief valve is set to proper pressure.

K) Valve system restricted Inspect and repair or replace defective parts, check system for contamination.

Excessive Wear to Hydraulic Components:

Problem Solution

A) Fluid contamination Flush fluid system, replace with new fluid.

B) Components misaligned Inspect and realign.

C) High operating pressures Gauge and set to proper pressure.

D) Exhausted fluid (depletion of additives) Flush fluid system, replace with new fluid.

E) Air in fluid Check for leaks, and be certain fluid suction in tank is well below hydraulic fluid in reservoir.

F) Shortened bearing life Check alignment, insure proper lubrication to non-sealed bearings.

Slow Tong Speed:

Problem Solution

A) Restricted supply line Clear supply line and check intake on reservoir.

B) Low fluid level Add fluid to proper volume.

C) Air leak Locate and repair leak.

D) Pump speed insufficient Assure proper pump speed for application.

E) Damaged or worn equipment Isolate pump and check pressure to determine whether motor or pump is defective. Repair or replace defective part.

F) Pump not primed Check fluid viscosity and restrictions of intake line. Replace fluid if inadequate for operating temperature.

G) Low or no flow from supply line Check to assure couplings are securely fastened.

H) Hydraulic bypass valve malfunction Inspect. Adjust unloading pressure. Replace or repair as necessary.

TROUBLESHOOTING


HYDRAULIC TONG SYSTEM

Insufficient Torque:

Problem Solution

A) Door switch malfunctioning Check to make sure door is completely closed. Inspect door switch and dump valve. Replace or repair door switch and/or dump valve.

B) Relief valve malfunctioning Relief set too low, broken valve spring, contamination or defective seals.

C) Damaged or worn pump parts Inspect, repair, or replace.

D) Slow pump speed Assure proper pump speed for application.

E) Improper system fluid Check fluid viscosity and replace fluid if inadequate for operating temperature.

F) Directional control valve set improperly Check relief and directional control valve. Neutral should return slightly to reservoir.

G) Damage tong motor Inspect, repair, or replace.

H) Restriction of supply line, excessive back pressure Check to assure couplings are securely fastened.

I) Defective gauge or load cell Inspect, repair, or replace. Assure unit has been calibrated to proper arm length. NOTE: When using Clincher integral backup system, it is the length of backup arm, NOT the tong arm length.

Difficulty Shifting Gears:

Problem Solution

A) Broken key in shifting yoke Inspect and replace key stock in shifting yoke.

B) Worn or damaged shifting yoke pins Inspect and replace broken or worn pins.

C) Insufficient lubrication Pump grease into both zerts located on shift housing.

D) Detent ball bearing spring set too tight Inspect and relieve pressure by adjusting set screw/spring plunger on shifting gear PN 55084-02.

Failure to Grip Tubulars:

Problem Solution

A) Jaws move out from neutral, but fail to penetrate pipe. Tong not perpendicular.

Inspect die size and replace with correct dies for pipe. Wrong size dies for tubulars. Assure suspension of tong is perpen-dicular to tubulars. Adjust hanger as necessary.

B) Jaws fail to move out of neutral. Brake band not tight enough, faulty cam followers, rust debris or damage to jaws.

Inspect for excessive wear on brake band. Inspect and replace defective cam followers. Remove rust and debris from jaws, and jaw pockets. Inspect jaw rollers and pins for wear, flats, and lubrication. Repair, replace, and lubricate as needed.

C) Tong will not release from tubular. Brake band not tight enough, defective cam followers in cage plate, insufficient lubrication to jaw pin and roller.

Inspect for excessive wear on brake band. Inspect and replace defective cam followers. Remove rust and debris from jaws, and jaw pockets. Inspect jaw rollers and pins for wear, flats, and lubrication. Repair, replace, and lubricate as needed.

D) Tong motor runs but ring gear does not rotate. Broken gears or defective shift in hydraulic tongs system.

Inspect and replace defective gears. Inspect and repair or replace defective shifting parts.

TROUBLESHOOTING


HYDRAULIC TONG SYSTEM

Failure to Grip Tubulars:

Problem Solution

E) Tong binds under light load. Worn or damaged cam followers, dumbell roller bearing, or idler bearing.

Inspect and replace defective parts.

F) Ring gear rotates while control lever is in neutral. Replace control valve.

G) Shift will not stay in set position. Lost spring plunger.

Replace spring plunger.

H) Hydraulic fluid leaking from motor. Damaged or worn motor shaft seal.

Replace motor shaft seal.

HYDRAULIC BACKUP SYSTEM

Failure to hold tubulars:

Problem Solution

A) Incorrect die for size tubular Check pipe OD and match die size to pipe OD.

B) Dies have material compacted in tooth area; worn teeth.

Clean dies with wire brush and inspect. Replace with new dies if necessary.

C) Power unit pressure set incorrectly Inspect relief valve on power unit to make sure enough system pressure is being delivered to backup.

D) Counter balance valve not holding pressure Remove side plates on backup. Bench test and replace the defective counter balance valve.

E) Internal leakage in backup cylinder Disconnect lines and bench test cylinder. Repair or replace as necessary.

F) Jaws will not retract. Counter balance valve is stuck.

Replace counter balance valve.

G) External leakage of cylinder Repair or replace cylinder.

H) Control valve set to neutral, but jaws extend. Inspect control valve for damage and/or incorrect spool. Repair or replace as necessary.

SECTION 7 TONG SPARE PARTS LIST


Part Number Quantity Description

12501437 1 Seal for Rineer Motor

77217 2 Dovetail Jaw Pins

77218 2 Dovetail Jaw Rollers

1001 8 1/8 NPT Zerts

SLV1000-01 1 Door Switch Assembly

77215 1 Brake Band Assy.

3911873006 1 VA35-WHA Relief Cartridge

ACCESSORIES AND OPTIONS


Several different accessory items are available for the CLINCHER Tong to allow them to be customized to provide

a system most appropriate for the end user’s application.

CLES7625 STD Tong Accessories Compression Load Cell and Torque Gauge directly measures applied torque

Tension Load Cell and Torque Gauge directly measures applied torque

Solenoid Operated Module for Dump Valve (for non-hazardous services)

allows computer to limit torque applied

Adapter for Turns Proximity Switch allows computer to sense rotation

Lift Cylinder with Integral Spring Hanger controls vertical position

TSP-80 Tong Speed Control allows slow speed rotation with full torque

2 Speed Motors

Alternate Motor Displacements Please note that with the exception of the Lift Cylinder with Integral Spring Hanger, the above accessories are not ‘CE Marked’.

SECTION 9 STD TONG ILLUSTRATIONS


7 5/8" STD TONG ASSEMBLY (Assembly No. CLES7625) ......................................................................................... 9 - 3

GEAR TRAIN ................................................................................................................................................................. 9 - 4

RING GEAR ASSEMBLY (Assembly No. 77248).......................................................................................................... 9 - 4

SEVERE SERVICE CAM FOLLOWER ASSEMBLY (Assembly No. SSCF2250) ....................................................... 9 - 4

DOOR CAM ASSEMBLY (Assembly No. 77224).......................................................................................................... 9 - 4

IDLER GEAR ASSEMBLY (Assembly No. 7700701).................................................................................................... 9 - 5

PINION GEAR ASSEMBLY (Assembly No. 77201)...................................................................................................... 9 - 6

PINION BEARING ASSEMBLY (Assembly No. 77243) ............................................................................................... 9 - 6

PINION ENCODER BEARING ASSEMBLY (Assembly No. 77030) ........................................................................... 9 - 6

HIGH DRIVE GEAR ASSEMBLY (Assembly No. 77206) ............................................................................................ 9 - 7

DRIVE ASSEMBLY (Assembly No. 77071) MOTOR ASSEMBLY (Assembly No. 7702001) ..................................... 9 - 8

MOTOR ASSEMBLY..................................................................................................................................................... 9 - 9

CAGE PLATE ASSEMBLY (Assembly No. 7703701) ................................................................................................... 9 - 10

REVERSING PIN WELDMENT (Assembly No. 77220)................................................................................................ 9 - 10

TONG DOOR ASSEMBLY (Assembly No. 7704601).................................................................................................... 9 - 11

SPRING PLUNGER ASSEMBLY (Assembly No. 77258).............................................................................................. 9 - 11

DOOR SWITCH ASSEMBLY (Assembly No. 77250) ................................................................................................... 9 - 11

BRAKE BAND ASSEMBLY (Assembly No. 77215) ..................................................................................................... 9 - 12

BRAKE BAND TAB ASSEMBLY (Assembly No. 77246) ............................................................................................ 9 - 12

FRONT TONG LEG ASSEMBLY (Assembly No. 77261) ............................................................................................. 9 - 12

REAR TONG LEG ASSEMBLY (Assembly No. 77262)................................................................................................ 9 - 12

HANGER BRACKET ASSEMBLY (Assembly No. 55001) ........................................................................................... 9 - 13

7 5/8" STD TONG DOVETAIL JAW SET ASSEMBLY .............................................................................................. 9 - 14

VALVE BANK ASSEMBLY.......................................................................................................................................... 9 - 15

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Page 9 - 5

IDLER GEAR ASSEMBLYASSEMBLY NO. 7700701

8.5 8.7

8.68.3

8.1

8.4

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2.

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2.3

2.1

2.52.2



LOG #08/09/07

REV. # DATEREF: P:\Manuals\Equip Manuals\Dwgs\CLES7625\77201 Pinion.wpg

Page 9 - 6

PINION GEAR ASSEMBLYASSEMBLY NO. 77201

PINION ENCODERBEARING ASSEMBLY

P/N: 77030

PINION BEARING ASSEMBLYP/N: 77243

8.8.8.8.8.8.

8.

PINION ENCODER BEARING ASSEMBLYASSEMBLY NO. 77030

PINION BEARING ASSEMBLYASSEMBLY NO. 77243

9.9.9.9.

9.

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9.1

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REV. # DATEREF: P:\Manuals\Equip Manuals\Dwgs\CLES7625\77206 High Dr Gear.wpg

Page 9 - 7

HIGH DRIVE GEAR ASSEMBLYASSEMBLY NO. 77206

1193

276 1"-14 HEX NUT

1008-A 1/4" x 1 1/2" ROLL PIN

1

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NOTE:NEVERSEEZ NUT & ROD. TORQUE NUTTO 550 FT-LBS. DRILL 1/4" HOLE THRUNUT & ROD. INSERT ROLL PIN.

1



LOG #12/11/07

REV. # DATEREF: P:\Manuals\Equip Manuals\Dwgs\CLES7625\77071 Drive rev1.wpg

1

Page 9 - 8

DRIVE ASSEMBLYASSEMBLY NO. 77071

MOTOR ASSEMBLY NO. 7702001

Item # Qty. Part Number Part Name

2.1 1 77244 MOTOR

2.2 1 7701901 MOTOR SHAFT

2.6 4 1103 1/2" LOCK WASHER

2.5 4 1110 1/2"-13 x 1" HHCS

2.3 1 55088 SEAL RETAINER

2.4 1 12501437 POLYPACK SEAL

2.1

2.2

2.3

2.4

2.5

2.6

Rev. Date Description

Item 8-Corrected PN from 1300-02 to 1193. Item 9-Replaced 1" LW1 12/11/07PN 1218 & 1"-8 Jam Nut PN 1295 with 1"-14 Hex Nut PN 276 & addednote. Item 11-Added PN 1008-A.

iCOMPONENTSOF MOTOR

i RINEERGA-15 MOTOR

i SNAP RINGP/N: 1945

i MOTOR SHAFTBEARINGP/N: 0150710

i O-RINGP/N: 2-150

i SNAP RINGP/N: 0150111

POLYPACKP/N: 12501437

SEAL RETAINERP/N: 55088

MOTOR SHAFT


REF: P:\Manuals\Equip Manuals\Dwgs\Motor\Motor CLE5500+.wpg


LOG #10/04/06

REV. # DATEMOTOR ASSEMBLY

Page 9 - 9

W/ OUT WIPER RING

SNAP RINGP/N: 0150111

SEAL RETAINERP/N: 55088

POLYPACKP/N: 12501437

O-RINGP/N: 2-150

MOTOR SHAFTBEARINGP/N: 0150710

SNAP RINGP/N: 1945

MOTOR SHAFT

FOR CLARITY PURPOSE ONLYNOT TO SCALE

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BRAKE BAND RINGP/N: 77211

BRAKE BAND LUGP/N: 77214(2) REQD.

BRAKE BAND PADP/N: 77223

27.27.

27.

BRAKE BAND ASSEMBLY NO. 77215(2) REQD.

Page 9 - 12

30.3

30.230.1

BRAKE BAND TAB ASSEMBLY NO. 77246

30.30.

30.

(4) REQD.

FRONT TONG LEG ASSEMBLY NO. 77261(2) REQD.

24.24.

24.

24.1

24.2

24.3

REAR TONG LEG ASSEMBLY NO. 77262(1) REQD.

23.23.

23.

23.1

23.3

23.2



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REV. # DATEREF: P:\Manuals\Equip Manuals\Dwgs\CLES7625\77215 77246 77261 77262.wpg

HANGER BRACKET UPRIGHTP/N: 55163(2) REQD.

3/4"-10 x 3" HHCSP/N: 1176(2) REQD.

3/4" THREADED PIPE CAPP/N: 1613(2) REQD.

UPPER PADEYE BARP/N: 45001-S3A

(2) REQD.

3/4"-10 x 1 3/4" HHCSP/N: 1173(2) REQD.

3/4"-10 NYLOCK NUTP/N: 1167(2) REQD.

BATMAN HANDLEP/N: 45001-S1

UPPER PADEYE TABP/N: 45001-S3B

(4) REQD.

i

i

i

i

i COMPONENTS WELDED TOGETHER

Page 9 - 13



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REV. # DATEREF: P:\Manuals\Equip Manuals\Dwgs\CLE5500\Hanger 55001.wpg

HANGER BRACKET

ASSEMBLY NO. 55001

ASSEMBLY

3

2

5

7

1

6

4



LOG #08/09/07

REV. # DATEREF: P:\Manuals\Equip Manuals\Dwgs\CLES7625\CJDT77X Jaws.wpg

7 5/8" STANDARD TONG

SEE CHART FOR ASSEMBLY NUMBERS

DOVETAIL JAW ASSEMBLY

Page 9 - 14

1 1 SEE CHART LEFT JAW WELDMENT

Item Qty. Part Number Part Name

4 1 SEE CHART RIGHT JAW WELDMENT

3 2 77217 ROLLER PIN

2 2 77218 JAW ROLLER

6 4 234 3/8"-16 x 1/2" SHCS

5 4 DTI1602 1 1/4" W x 1/2" T x 5" L STRIP DIE

7 2 1044 3/8"-16 x 3" SHCS

Jaw SetAssembly Number

Left Jaw WeldmentPart Number

Right Jaw WeldmentPart NumberSize

4 1/2" CJDT77X4500 77X4500L 77X4500R

5" CJDT77X5000 77X5000L 77X5000R5 1/2" CJDT77X5500 77X5500L 77X5500R7" CJDT77X7000 77X7000L 77X7000R7 5/8" CJDT77X7625 77X7625L 77X7625R

5

1

3

4

7

2

LIFT CYLINDER

TONG

8

10

9

106

SHIFT CYLINDER

1 1 VA35-WHA HI-BOY WORK SECTION

Item # Qty. Part Number Description

2 1 VA35-AA440 INLET VALVE W/O RELIEF

3 1 3911873006 RELIEF CARTRIDGE

4 1 VA35-DA4 WORK SECTION

5 1 VA35-MA4 WORK SECTION

6 1 VA35-TR55 OUTLET SECTION

7 3 A35-V1526K-8 A35 8" HANDLE

8 2 X2-40 HHCS 1/2"-13 x 4 1/4"

9 1 X2-45 HHCS 1/2"-13 x 4 1/2"

10 3 1103 LOCKWASHER 1/2"



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VALVE BANK ASSEMBLY

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CLINCHER LOAD CELL AND TORQUE GAUGE ASSEMBLIES


The CLINCHER Tong is available in the version which accommodates tension style load cells. All information contained in this Technical Manual refers to products which

utilize tension load cells. Contact SUPERIOR for information concerning products using compression load cells.

Part Number SM25-38-T

Torque Rating 25,000 ft lbs

Handle Length 38 inches

Loadcell Type Tension Style

Loadcell Manufacturer SUPERIOR MANUFACTURING & HYDRAULICS

Loadcell Part Number CLC200

Torque Gauge Mfr. AOI or equivalent

Torque Gauge Size 6"

Gauge Mount “L” Bracket

Hose Length 6 ft.

Assembly Documentation Calibration Certificate

CLINCHER Load cells and Torque Gauges are produced by several manufacturers. The information provided by MD TOTCO or Acadiana Oilfield Instruments may not be

applicable to all torque gauges or load cells. This reference information is provided with the permission of MD TOTCO and Acadiana Oilfield Instruments.

CLINCHER LOAD CELL AND TORQUE GAUGE ASSEMBLIES


To request copy of AOI Instruction Manual, please contact:

Superior Manufacturing & Hydraulics 4225 Hwy. 90 East Broussard, LA 70518 Phone: 337-837-8847 Fax: 337-837-8839 www.superior-manf.com

SECTION 12 MOTOR SERVICE MANUALS


To request copy of Rineer Motor Service Manuals, please contact:


SECTION 13 VALVE TECHNICAL DATA


To request copy of Valve Technical Data, please contact:


7-5.8 std tong

Documents