PS21

Power Slip System

USER’S MANUAL

REFERENCE REFERENCE DESCRIPTION

PS21 Power slips
This document contains proprietary and confidential VarcoBJ BV
information which is the property of National Oilwell Nijverheidsweg 45
Varco, L.p, its affiliates or subsidiaries (all collectively referred
to hereinafter as "NOV"). It is loaned for limited purposes
4879 AP Etten-Leur
only and remains the property of NOV. Reproduction, in P.O. Box 17
whole or in part, or use of this design or distribution of this 4870 AA Etten-Leur
information to others is not permitted without the express The Netherlands
written consent of NOV. This document is to be returned to
NOV upon request or upon completion of the use for which Tel + 31-76-5083000
it was loaned. This document and the information contained Fax + 31-76-5046000
and represented herein is the copyrighted property of NOV. www.nov.com
DOCUMENT NUMBER REV

201547-10-MAN-001 K
November 2007

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 User’s Manual
PS21
Power Slip

REFERENCE REFERENCE DESCRIPTION

PS21 Power Slip
This document contains proprietary and confidential information which is the property of
National Oilwell Varco, L.p., its affiliates or subsidiaries (all collectively referred to
VarcoBJ
hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of Nijverheidsweg 45
NOV. Reproduction, in whole or in part, or use of this design or distribution of this
information to others is not permitted without the express written consent of NOV. This 4879AP Etten-Leur
document is to be returned to NOV upon request or upon completion of the use for which
it was loaned. This document and the information contained and represented herein is
Tel: +31-76-5083000
the copyrighted property of NOV. Fax: +31-76-5046000
DOCUMENT NUMBER REV

201547-10-MAN-001 K

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 Document number 201547-10-MAN-001
Revision J
Page 2 of 108

Revision History

K 11.17.2007 Reprint + update PGF KdL AK

J 11.27.2006 Reprint + update PGF KdL AK
Rev Date Reason for issue Prepared Checked Approved

Change Description

Revision Change Description

K Chapter drawings: Updated drawings.
K Chapter trouble shooting: Updated trouble shooting.
K Chapter drawings: Updated test specifications.
J Chapter Installation and commissioning: Size component data improved
J Chapter Maintenance: Description paper test procedure improved
J Chapter Operations: Remark added: The required lift tool for #3 hand slip bowl has PN 50004550-
21
J Chapter Installation and commissioning: Remark added: Lift the tool with centering rams in closed
position
I Not issued
H Chapter Operation: Umbilical procedures added
H Chapter Maintenance: Hydraulic hinge pin wear data added

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Table of Contents
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Special information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Identification numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Lifting points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PS21restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Applicable patent number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Warning plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Specifications and requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Centering device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Back up torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Minimum string weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Design Safety Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Major components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Centering device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hydraulic manifold block (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic Hook Up Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Slip set indicator valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lubrication and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
General safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Recommended specifications of hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . 21
Recommended hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Recommended grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Functional checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Daily lubrication procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Lubrication of the PS slips and bowl in RST configuration . . . . . . . . . . . . . . . 24
Lubrication Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Lubrication slips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Lubrication Insert carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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Weekly lubrication procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Automated greasing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Six monthly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
In case of old system with SV1 and SV2 valves (see drawing 202970-1) . . . 28
In case of any other system (see drawing 50004446) . . . . . . . . . . . . . . . . . . 29
Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 Year maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5 Year maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Slip test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Evaluation paper test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Automated flushing procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Hydraulic filter maintenance procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Wear data criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Wear data bore of bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Wear data hydraulic hinge pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Acceptance criteria for rig floor equipment components . . . . . . . . . . . . . . . . . 34
Discontinuities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation of the Hook Up Kit (HUK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Functions as per hydraulic schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
General function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Hook Up Kit (HUK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Flushing / filtrating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Manifold PS-HUK connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Connecting the hydraulic manifold block (RST configuration) . . . . . . . . . . . . 39
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
LOGO PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Copying data from the card to the LOGO . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Configuring the parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Lifting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Lifting the PS by the hoist swivel rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Procedure opening/closing the top covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installation of the PS in the Rotary Support Table. . . . . . . . . . . . . . . . . . . . . . 47
Handling the top covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installing the slip assembly in the PS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installation of the insert carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Dressing the insert carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Load rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Basic insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Dressing kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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Table of Contents
Dressing the slips/insert carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Determining pipe crushing loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
PS21 Size components data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Reference table for inserts in slip body 10 ¾” . . . . . . . . . . . . . . . . . . . . . . . . . 54
Reference table for inserts in slip body 10 3/4” . . . . . . . . . . . . . . . . . . . . . . . . 55
Hand slip bowl / stainless steel ram insert / load rings . . . . . . . . . . . . . . . . . . 56
Stainless steel ram insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Pipe wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Work order first usage PS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
System Requirements check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Procedure disconnecting hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Procedure operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Removal of PS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Exceptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Procedure removing the PS from drill pipe while in rotary. . . . . . . . . . . . . . . . 60
Connecting and disconnecting of the hydraulic hoses . . . . . . . . . . . . . . . . . . 60
Procedure dis-connection hoses in slips up position . . . . . . . . . . . . . . . . . . . . 61
Override button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Using handslips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Running umbilical lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Option 1; Quickest way . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Option 2; Alternative procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Field questions with regard to the umbilical guide . . . . . . . . . . . . . . . . . . . . . . 66
Assembly and dis-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Before (dis)assembly of the PS make sure: . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Assembly of the PS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Procedure changing the ram guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Procedure (dis)-connection of the hydraulic hoses. . . . . . . . . . . . . . . . . . . . . 70
Hydraulic actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Cylinder part numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Disassembly of cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Replacing of the RH actuator seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Assembly of the barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Replacing of the LH actuator seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Assembly of the levers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Assembly of the hydraulic cylinders into the PS . . . . . . . . . . . . . . . . . . . . . . . 72

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Assembly of the Hoisting Swivel Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Assembly of the manifold block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Assembly cover plate hinge pin assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Assembly centering device cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Assembly of the PS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Prior to trouble shooting a problematic PS . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Trouble shooting Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1. Slipping pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2. The PS functions incorrectly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3. Slips don’t work properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4. The slips do not raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5. The slips don’t move up or down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6. Sagging slips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7. Faulty signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8. The slips are travelling too slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9. Problems with rams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
10. Problems with rams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
11. Problems with insert carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
12. Problems with the insert carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
13. Problems with slips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
14. Problems with the inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
15. The lifting eyes on the body bail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
16. Problems with tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Appendixes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
General HUK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
50004442 Ass’y HUK manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
50004511-1 Grease manifold ass’y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Recommended commissioning spares pn 202200-11 . . . . . . . . . . . . . . . . . . 91
Insurance spares 202200-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Risk assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Identified potential hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Severity, Frequency, Probability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Evaluate risks and document the decisions taken. . . . . . . . . . . . . . . . . . . . . . 95
Fault Tree Analyses (FTA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Storage, transport & scrapping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Scrapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Lubrication before storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Torque values (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

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Table of Contents
Torque values (metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Drawings + Test procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Test procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Dimensional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Assembly drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Critical area drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

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Table of Contents

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General information
Intended Audience
This manual contains installation, operation, maintenance and parts information. Information in
this manual should enable qualified personnel to install, operate and troubleshoot this system.
Every effort has been made to ensure the accuracy of the information contained herein. National
Oilwell Varco, it’s affiliates or subsidairies (hereafter NOV) will not be held liable for errors in this
material, or for consequences arising from misuse of this material.

Special information
Detailed descriptions of standard workshop procedures, safety principles and service operations
are not included. Please note that this may manual contain warnings about procedures which
could damage equipment, make it unsafe, or cause PERSONAL INJURY. Please understand
that these warnings cannot cover all conceivable ways in which service (whether or not
recommended by NOV) might be done, or the possible hazardous consequences of each
conceivable ways. Anyone using service procedures or tools, whether or not recommended by
NOV, must be thoroughly satisfied that neither personal safety nor equipment safety will be
jeopardized.
All information contained in this manual is based upon the latest product information available at
any time of printing. We reserve the right to make changes at any time without notice.

Illustrations
Illustrations (figures) represent a graphical representation of equipment components for use in
identifying parts or establishing nomenclature. These figures may or may not be drawn to scale.
For more specific component information pertinent to your rig configuration, see the technical
drawings that accompany your NOV documentation.

Conventions
Notes, Cautions, and Warnings
Notes, cautions, and warnings are used throughout this manual to provide readers with
additional information, and to advise the reader to take specific action to protect personnel from
potential injury or lethal conditions. They may also inform the reader of actions necessary to
prevent equipment damage.

Please pay close attention to these advisories.

Note: The note symbol indicates that additional information is provided about
the current topics.

Caution: The caution symbol indicates that potential damage to equipment or

injury to personnel exists. Follow instructions explicitly. Extreme care
should be taken when performing operations or procedures preceded by
this caution symbol.

Warning: The warning symbol 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.

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Safety Requirements
NOV equipment is installed and operated in a controlled drilling rig environment involving
hazardous operations and situations. Proper service and repair is important for safe and reliable
operation. Operation and service procedures provided by NOV manuals are the recommended
methods of performing those operations.

CAUTION: To avoid injury to personnel or equipment

damage, carefully observe the following safety
requirements.

Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on the
equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool
operation, and maintenance to ensure their safety.

CAUTION: During installation, maintenance, or repair of

equipment, personnel should wear protective gear.
Protective gear must be worn during certain operation.

Contact the NOV training department for more information about equipment operation and
maintenance training.

Recommended Tools
Service operations may require the use of tools designed specifically for the purpose being
described. NOV recommends that only those tools specified be used when stated. Ensure that
personnel and equipment safety are not jeopardized when using service procedures or tools not
specifically recommended by NOV.

General System Safety Practices

The equipment discussed in this manual may require or contain one or more utilities, such as
electrical, hydraulic, pneumatic, or cooling water.

CAUTION: Before installing or performing maintenance or

repairs on equipment, read the following instructions to
avoid endangering exposed persons or damaging
equipment.
‰ Isolate all energy sources before beginning work.
‰ Avoid performing maintenance or repairs while the equipment is in operation.
‰ Wear proper protective equipment during equipment installation, maintenance, or repair.
Replacing Components
‰ Verify that all components (such as cables, hoses, etc.) are tagged and labelled during
disassembly and reassembly of equipment to ensure correct instalment.
‰ Replace failed or damaged components with NOV certified parts. Failure to do so could
result in equipment damage, or personal injury.

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Routine Maintenance
Equipment must be maintained on a regular and routine basis. See the service manual for
maintenance recommendations.

CAUTION: Failure to conduct routine maintenance could

result in equipment damage or injury to personnel.

Proper Use of Equipment

NOV equipment is designed for specific functions and applications, and should be used only for
their intended purpose.

Identification numbers
You will find the identification of the tool stamped into the body near the manifold block. The
serial number is preceded by NL..........

Lifting points
The lifting procedures should carefully be observed and carried out according to the manual.

PS21restrictions
‰ Static loads must not exceed 500 short tons (475 metric tons)
‰ Back up torque applied on the locks must not exceed 120,000 ft/lbs (163,000 Nm)
‰ Static load applied on the closed cover must not exceed (on one point) 20,000 lbs
(9,000Kg)
‰ Static load applied on the Bit-breaker-plate must not exceed 50.000 lbs (22,500Kg)
‰ Torque on/of the cover/bit breaker must not exceed 100.000 ft-lbs (135,000Nm)
‰ Depending on the weight of the string, the back up torque must not exceed 45,000ft-lbs
(60,000Nm)
Applicable patent number
"Patents Pending U.S. & Worldwide"
“(D) Varco I/P, Inc., US6,845,814 B2”

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Warning plates

Warning plate p/n #

201646: Be careful.
Keep hand out of
moving parts.

WARNING: The warning plates must be present on the

PS. Do not remove the labels.

CE marking
The PS complies to the Machinery Directive 89/392/EEC and the Directive 94/9/EC “Equipment
and protective systems in potentially explosive atmospheres”

The marking is as follows:

Ex II 2G c T5
WARNING: Care should be taken to avoid creating
possible ignition sources, like sparks, due to improper
use of the tool in combination with other equipment.

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General specifications
Specifications and requirements
Subject Description
Weight & 4,800 lbs
Weight PS without slip assembly
Dimensions 2,160 Kg
800 lbs
Weight PS slip assembly
360 Kg
Depending on configuration, see
Dimensions
Dimensional Drawings
Rating PS Pipe size 2 3/8” up to 14”
Max. 500 Short tons (453 Metric
Pipe weight
tons)
Rotary size Rotary size 37,5”
Static vertical load bearing capacity on top 10 Short tons
cover (on one point) 9 metric tons
50,000 lbs
Maximum static load on bit braker plate
22,500 kg
120,000 ft lbs
Maximum back-up torque on locks
163,200 Nm
100,000 ft lbs
Maximum torque on bit braker plate
135,000 Nm
Max. back up torque (depending on string 45,000 ft/lbs max
weight) 60.000 Nm max
Style and sizes of
Universal slip with insert carriers Pipe up to 11 1/8”
tubular
Universal ram with ram inserts to center
Pipe up to 11 1/8”
pipe
Pipe 10 3/4” - 11 7/8”
Size specific slips depending on dressing
Pipe 12 3/4” - 14”
Pipe 10 3/4” - 11 7/8”
Size specific rams
Pipe 12 3/4” - 14”
All tubing and hoses connecting the
Hydraulic system Tubing and hoses PS with the HPU must have a min.
diameter of 1/2”
The tank line must be connected
Tank line directly into tank, to prevent back
pressure
Minimum working pressure 2,300 psi (15,857 KPa)
3,000 psi (20,680 KPa) reduced to
Maximum inlet pressure 2,500 psi (17,236 KPa) within
manifold
Maximum oil temperature 140 deg. F (60 deg C)
A closed center hydraulic power unit
or closed center ring line with 2,500
psi (17,336 KPa) working pressure
Power unit
and 5 Gpm (19 l/min.) minimal flow is
needed. A minimum flow of 10 Gpm
(38 l/min.) is recommended
Maximal allowable back (tank) pressure 200 psi (1,378 KPa)
Hydraulic oil used shall be according the SAE class 3
following specification: ISO 15/12
NAS class 6
Filter to be applied before HUK @50 μm

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NOTE: Optimum pressure is 2,500 psi (17,236 KPa). The

pressure must not be lower than 2,300 psi (15,857 KPa)
for the PS.

NOTE: A pressure of min. 2,300 psi (15,857 KPa) and a

back (tank) pressure of maximum 200 psi (1,378 KPa) is
required. The sequence operation of the ram-guide
cylinders and the slip cylinders is automatically controlled
by the manifold inside the PS. The sequence valve is
activated by a pressure difference between the slip up
hose and the slip set hose. The PS will function best when
the pressure in the activated hose is 2,500 psi (17,236
KPa) and the pressure in the other hose is as low as
possible. With these pressure settings, a centering force of
10 short tons (9 metric tons) is generated by the ram
guides.

General description
‰ The PS is a hydraulic operated power slip which is equipped with replaceable slips and
insert carriers to handle various styles and sizes of tubular.
‰ The PS can handle casing, drill pipe and drill collars and tubing.
‰ The PS can be used in combination with the Rotary Support Table.
‰ When using a Varco RST Rotary Support table it’s not needed to disconnect the hoses, as
arrangements are made in the RST to operate the PS (slips up, slips set and signal) by
means of a hydraulic slip ring.
‰ The PS slips will set or raise when a command is given by the driller. Setting and raising
slips of the PS is remote controlled. By detecting the signal-line pressure from the PS it is
determined that the PS slips are set.

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Insert carriers

Slips
Ram insert

Hydraulic
actuator

Top
Universal cover
ram guide
Top cover
lock
Synchronisation
shaft

Hinge pin Body

Door

Centering device
The centering device centers the pipe prior to setting the slips, when the pipe is hard to one side
due to rig movements (floaters) or heavy directional drilling.
In the centering device, a ram guide in each top cover half pushes the pipe to the center. This
happens before the slip cylinders are actuated. These centering ram guides operate in an
automatic sequence with the slips.

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Back up torque
The PS21 can generate a back-up torque up to 45,000 ft / lbs (61,010 Nm), depending on weight
and type of string. Therefore the actual values in below graph can vary, and the PS21 values will
be a little higher as shown below.

x 1000 90
10.75”
80
Max. back up torque (ft lbs)

70
13.375 ”
60 limit PS 30
50 limit PS 21
40
30
20
10
0
0 10 20 30 40 50 60
Additional pipe weight (Sh.Tons)

Maximum torque PS21 = 45,000 ft / lbs (61,010 Nm)

Minimum string weight

WARNING: Athough the theoretical power up force of
the hydraulic actuators is 9,400 Lbs (4,263 Kg), in
some conditions (like heavy and horizontal drilling),
combined with a string weight BELOW 22,200 lbs
(10,000 Kg) the PS may open the slips in case the
command <slips open> is given

WARNING: The power DOWN force generated by the

hydraulic actuators is maximum 10,000 Kg (22,200
lbs). In case of a hydraulic power failure, NO power
down force is available at all.
Design Safety Factor
The design-safety factor and the design verification of the PS is in accordance with requirements
of API specification 7K.

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Major components
Centering device

Cylinder Knuckle pin Universal ram Ram insert

mounting guide
plateMounting
Hinge pin

Hydraulic
cylinder

Top cover
Hinge pin (2x) +
seals

Hinge boss

The ram inserts are pipe size specific and should be changed with every slip/insert carrier
change.

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Hydraulic manifold block (typical)

The symbols “Signal”, “Slips up” and “Slips set” are stamped into the manifold block and indicate
the proper connection.
The hydraulic connections are made by Quick Disconnects (QD)

Slips down Slips up Signal

Grease

Hydraulic Hook Up Kit

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Slip set indicator valves

In order to secure a reliable “slip-set” signal, the PS is provided with two “slip set indicator
valves”. The valves allow the signal “slips set” to pass to the drillers cabin when both the side
slips are set properly.

Valves
(2 places)

PS-21 image up-side-down

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Lubrication and maintenance

General safety notes
WARNING: Do not weld on PS’s parts or body.

WARNING: Make sure that all hydraulic lines are

isolated before ANY work is carried out on the PS.
Shut off the Power Unit / Close the valves.

WARNING: Carry out maintenance according to the

manual.

Recommended specifications of hydraulic fluid

The requirements for the hydraulic oil are based upon the best
performance of the cylinders at specific temperatures / viscosity.
Recommended oil type Mineral oil type HLP (DIN 51524) or equivalent
Surrounding temperature
-20° C up to 50° C (-4° F up to 122° F)
range
Oil operational temperature
40° C up to 50 °C (104° F up to 122° F)
range
Minimum viscosity 13cSt
Maximum oil temperature 60° C (140° F) measured in the tank line
Viscosity at working
20 cSt up to 43 cSt
temperature
Optimum working viscosity 35 cSt

Determination of the required viscosity class regarding the

working temperature
Viscosity class Working temperature (acc. ISO 3448) ° C
32 30 up to 50 ° C (86° F up to 122° F)
46 40 up to 60 ° C (104° F up to 140° F)
68 50 up to 70 ° C (122° F up to 158° F)
100 60 up to 80 ° C (140° F up to 176° F)

Recommended hydraulic fluid

Above -20° C Below -20° C
Castrol Hyspin AWS-46 Hyspin AWS-32
Chevron AW Hyd oil 46 AW Hyd oil 32
Exxon Nuto H 46 Nuto H 32
Gulf Harmony 46AW Harmony 32AW
Mobil DTE 25 DTE 24
Shell Tellus 46 Tellus 32
Texaco Rando oil HD 46 Rando oil HD 32
Union Unax AW 46 Unax AW 32

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Recommended grease
Applica- Temperature range Brand Type Part Remarks
tion Number
Colder area’s like North Sea MOLUB
Back of slips Minimum temperature -15°C ALLOY
Tribol 59000045
/ bowl Maximum temperature + 968 SF
100°C Heavy
Warmer area’s, like Gulf of
MOLUB
Mexico Minimum
Back of slips ALLOY
temperature +10°C Tribol 59000046
/ bowl 936 SF
Maximum temperature +
Heavy
100°C
For warmer and colder This type is
area’s Minimum conform
Back of
temperature --30°C Autol TOP 2000 59000194 Norwegian
slips / bowl
Maximum temperature + Environmental
110°C OLF Standard
MOLUB
Hydraulic
For warmer and colder ALLOY
actuator Tribol 59000045
area’s 968 SF
housing
Heavy
Actuator For warmer and colder
Castrol AP2 na
roller bearing area’s

Expected usage of grease when using an automated greasing system: Every grease cycle will
apply about 350 Cubic Centimeter (21 Cubic Inches) to the slips/bowl. Theoretically one can run
the PS for 50 hours continuously (20 up/down cycles) before renewing the bucket.

NOTE: To reduce the chance of inserts seizing in the

insert slots, NOV recommends to remove inserts after
each job, preserve the insert slot with light machine oil,
AP-2 grease or any other preservation fluid that does not
affect the friction coefficient with string weight compared
to a none preserved insert slot.

Daily maintenance
Inspection
Check for worn and damaged parts
‰ Check for worn and damaged parts
‰ Check for loose and missing parts
‰ Check correct sizes of slips, insert carrier and top guide/ram.
‰ Check correct installation of these parts
‰ Check hoses for signs cracks, wear or abrasion.
‰ Inspect hoist swivel ring parts
a. corrosion
b. wear
c. damage
d. if bail is bent or elongated
‰ Check and clean rotary table
‰ Check locking of:
a. bolts and nuts

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b. safety wire
c. slotted nuts & cotter pins
d. bend lock taps safety latch pins & lock bars
e. roll and dowel pins
f. snap ring cotter pins
Functional checks
Check for the proper function of the PS
‰ Connect PS30 to control manifold and check:
a. Check, when slips up: slips raise then centering rams go out.
b. Check, when slips set: centering rams go in first then slips set
c. Check for any hydraulic leakage
d. Check hydraulic pressure
e. Check slips down signal is on when slips are set
f. Check slips down signal is off when slips are up
g. Check slips up signal is on when slips are up
h. Check slips up signal is off when slips are down.
i. Check the anti-sagging slips system when the pressure is off
‰ In case the PS door was open
a. Check that the removable hinge pin has been reinstalled properly
‰ Check the correct engagement of the slip and insert carrier quick release mechanism
‰ Check the correct installation and locking of the centering rams and ram inserts
‰ Check proper engagement of the top cover lock
‰ Flush the system
Lubrication
Lubricate the PS according to the lubrication procedure
‰ After every run of 50 stands of pipe
‰ Prior to cementing
‰ When loads will be hanging for more than 1 hour
‰ Prior to storage

Daily lubrication procedure

See also greasing instruction chart

WARNING: Do not apply grease to the back side of

insert carriers (except for the dove tail slot) at the
inner bore of the slips and to the dove tail slots
retaining the inserts and back side of the inserts

CAUTION: Do not use pipe dope (anti seize compound)

for lubricating the PS.

CAUTION: Failing to comply to the lubrication instructions

can lead to sticking slips.

NOTE: NOV strongly recommends applying grease at the

beginning and finish of every trip with the PS

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Lubrication of the PS slips and bowl in RST configuration

For lubricating the PS, separate grease lines MUST be connected according to above schedule
in order to lubricate the bowl and slips.

NOTE: The RST does NOT lubricate the PS.

Lubrication Top Cover

See also greasing instruction chart

Job
Flush and filter the system
Grease the nipples on the outside of the top cover 2 plc
Grease the nipples on the inside of the top cover for the ram guides
Grease the nipples on the knuckle pins
Grease the hinge pins

Nipple Brush

Nipple
Nipple
Nipple
outside

Nipple

Nipple
Nipple 2
places

8 Grease nipples and lubrication points each top covers half

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Lubrication slips
See also instruction chart

Job
Grease the back of the slips
Grease the insert carrier latch
Grease the hinge pins
Grease the sliding mechanism slip lock pin
Grease the dovetail

Greasing nipples Sliding Greasing

insert carrier latch mechanism the dovetail
slip lock pins
(6 places) (brush)

Greasing
Back side slips
nipples
hinge pin (4 (9 ribs)
places)

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Lubrication Insert carrier

See also instruction chart

Job
Grease the dovetail slot
Grease the lock trigger

Lubricate the dove tail slot and the lock

trigger

WARNING: Do not apply grease to the back side of

the insert carriers (except for the dovetail slot), to the
inner bore of the slips, to the dovetail tail slots
retaining the inserts and the back side of the inserts.

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Weekly lubrication procedure

See also instruction chart

Part Method
Grease the two indicator valves Grease nipple
Grease the slot in the ram guides
Grease the top cover lock plate
Apply with brush
Grease the slip assy mounting pins
Grease the door hinge pins body 4x Grease nipple
Grease the cylinder levers 2 plc Grease nipple

Actuator Slip assy

lever 2 plc mounting
pins

Ram guide
slot (2plc)

Top cover Indicator

lock plate valves (2plc)
at botttom
(not shown)

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Automated greasing system

CAUTION: The automatic greasing system will NOT
supply grease to the bowl and slip in the RST
configuration

The performance of the PS power slip is directly related to the greasing of the backside of the
slips. This is carried out by applying grease to the grease nipples on the manifold block 2 plc.
Grease will automatically come out the bores as follows:
‰ First to the center slip “port A” and then to the left - and right - hand slips “port B+C”.
‰ The restrictors in the body take care about equal distribution
Six monthly maintenance
1. Clean tool thoroughly
2. Check all grease restrictors are open
3. Check whether all grease nipples are present and functioning
4. Check condition of inline filters in hook-up manifold
5. Check the condition of the main hydraulic filter according to the procedure
6. Grease tool according to daily + weekly greasing procedure
7. Check PS body & slip assembly by paper test according to TSEL-0054
8. Carry out a hydraulic function test as follows:
In case of old system with SV1 and SV2 valves (see draw-
ing 202970-1)
‰ Check gauge (PG1) if rig pressure is at least 2,000 psi (13,789 KPa)
‰ Command slips set
‰ Check SV1 gauge (PG2) reads 1,800 Psi (12,410 KPa) (Hook Up Kit panel)
‰ Check signal “slips set” ONLY is showing in drillers cabin
‰ Command “slips up”
‰ Check SV2 gauge (PG3) reads 1,500 Psi (10,340 KPa) (Hook Up Kit panel)
‰ Check signal “slips up” ONLY is showing in drillers cabin
‰ Check gauge (PG1) reads <1,800 Psi (10,340 KPa) if low pressure alarm is triggered
when rig pressure is below 1,800 Psi (12,410 KPa)
‰ Check if required the pressure switch settings as follows

CAUTION: The pressure switches are shop-set. Do not

adjust any of the setting unless a faulty pressure switch is
swapped out. Even then extreme caution must be taken
preventing wrong adjustment, leading to a faulty signals.
When in doubt; contact NOV for guidance.

Pressure setting PRV1 (slips up)

‰ The Pressure Reducing Valve (PRV1) is standard adjusted at 1600 Psi. This is the
pressure you need when the Mounting plate is used in combination with a PS-21.
‰ When the Mounting plate is Hooked up to a PS-30 then you must adjust the Pressure
Reducing Valve (PRV1) at 2000 Psi. (Connect a Pressure Gauge at Port B1 on Manifold
202981.)

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Pressure setting of low alarm pressure switch PS1

‰ Start with a low pressure on the Power unit and raise the pressure slowly up to 2000 Psi.
Than adjust the pressure switch PS1. The pressure switch PS1 has to give a signal when
the System Pressure is below 2000 Psi.
‰ Pressure Switch PS1 is normally closed.
Pressure setting of slips set pressure switch PS2
‰ Verify 1800 psi pressure setting of pressure switch PS2. Slips have to be
‰ Pressure Switch PS2 is normally open.
‰ If you don’t have a signal check first that you have a signal on the S1 port of the PS-21/30
manifold. If yes than check the setting of cartridge SV1 in manifold 202981
Pressure setting of slips up pressure switch PS3
‰ Verify 1500 psi pressure setting of pressure switch PS3. Slips have to be command to UP
and pressure has to be provided to port S1.
‰ Pressure Switch PS3 is normally open.
‰ If you don’t have a signal check first that you have a signal on the S1 port of the PS-21/30
manifold. If yes than check the setting of cartridge SV2 in manifold 202981.

In case of any other system (see drawing 50004446)

‰ Check gauge (PG1) if rig pressure is at least 2,000 psi (13,789 KPa)
‰ Command slips set
‰ Check gauge (PG3) reads 1,800 Psi (12,410 KPa) (Hook Up Kit panel)
‰ Check signal “slips set” ONLY is showing in drillers cabin
‰ Command “slips up”
‰ Check gauge (PG2) reads 1,600 Psi (10,340 KPa) (Hook Up Kit panel)
‰ Check signal “slips up” ONLY is showing in drillers cabin
‰ Check gauge (PG1) reads <2,000 Psi (13,789 KPa) if low pressure alarm is triggered
when rig pressure is below 2,000 Psi (13,789 KPa)
‰ Check if required the pressure switch settings as follows

CAUTION: The pressure switches are shop-set. Do not

adjust any of the setting unless a faulty pressure switch is
swapped out. Even then extreme caution must be taken
preventing wrong adjustment, leading to a faulty signals.
When in doubt; contact NOV for guidance.

Pressure setting of low pressure alarm switch

‰ Pressure Switch PS1 (E12) is normally closed and set at 2000 Psi.
‰ Start with a low pressure on the Power unit and raise the pressure slowly up to 2000 PSI,
than adjust the Pressure Switch PS1. The Pressure Switch PS1 has to give a signal when
the System Pressure is below 2000 PSI.
Pressure setting of slips up pressure switch
‰ Pressure Switch PS2 (E13) is normally open and set at 1600 PSI.

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‰ Verify 1600 PSI pressure setting of pressure switch PS2. Slips have to be command to
UP and pressure has to be provided to port S1.
‰ If you don’t have a signal check first that you have a signal on the S1 port of the PS-21/30
manifold. If yes than check the pressure off B1 (slips UP). Still no signal check valve DV3
works properly.
Pressure setting of slips set pressure switch
‰ Pressure Switch PS3 (E11) is normally open and set at 1800 PSI.
‰ Verify 1800 PSI pressure setting of pressure switch PS3. Slips have to be command to
SET and pressure has to be provided to port S1.
‰ If you don’t have a signal check first that you have a signal on the S1 port of the PS-21/30
manifold. If yes than check the pressure off A1 (slips SET).Still no signal check valve DV3
works properly.
Pressure setting of grease empty indication
‰ Pressure Switch PS4 (E17) grease empty indication is normally open and set to
accommodate grease empty indication: 1000-1200 PSI.
Annual Maintenance
Procedure
1. Clean the PS thoroughly
2. Check all bolts and nuts for the proper make up torque and lock wire
3. Check the PS visually for extreme wear, abnormalities. If in any doubt, contact an
authorized NOV repair facility.
4. Lubricate the PS according to procedure
5. Replace the top cover hinge boss screws by new ones (same grade 8), assemble and
torque as per torque table for bolts and nuts according to the instruction below.

3 1 2 4
Hand tight first in order of 1,2,3 and 4.
Torque as per Torque Table in order of 1,2,3 and 4.

6. Carry out a paper test according to the TSEL-0054.

7. Carry out functional testing according TSEL-0035.
8. Check hydraulic setting of the HUK according to TSEL-0050

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2 Year maintenance
Procedure
1. Clean the PS thoroughly
2. Check the PS visually for extreme wear, abnormalities. If in any doubt, contact an
authorized NOV repair facility.
3. Lubricate the PS according to procedure
4. Carry out a paper test according to the TSEL-0054.
5. Remove hydraulic actuators from the body. Check cylinders for:
‰ Rust
‰ Denting
‰ Cracks
‰ Damage
6. Dis-assemble the hydraulic actuators, top cover hinge pins and top cover cylinders
according to Chapter “ASSEMBLY”.
‰ Replace the actuator seals (seal kits available)
‰ Lubricate the actuators according to the drawings
‰ Replace the seals of the top cover hinge pins
‰ Replace the seals of the top cover cylinders
7. Test the actuators according to TSEL-0127
8. Carry out functional testing according TSEL-0035.
9. Check hydraulic setting of the HUK according to TSEL-0050
5 Year maintenance
Procedure
1. The PS must be checked completely. It is advised to have this carried out in a NOV
authorized repair shop. Please contact NOV for guidance.

Slip test procedure

A slip test is the best way to determine the degree of rotary equipment wear. For accurate
results, use a hook load as advised in TSEL-0054.
‰ Clean an area of pipe where there are no insert marks
‰ Clean the slip inserts with a wire brush.
‰ Wrap a layer of test paper around the cleaned section of pipe, use friction tape to hold the
paper to the pipe.
‰ Carefully set the slips, guide the pipe as smooth as possible during movement of the slip.
‰ Carefully raise the slips, ensuring the paper doesn’t get damaged due to the moving slips.
‰ Evaluate the second layer of paper. If full insert contact is indicated, no further analyses is
necessarily as wear, if at all, is accepted.

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Evaluation paper test

Accepted wear?
Assemble PS and carry
YES out final inspection
NO before installation

Replace inserts (in the same slip)

Carry out paper test

Accepted wear? Fit for service.

Assemble PS with NEW
YES
NO inserts and carry out
final inspection before
Replace slip with new slip and installation
inserts
Carry out paper test

Accepted wear? Fit for service.

Assemble PS with NEW
YES
slips and carry out final
NO inspection before
installation
Remove PS from service. Please
contact NOV for guidance.

Automated flushing procedures

NOTE: Clean hydraulic fluid is essential for optimal
performance of the PS. The flushing system allows the
PS unit to be flushed with oil before start up, especially
after reconnecting the hoses. Flushing is carried out by
reversing the flow in the signal line for slips up / slips set,
and therefore the ports in the slip ring and the PS
manifold. Flushing must be carried out for a period of 30
seconds. Carry out a flushing cycle after reconnecting the
hoses.

Procedure
1. Set the slips
2. Switch PS into neutral position (PS to tank)
3. Put the flush valve handle into Flush-mode for appr. 30 seconds
4. Switch the valve back
5. Operate the slips up
6. Put the valve handle into Flush-mode for appr. 30 seconds
7. Put the flush handle back into “Normal-operation-mode”

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Hydraulic filter maintenance procedure

Filter indicator:
Green = OK
Red = Replace

NOTE: Depending on the quality of the hydraulic fluids, it is

important to check the condition of the filters in the hook-up-kit
and the inline filter with regular intervals. The filters are
designed to stand for at least one year in conditions as required
in this manual. However, rig conditions may differ from these
required conditions, or change by contamination, incidents,
repairs etc. Depending on the rig conditions it is advised to
carry out a filter check after ONE months of service, after SIX
months and after ONE YEAR of service. Depending on the
results of the checks the intervals between checks can be
increased or decreased.
Wear data criteria
A

Hinge pin wear data PS21

Stationary hinge pin 202205-1
Removable hinge pin 202206-1
Total clearance "A" max 0.050” (1.27 mm)
Hinge pin min. dia new 2.365” (60.071 mm)
Max. body bore dia new 2.380” (60.452 mm)
Bore diameter worn max 2.405” (61.087 mm)

Wear data bore of bowl

Carry out the bore wear test according to the TSEL-0054 (Papertest)

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Wear data hydraulic hinge pin

Description Diameter (inch)
New centering cylinder hinge hole 1.375 +0.000/+0.010
Max. worn centering cylinder hinge hole: 1.400
New centering ram hinge hole 1.375 - 1.380
Max. worn centering ram hinge hole: 1.400
New top cover hinge hole 1.500 -0.000/+0.005
Max. worn top cover hinge hole: 1.520
New top cover hinge pin 1.497 - 1.494
Max. worn top cover hinge pin: 1.484

Acceptance criteria for rig floor equipment components

References
‰ ASTM E 709; Standard practice for magnetic particle examination
‰ ASTM A 275; Standard test method for magnetic particle examination of steel forging
‰ ASTM E 125; Reference photographs for magnetic particle indications on ferrous castings
‰ MSS SP-55; Quality Standard for Steel Castings Visual Method
‰ Varco BJ critical area drawings
‰ API Specification 7K and Varco BJ standards
‰ Of above references the latest editions shall apply.
Qualifications
‰ All personnel performing and interpreting examinations using this work instruction shall be
qualified in accordance with the guidelines of ASNT-TC-1A (latest edition).
Method
‰ The magnetic particle examination method consists of magnetising the area to be
inspected and then applying wet magnetic particles to the surface of the test area.
Surface Condition
‰ Surface to be inspected shall be cleaned and free from oil, grease, sand and loose rust or
scale, which may interfere with satisfactory inspection.
Equipment List
1. - Tiede Universal SW 170- Magnaflux CRV 20
2. - Tiede Yoke or equivalent
Examination
‰ In case of critical hoisting equipment or manual tong components examination before load
test may be limited to the machined surfaces of the components. Examination after load
test shall be 100% of all assessable surfaces.
‰ Unless otherwise specified, magnetic particle examination shall be carried out by the
continuous method. Examinations shall be carried out with sufficient overlap to assure
100% coverage of the area or part under inspection.
‰ The temperature of the wet particle suspension and/or the surface of the part inspected
shall not exceed 60° C.

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Evaluation of Indications; relevant indications

‰ Only those indications with major dimensions greater than 1/16 inch (1,6 mm) and
associated with a surface rupture shall be considered relevant.
‰ Relevant indications are indications that result from discontinuities within the test part.
Non relevant indications are indications that result from excessive magnetizing current,
structural design or permeability variances within the test parts.
‰ Any indication believed to be non-relevant shall be regarded as relevant and shall be re-
examined to determine whether an actual defect exists.
‰ Linear indications shall be considered as those having a length of more than three times
the width. Rounded indications shall be considered as those having a length less than
three times the width.
‰ A lined indication shall be considered as a group of three or more indications which touch
an imaginary straight line connecting any two of the group.
Reporting
‰ When no indications outside the acceptance criteria have been detected, stamp the shop
order with the magnetic particle examination stamp and add the required information.
‰ When indications outside the acceptance criteria have been detected, stamp the shop
order with the same stamp. In addition an Inspection Report must be completed
‰ ASTM E 125 and, where applicable, Varco critical area drawings shall be used as a
reference standard for the evaluation of magnetic particle indications.
When no critical area drawings are available all areas shall be considered non-critical.

Discontinuities
Maximum permitted degree
Type Discontinuity description Critical area Non Critical area
I Hot tears and cracks 1/4” (6.25mm) Degree III
II Shrinkage Degree II Degree III
III Inclusions Degree II Degree IV
IV Chills and unfused chaplets Degree I Degree II
V Porosity1/24” Degree II Degree II

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Installation and commissioning

WARNING: The control panel may differ from rig to rig,
but the PS MUST be processed through a PLC or
another control unit to prevent undesired
simultaneous commands from e.g. BX-elevator and
PS.
Installation of the Hook Up Kit (HUK)
Please refer to the general arrangement drawings and the hydraulic and electric schematics for
additional information.

Functions as per hydraulic schematic

PS 1 Pressure switch low pressure alarm
PS 2 Pressure switch for signal slip up
PS 3 Pressure switch for signal slip set
PS 4 Pressure switch grease bucket empty
DV 1: Directional control valve, operating the slips
DV 2: Directional control valve, operating the flushing system.
DV 3: Directional control valve, controlling the signal pressure
DV 4: Directional control valve, operating the grease pump
DV 5: Directional control valve, operating the control valve DV6.
DV 6: Directional control valve, distributing grease to the center or LH/RH slips
PC 1 - 2 Pilot operated pressure reducing valve
PR 1 Pilot operated pressure relieve valve
CV 1 -2 Check valves
F1 - 2 Filter
PG 1 Pressure gauge to check system pressure
PG 2 Pressure gauge to check slips up signal
PG 3 Pressure gauge to check slips set signal
PG 4 Pressure gauge to check flushing pressure
PG 5 Presssure gauge to check pressure setting for grease pump

General function
PC 1 and PC 2: The control manifold can be connected to a closed center power supply with
working pressure between 2500 - 3000 psi (17,236 - 20,684 KPa). PC 1 is set at 2,500 psi
(17,236 Kpa) to protect the PS21/30 against overloading. PC2 reduces the pressure to 1,500
psi for reducing the flushing and greasing pressure.
PS 2 and PS 3: When the slips are up or set, the PS gives a hydraulic signal back to the control
manifold.

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Connections
NOTE: The valves are pre-set and ONLY to be adjusted
by NOV personnel.

Hook Up Kit (HUK)

Pressure
switch low Junction box
pressure with PLC
alarm PS1
Pressure
switch slips Pressure
up PS2 switch
empty
Pressure grease
switch slips bucket PS4
set PS3
Push button
manual
grease cycle
Manifold block
PS21/30

Flushing
handle Manifold block
grease

Presure filter

Flushing / filtrating system

An inline filter is placed between the rig pressure ring line and the pressure line going into the
PS hook up system.
In addition a flushing manifold directs return oil from the PS into the return ring line of the rig.

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Manifold PS-HUK connection

Connecting the hydraulic manifold block (RST configura-

tion)
NOTE: Clean the hydraulic couplings thoroughly prior to
connecting

Software
With the Siemens LOGO Programmable Logic Controller (PLC), the greasing frequency and
quantity can be adjusted as follows to meet job specific requirements

Settings
Use the buttons on the front side of the SIEMENS LOGO to change the parameters for the timer.
Two settings are important;
1. The time the solenoid is operated to accomplish a full pump stroke (B20 and B22). The
higher the viscosity the longer it takes to make a full pump stroke. A is the center slip. B
and C are the left hand and right hand slips.
2. The time a greasing sequence is taking (B08 and B09). The type of grease and the
viscosity determines these parameters.
B06 is the number slips set after which a grease cycle starts. This depends on the grease
properties and field conditions.

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LOGO PLC
The following pages are a quick reference for the copying of data and the configuration of the
parameters. Pls. refer to the Siemens LOGO-manual for all user’s information.

Copying data from the card to the LOGO

You have a program module (card) that contains your cir-
cuit program. There are two ways to copy it to LOGO!:
Automatically during the startup of LOGO!
(POWER ON) or
by means of the “Card” menu of LOGO!.

Note
If the program on the module/card is protected with the
password X, the copied program in the LOGO! is also pro-
tected with the same password.

Automatic copying during the startup of LOGO!

Proceed as follows:
1. Switch off the power supply to the LOGO!
(POWER OFF)
2. Remove the slot cover.
3. Insert the program module/card into the relevant slot.
4. Switch on the power supply to the LOGO!
LOGO! copies the program from the program module/card
to LOGO!. When LOGO! has finished copying, it opens the
main menu:

>Program..
Card..
Clock..
Start

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Note
Before you switch the LOGO! to RUN, you must ensure
that the system you are controlling with LOGO! does not
represent a source of hazard.

1. Move the ’>’ cursor to ’Start’: Press or

2. Press OK.
Copying by means of the “Card”menu
--
.
To copy a program from the program module (card) to
LOGO!:
1. Insert the program module (card)
2. Switch the LOGO! to programming mode (ESC / >Stop).

>Program..
Card..
Clock..
Start
3. Move the ’>’ cursor to ’Card’: Press or
4. Press OK. The transfer menu opens.
5. Move the ’>’ cursor to ’Card LOGO’:
Press or

Card
>Card = LOGO!
CopyProtect

6. Press OK.
LOGO! copies the circuit program from the program mod-
ule (card) to LOGO!. When LOGO! has finished copying, it
automatically returns to the main menu.

CAUTION: Do not select LOGO to CARD, when LOGO

shown “NO PROGRAM”. This will erase the memory of
the program module (Card)

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Configuring the parameters

Selecting the parameters

To select a parameter:
1. On the parameter assignment menu, select
’Set Param’: Press or
Stop
>Set Param
Set Clock
Prg Name
2. Confirm with OK.
LOGO! shows the first parameter. If no parameter can
be set, you can press ESC to return to the parameter
assignment menu.
Block number
B9 1 Display number for functions with
several displays
T =60:00s The value set at pa-
rameter T (Time)
The current time in the
Ta =06:00s LOGO!

No Param No parameters for editing:

Press ESC to return to the paramete
Press ESC ment menu

3. Now, select the desired parameter:

Press or .
4. Select the parameter you want to edit, and press OK.

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Modifying parameters
You first select the parameter you want to edit.
.
You change the value of the parameter in the same way as
you did in programming mode:
1. Move the cursor to the point at which you want to make
the change: Press or
2. To change this value: Press or
3. To apply the value: OK
Change: Press or
B9
T =80:00s Move: Press or

Ta =06:00s Done: OK

Note
Alongside with a change of the time parameters when the
system is in RUN, you can also change the timebase (s =
seconds, m = minutes, h = hours). This does not apply if
the time parameter represents the result of another func-
tion. In this case you
can neither change the value nor the timebase.
The current time is reset to zero when you change the
timebase.

Current value of a time T

View of a time T in parameter assignment mode:

B9
T =80:00s Configured time T

Ta =06:00s Current time Ta

You can change the configured time T.

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Current timer value

View of a timer cam in parameter assignment mode:

B1 1
D=M–W–F––
On = 09:00
Off=10:00
You can change the on/off times and the day.
Current value of a counter
View of a counter parameter in parameter assignment
mode:

B3 B3
or
On =001234 On =123456
Off=000000 Off B021
Current
Cnt=000120 count value
Cnt=000120
You can change the on/off threshold. This does not apply if
the on or off threshold represents the result of another
function.
Current value of an hour counter
View of an hour counter parameter in parameter assign-
ment mode:

B16
MI = 0100h Time interval

MN = 0017h Time-to-go

OT =00083h Total operating hours

You can edit the configured time interval MI.

E.g. B03 represents the function block you can see in the table below. T for the set value and Ta
for the actual value..

Function Description Org. Set

B03 Indicating light "low grease pressure” 00.40
B06 PS cycle counter 25
B08 Grease cycle time on outlet port A 15
B09 Grease cycle time on outlet port "B+C" 25
B17 PS cycle counter n/a
B20 Time grease cylinder down 00.40
B22 Time grease cylinder up 00.40
B27 PS cycle counter n/a

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Lifting procedure
Weights
Weight & Dimensions Description
Weight PS without slip assembly incl. top 4,800 lbs
covers 2,160 Kg
800 lbs
Weight PS slip assembly
360 Kg
33 lbs
Hinge pin
15 Kg
510 lbs
Top Cover (single half)
230 Kg
165 - 330 lbs
Insert carrier
75 - 150 Kg
22 lbs
Manifold block PS
10 Kg
250 lbs
Bit braker plate
112.5 Kg
200 lbs
4-way lifting sling pn 200982-1
90 Kg
44 lbs
2-way lifting sling pn 50004551
20 Kg
Special slip handling tool for slip handle 33 lbs
pn 50004552 15 kg
Lifting hook for lifting insert carriers pn 16 lbs
50004600-1 (pogo stick) 7 Kg

Lifting the PS by the hoist swivel rings

The hoisting swivel rings on the body must be used to lift the PS

Hoisting swivel rings + 4-way lifting sling p/n 200982-1

NOTE: In order to pull the PS sideways by means of a

tugger line, the tugger line can be fitted to the additional
shackle on the outside of the spreader bar of the 4-way
lifting sling. This to prevent the bails of the hoist swivel
rings from bending open.

CAUTION: When lifting the PS with CLOSED top covers ,

ensure the centering rams are in CLOSED position.

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Procedure opening/closing the top covers.

1. Use the L-bars on the top cover to close and open the top-cover.

2. Lifting L-bar on top-cover. Use the special lifting stick p/n 202293

3. Lift the top cover until it is almost vertical. Than push it until it flips through its center of
gravity. Do not lift too far as the PS or top cover may get damaged.

NOTE: For removing the top cover from the body,

additional lifting eyes (2x) must be used

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Installation of the PS in the Rotary Support Table.

WARNING: Lift the PS by the four lifting eyes only and
never by other parts ! Use the four way lifting sling p/n
200982-1

Procedure
1. Lift the PS with the lifting sling (picture: closed top covers)
2. Make sure that the lock pins are in retracted position.
3. Lower the PS in the drill floor or rotary support table.
4. Locks in locking position
5. Turn locks (2) into locked position.(picture: PS outside rotary support table)

NOTE: Make sure the manifold block of the PS is on the

side where the connections in the rotary support table are

6. Lock disengaged (see arrow)

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Handling the top covers.

NOTE: Use the pogo-stick on a tugger line to open and
close the top covers.

The top cover lock

Procedure
1. Disengage the cover lock.
2. Connect the pogo stick to the lifting bracket
3. Push the top cover till it flips through it’s center of gravity.
4. Lower the cover.
Installing the slip assembly in the PS
WARNING:Make sure that all hydraulic lines are
isolated or that the ball-valve is closed before any work
is carried out in the PS

45 degree angle

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Procedure
1. Open the top covers using insert carrier lifting hook p/n 50004600(-) with a tugger line.
2. Grease the ribs on the inner bore of the PS.
3. Grease the ribs of the slip assembly
4. Place the lifting arms 1/3 down, 45°. This position allows easy engagement of the slip pin.
Give the command <slips down> and stop the movement of the arms with the ball valve.

5. Lift the Slip in the PS by using the lifting tool for PS-slip assembly pn 50004551
6. Line up the slip mounting pins.

7. Spread the slip handles by using the special slip handle operating tool pn 50004552
8. Make sure the slip handles are in the lock position.
9. Disengage the slip assembly lifting tool

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Installation of the insert carriers

(while in the Rotary Support Table)

Procedure
By using the revised pogo stick pn 50004600-1
1. Lean the insert carrier forward, lower it and engage. Pull the insert carrier backwards and
lower it till the latch locks it.
2. Lower the insert carrier
3. Make sure the insert carrier is locked by the latch

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Dressing the insert carrier

basic insert
(yellow)

Lock trigger
Lock screw +
spring washer

Load ring (1x)

+ cotter pins
(2x)

Load rings
Depending on the size of the insert carrier, one or two “load rings” have been added. The
following insert carriers have this modification.
Don’t forget
‰ to place the cotter pins (2x per load ring)
‰ to place the basic insert
‰ to place the lock screws and spring washers
Basic insert
The insert carriers have to be dressed with one plastic basic insert with the size printed in it.

Dressing kits
For replacement of the inserts, a dressing kit is available, containing inserts, loadring(s), size
inserts, lock screws, spring washers and cotter pins.

Rating
Due to the fact that the strength of smaller size pipes do not permit high hook loads, a
downrating is applicable according to the tables.

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Dressing the slips/insert carriers

CAUTION: DO NOT grease the grooves

CAUTION: The bottom inserts must be tapered in case of

a groove.

Procedure
NOTE: The basic insert is a plastic insert, marked with the
dress size, replaces one of the inserts

1. Remove the screws and spring washers on top of the insert carrier assembly
2. Dress the slip assembly and lock it with socket head lock screws and lock washers.
3. The inserts have the part number stamped in the back
4. Do not forget the size (basic) inserts
5. The PS21 has one load ring.
6. Grind and re-mark the size marking when changing the size of the inserts.
7. In the table you will find the dressing kits, consisting out of inserts, cotter pins, bolts and
lock washers.

Determining pipe crushing loads

WARNING: Keep in mind that the actual rating is

determined by the pipe. Below formula is based on an
ideal situation where the pipe is completely
circumferential clamped. In reality, especially for big
sizes, the slips do not enclose the pipe completely,
hence the risk for crushing the pipe is higher.

Applicable for casing with wall thickness t > 0.1 R. Critical hook load of pipe at
slip contact.
F = Qyp * A * 1
1 + RK + ⎡ RK ⎤²
L ⎣ L ⎦
No safety factor to account for dynamic factors is used in this formula
F = Crushing load in lbs.
Qyp = Yield stress of pipe in psi.
A = Sectional area of pipe in inch²
R = Outside radius of pipe in inches.
L = Length of slip contact in inches.
K = Crushing factor (used =) 2.6

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PS21 Size components data

Slip p/n Clamping Pipe Zip DC Plain Rating Slip assy / Dressing Kit* p/ Insert p/ Load ring p/n Ram / Ram- Throat
diameter type inches DC [Tons] Insert Carrier n n inserts p/n opening(slips
inches inches p/n up) inches

14 Csg -- -- 500 202250-1400 51202250-1400 2635 -- 202347-1400 18

Inserts directly

13-5/8 Csg -- -- 500 202250-1363 51202250-1363 2653 -- 202347-1363 17-5/8

13-1/2 Csg -- -- 500 202250-1350 51202250-1350 2652 -- 202347-1350 17-1/2
in slip

13-3/8 Csg -- -- 500 202250-1338 51202250-1338 2636 -- 202347-1338 17-3/8

13 Csg -- -- 500 202250-1300 51202250-1300 40 -- 202347-1300 17
12-3/4 Csg -- -- 500 202250-1275 51202250-1275 2657 -- 202347-1275 16-3/4
11-7/8 Csg -- -- 500 202253-1188 51202253-1188 2651 -- 202347-1188 15-7/16
11-3/4 Csg -- -- 500 202253-1175 51202253-1175 2637 -- 202347-1175 15-5/16
** 11-1/8 Csg -- -- 500 202270-1113 51202270-1113 2651 -- 202346-1113 15-3/4
** 11 Csg -- -- 500 202270-1100 51202270-1100 2637 -- 202346-1100 15-1/2
10-7/8 Csg -- -- 500 202270-1088 51202270-1088 2651 -- 202386-1088 15-1/2
10-3/4 Csg -- -- 500 202270-1075 51202270-1075 2637 -- 202346-1075 15-3/8
10 Csg -- -- 500 202270-1000 51202270-1000 2638 -- 202346-1000 14-3/4
9-7/8 Csg -- -- 500 202270-988 51202270-988 2650 -- 202346-988 14-9/16
9-5/8 Csg -- -- 500 202270-963 51202270-963 2656 -- 202346-963 14-5/16
9-1/2 Csg -- -- 500 202270-950 51202270-950 2657 -- 202346-950 14-1/4
9-1/8 Csg -- -- 500 202279-913 51202279-913 2637 -- 202346-913 14-1/4
8-5/8 Csg -- -- 500 202279-863 51202279-863 2652 -- 202346-863 13-1/2
7-3/4 Csg -- -- 500 202279-775 51202279-775 17080 -- 202346-775 13
7-5/8 Csg -- -- 500 202273-763 51202273-763 2633 50004573-3 202346-763 12-1/2
7 Csg -- -- 500 202273-700 51202273-700 2623 50004573-3 202346-700 11-7/8
6-7/8 Csg/DP -- -- 500 202273-688 51202273-688 2638 50004573-3 202346-688 11-3/4
6-5/8 Csg/DP -- -- 500 202273-663 51202273-663 2632 50004573-3 202346-663 11-5/8
6-1/2 Csg -- -- 500 202369-650 51202369-650 2173 50004573-2 202346-650 11-1/2
6-9/64 Csg/DP -- -- 500 202369-614 51202369-614 2172 50004573-2 202346-614 11-1/8
6 Csg/DP -- -- 500 202369-600 51202369-600 2169 50004573-2 202346-600 11
5-7/8 DP -- -- 500 202369-588 51202369-588 2623 50004573-2 202346-588 11
5-11/16 Csg/DP -- -- 500 202369-568 51202369-568 2650 50004573-2 202346-568 10-7/8
5-1/2 Csg/DP -- -- 500 202274-550 51202274-550 2170 50004573-5 202346-550 10-3/4
5 Csg/DP -- -- 500 202274-500 51202274-500 2169 50004573-5 202346-500 11-1/4
4-1/2 Tbg/DP -- -- 500 202274-450 51202274-450 2168 50004573-5 202346-450 9-3/4
** 4 Tbg/DP -- -- 500 202278-400 51202278-400 2165 50004573-6 202346-400 9-3/8
** 9-1/2 DC 10 9-1/2 350 202271-950 51202271-950 2633 -- -- 14-3/16
202250-5

** 9-1/4 DC 9-3/4 9-1/4 350 202271-925 51202271-925 2655 -- -- 13-15/16

9 DC 9-1/2 9 350 202271-900 51202271-900 2633 -- -- 13-11/16
8-3/4 DC 9-1/4 8-3/4 350 202271-875 51202271-875 2655 -- -- 13-9/16
8-5/8 DC 9-1/8 8-5/8 350 202271-863 51202271-863 2653 -- -- 13-1/2
8-1/2 DC 9 8-1/2 350 202271-850 51202271-850 2652 -- -- 13-7/16
8-1/4 DC 8-3/4 8-1/4 350 202271-825 51202271-825 2638 -- -- 12-7/8
8-1/8 DC 8-5/8 8-1/8 350 202271-813 51202271-813 2650 -- -- 12-3/4
8 DC 8-1/2 8 350 202272-800 51202272-800 2633 -- -- 13-1/4
7-3/4 DC 8-1/4 7-3/4 350 202272-775 51202272-775 2655 -- -- 13
7-5/8 DC 8-1/8 7-5/8 350 202272-763 51202272-763 2172 -- -- 12-1/2
7-1/2 DC 8 7-1/2 350 202272-750 51202272-750 2652 -- -- 12-3/4
7-3/8 DC 7-7/8 7 3/8 350 202272-738 51202272-738 2636 -- -- 12-1/2
7-1/4 DC 7-3/4 7-1/4 350 202272-725 51202272-725 2638 -- -- 12-1/2
** 6-3/4 DC 7-1/4 6-3/4 350 202275-675 51202275-675 2633 -- -- 11-1/4
6-1/2 DC 7 6-1/2 350 202275-650 51202275-650 2633 -- -- 11
6-1/4 DC 6-3/4 6-1/4 350 202275-625 51202275-625 2655 -- -- 10-7/8
6 DC 6-1/2 6 350 202275-600 51202275-600 2652 -- -- 10-7/8
5-3/4 DC 6-1/4 5-3/4 350 202275-575 51202275-575 2638 -- -- 10-5/8
5-5/8 DC 6-1/8 5-5/8 350 202275-563 51202275-563 2650 -- -- 10-1/2
3-1/2 Tbg/DP -- -- 350 202277-350 51202277-350 2162 50004573-4 202346-350 8-7/8
3-1/8 Tbg/DP -- -- 350 202277-313 51202277-313 2172 50004573-4 202346-313 8-7/8
2-7/8 Tbg/DP -- -- 350 202277-288 51202277-288 2161 50004573-4 202346-288 8-1/2
2-3/8 Tbg/DP -- -- 350 202277-238 51202277-238 2160 50004573-4 202346-238 8-1/8
4-3/4 DC 5-1/4 4-3/4 225 202276-475 51202276-475 2165 -- -- 10
4-5/8 DC -- 4-5/8 225 202276-463 51202276-463 2655 -- -- 9-7/8
4-3/8 DC 4-3/4 4-3/8 225 202276-438 51202276-438 2172 -- -- 9-3/4
4-1/4 DC -- 4-1/4 225 202276-425 51202276-425 2166 -- -- 9-5/8
4 DC -- 4 225 202276-400 51202276-400 2638 -- -- 9-3/8
* Dressing kit includes: inserts, loadrings, size inserts and retainers. ** These insert carriers are size specific and CANNOT be redressed to another size

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Reference table for inserts in slip body 10 ¾”

In order to check whether the applied inserts are correct, check the dimension X according to
the table with an O.D. caliper.

The correct size insert carrier can be measured with an O.D. calliper using the formula:
X = 7 ½” – (nominal size clamping diameter) / 2

Nominal size Nominal pipe Dimension

clamping size(inches) of X
diameter Zip DC
(inches)

Inches Millimeter

14 - 0.5 12.7
13 5/8 - 0.688 17.5
13 3/8 - 0.813 20.6
12 3/4 - 1.125 28.6
11 7/8 - 1.563 39.7
11 3/4 - 1.625 41.3
11 1/8 - 1.938 49.2
10 3/4 - 2.125 54
9 7/8 - 2.563 65.1
9 5/8 - 2.688 68.3
9 1/8 - 2.938 74.6
8 5/8 - 3.188 81
7 3/4 - 3.625 92.1
9 1/2 - 2.75 69.9

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Reference table for inserts in slip body 10 3/4”

The correct size insert carrier can be measured with an O.D. calliper using the formula:
X = 7 ½” – (nominal size clamping diameter) / 2

Nominal size Nominal pipe Dimension

clamping size(inches) of X
diameter Zip DC
(inches)

Inches Millimeter

9 1/4 9 3/4 2.875 73

9 9 1/2 3 76.2
8 3/4 - 3.125 79.4
8 5/8 9 1/8 3.188 81
8 1/2 9 3.25 82.6
8 1/4 8 1/2 3.375 85.7
8 1/8 8 5/8 3.438 87.3
8 8 1/2 3.5 88.9
7 3/4 8 1/4 3.625 92.1
7.5 8 3.75 95.3
7 1/4 7 3/4 3.875 98.4
7 5/8 - 3.688 93.7
7 - 4 101.6
6 1/2 - 4.25 108
6 9/64 - 4.43 112.5
6 5/8 - 4.188 106.4
5¾ - 4.75 120.7
5 - 5 127
4¾ - 5.25 133.4
6 3/4 - 4.125 104.8
6 1/2 - 4.25 108
6 1/4 6æ 4.375 111.1
6 6¾ 4.5 114.3
5 3/4 6º 4.625 117.5
5 5/8 6 1/8 4.688 119.1
4.75 5 1/4 5.125 130.2
4 5/8 - 5.188 131.8
4 3/8 4æ 5.313 134.9
4 1/4 - 5.375 136.5
4 - 5.5 139.7
4 - 5.5 139.7
3 1/2 - 5.75 146.1
2 7/8 - 6.063 154
2 3/8 - 6.313 160.3

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Hand slip bowl / stainless steel ram insert / load rings

Number Partnumber Rating T Size Part number Size slip
(metric T) range slip (inch)
(inch)
#3 202361 100 (74) 8 5/8 – 2 3/8 202250-1/-5 10 3/4

NOTE: For handling the hand slips in the bowls, extended

hand slip handles are available: For SD-slips, order
50004604-1. For CMS-slips, order 50004604-2
Stainless steel ram insert
Stainless steel ram inserts are available for drill pipe size 6 5/8” and smaller. The stainless steel
ram insert gives a better anti-spark performance.

CAUTION: It’s always possible sparks are generated by

the use of the PS, even while using stainless steel ram
inserts.

The new drill pipe guides have a steeper lead-in chamfer on the top and bottom to better guide
the tool joint through the top guides (less impact). The contact area between pipe and ram insert
is enlarged
A wear groove is provided for indicating the maximum wear.

NOTE: When the stainless steel ram inserts are worn out,
have the inserts repaired by an authorised repair facility
rather than welding up in house, as the contour of the
insert require special machining facilities.

Pipe wiper
When tripping out drill pipe, NOV recommends a 19" spirol (Helical) wiper to be placed
underneath the tool.
This type of wiper can be installed while the tool is in the rotary table. Pull out the insert carriers,
then lower the wiper through the slips.

NOTE: Position the wiper UNDERNEATH the tool to keep

mud away from the moving parts inside the PS.

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Work order first usage PS

Action Applicable document
1. Check the system requirements and the PSEL-0002
pre-installation sheets.
2. Check tubing and hoses are minimal 1/2”
size
3. Check minimum work pressure 2,300 psi
(15, 857 KPa) available system pressure
4. Check maximum system pressure does
not exceed 3,000 psi (20,684 KPa)
5. Check Power unit: Minimum 5-10 Gpm
(19 l/min.-28 l/min.) at 2,300 – 3,000psi
(15, 857-20,684 KPa) available?
6. Check maximum oil temperature: Oil
temperature HPU does not exceed
140ºF (60ºC)?
7. Application filter. Verify filters fit properly.
8. Install PS in rig floor Installation drawings
and procedures in pre-
installation sheet PSEL-
0002
9. Conduct field commissioning procedure Field commissioning
and sign off commissioning sheet procedure TSEL-0067
10. Tool ready for operation

System Requirements check

Safety

WARNING: Make sure that all hydraulic lines are

isolated before any work is carried out on the PS

NOTE: Fit control manifold close to the hydraulic supply

and as near as possible to the PS

NOTE: Route the hoses on the rig floor to minimise

damage caused by cutting and dragging.

NOTE: Before starting operation, remove air from the

hydraulic circuit by cycling the slips full up and down for
about 10 times. Air in the circuit may lead to improper
functioning of the PS, and may lead to dropping of pipe.

CAUTION: NOV strongly recommends to only use one of

the NOV’s original PS controls to operate the PS. Other
controls may damage the hydraulic circuit of the PS

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Operations
WARNING: Be careful when operating the PS while
the topcovers are open

WARNING: Do not touch the PS

WARNING: Never raise the slips when the pipe load is

still suspended in the slips.

Operational safety
‰ Make sure that ALL hydraulic lines are isolated before any work is carried out in the PS.
‰ It is recommended to have the PS operated by the driller.
‰ For smooth operation, it is recommended to slightly lower the pipe with the elevator while
setting the PS slips.
‰ For smooth operation, it is recommended to slightly raise the pipe with the elevator while
releasing the PS slips.
‰ The rotary locks in the outside of the PS may only be needed on semi submersible rigs or
while floating in pipe when there is a chance the PS could come out of the rotary table.
Procedure disconnecting hoses
Disconnect the hoses in the following cases
1. The tool has to be lifted out of the rotary table.
2. The PS and table have to be rotated.
3. Any unwanted slip movements have to be prevented, especially when someone has to
work on the PS
Procedure operation
1. Check slips/carriers are set on correct section of the pipe. The PS must be set before
releasing the elevator. The PS is properly set when the slips down signal comes on.
2. When the rotary table and the PS have to be rotated, always uncouple the quick
disconnects on the PS prior to rotation. Not doing so may cause severe damage to the
PS, hydraulic hoses or controls.
3. Place the PS in the rotary table using all 4 lifting eyes and four way lifting sling p/n
200982-1.
4. Connect all hydraulic equipment and check correct functioning of the tool.
5. With the pipe string being held by the PS, make up or break the upper stand or joint, and
handle it.
6. Pick up the weight of the pipe string with the elevator, before raising the slips of the PS
7. Set the slips of the PS and then release the elevator.

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Removal of PS
Removal of the PS when pipe is in the hole

CAUTION: Be aware of losing parts while lifting. Prevent

this by using the insert carrier lifting look for lifting of insert
carriers and opening of the top covers.

WARNING: DO NOT lift the PS on the cover plate L-

bars

WARNING: Lift the PS out of the rotary table ONLY

with the 4 way lifting sling with curved spreader
beam. (part no. 200982-1), using ALL 4 hoist swivel
rings.

Exceptions
No insert carriers have to be removed to get pipe through the door in:
‰ PS21: 2-3/8" - 14" (complete size range)
No slips have to be removed to get pipe through the door in:
‰ PS21: 2-3/8" - 14" (complete size range)
Procedure removing the PS from drill pipe while in rotary.
‰ Take the load from the slips
‰ Raise the slips
‰ Depressurize the PS hook up hoses by using the PS neutral button and disconnect the
hydraulic hoses from the PS by disconnecting the Q.D's
‰ Unlock the rotary locks
‰ Unlock the top-cover lock
‰ Open the top-covers as described in the manual
‰ Remove the removable hinge pin from the PS door using the insert carrier lifting hook
(P.N.50004600-1)
‰ Lift the PS from the rotary table by using the four way lifting sling with curved spreader bar
(P.N. 200982-1)
‰ Open the PS door
‰ Move the PS away from the pipe / well center
Connecting and disconnecting of the hydraulic hoses
WARNING: Be careful when disconnecting hydraulic
hoses. Make sure pressure is of the hoses and the
weight of the string cannot generate pressure

Once disconnected from the controls, the slips will be hydraulically locked in the last position.
Once the hoses are disconnected, the hydraulic oil on either side of the cylinder pistons is
trapped in place and therefore the cylinders (slips and/or centering device) are locked in
position.

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Procedure dis-connection hoses in slips up position

1. Set PS in neutral position with the override button
2. Disconnect Quick Disconnects.
Override button
On the drillers console, a button is provided releasing all pressure from the system. In case
when the slips are up, the anti sagging seals in the LH-actuator in combination with a counter
balance valve inside the maifold block prevents the slips from setting.

Using handslips
Hand slips can be used to prevent the pipe from slipping through the PS, especially when
suspending low weights of string, e.g. at the start or finish of a trip. The PS will act as a
conventional master bushing with insert bowl when used properly.

WARNING: Using the PS with handslips results in not

being able to use the centering device. When running
deviated pipe, ensure the handslips are set properly
before suspending the load. Take safety precautions.

NOTE: For lifting the hand slip bowl #1, use the lift tool with part number 50004550-21.

Procedure
‰ Raise the slips
‰ Isolate the PS hydraulically
‰ Open the top covers, remove the ram-inserts
‰ Remove the insert carriers
‰ Install the hand slip bowls
‰ Put pressure back on
‰ Set the slips
‰ Check the slips for proper settings (slips set signal)
‰ Check the slips bowls. They have to match each other on contact spots
‰ Close the ball valve in the slips down hose.

CAUTION: If no ball valve is installed, ensure installation

will be carried out.

CAUTION:Ensure the PS slips are set before using the PS

for running hand slips. The hydraulic power in the PS is
required to prevent the PS from opening when using the
PS like a masterbushing. However, when opening the PS-
slips while using hand slips may cause the PS to open due
to the “wedge-action” of the handslips when the PS slip
assembly is not properly set.
‰ Close the top covers
‰ Use hand slips with extensions

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‰ Start running as usual with a master bushing, bowl and hand slips.

NOTE: Ensure the tooljoint will be sufficiently above the

top cover before attempting to place the hand slips in the
PS. If the tooljoint is too low, it will be hard if not impossible
to place the hand slips.
See chapter “Installation and Commissioning” for the appropriate part numbers for size and
rating of hand slip bowls and extension handles
.
Hand slip bowl (3 plc) Hand slips

Slips not set properly: Opening between hand slip bowls, slips
resting on 30° face
No handles showed in image

Slips set properly: Slips in 9° bowl

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Running umbilical lines

Option 1; Quickest way
See pictures 1,2,3, The easiest way to run the umbilical through the PS
1. Raise the slips of the PS
2. Rotate the rotary table until the pipe is hard to the movable ram in one of the top cover
halves. On a jack up it should be possible to keep the pipe offset towards the same top
cover half constantly.
3. With the pipe hard to one top cover half, open/flip away the other top cover half.
4. Set the PS slips. Check if the ram in the closed (= still flipped down)top cover half is able
to center the pipe and allow the slips to set correctly.
5. At this moment you will notice an approx. 4 x 4 inch gap between the 2 side slips and the
door. This is your room to run the umbilical through.
6. While running pipe in the hole you have to manually guide the umbilical into the indicated
gap while setting the slips.

WARNING: Always keep your hands out of the PS.

WARNING: Make sure that hands are kept away from

the moving ram inside the flipped-open top cover
half. Shield off the internal moving parts inside the
flipped-open top cover half by covering this top cover
half by means of a thick welding blanket or such.

Pic 1

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Pic 2

Pic 3

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Option 2; Alternative procedure

See pictures 10, 13, Same as option 1 but with both top-covers open
In most cases while running umbilical the pipe is not hard off center so the centering device is
not needed. Advantage of this is the great view on slips and umbilical, but disadvantage is the
opened covers sticking out over the drill floor.

WARNING: Ensure the PS can not rotate while the top

covers are open.

The umbilical guide (jpg 10) keeps the umbilical away from the slips. For this purpose two holes
for attachment need to be drilled in the door.
Umbilical-Guide-P.N#:50004680-21

CAUTION: Be aware of the centering rams in the top-

covers as they will be moving in and out when setting /
raising the slips.

NOTE: The umbilical has to come in from the door, left-

hand-, or right-hand PS side and will be guided by the
umbilical-guide.

Pic 10

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Pic 13

Field questions with regard to the umbilical guide

1. Are we allowed to run umbilical through the PS without the top-covers? Answer:
You do not need the PS top covers to run umbilical if the tubing or pipe is reasonable in center
and does not experience a lot of side load.
Disadvantages of running without the top-covers are;
‰ National Oilwell Varco does not recommend unauthorized disassembly and assembly of
top-covers in the field, because of the risk of hydraulically and mechanical failures
(warranty will be lost)
‰ When the top-covers are removed totally including the hinge bosses which is the most
practical way, you have to plug the hydraulic tubes to the hinge boss and greasing of the
side slips is lost
‰ Also the body and slips are now unprotected against deck hands to enter and get hurt
‰ When slips are set the space in between the left- and right-hand slip segment / insert-
carrier is about 1/4 inch and bigger
2. Are we allowed to cut out two spots of about 2 x 2 inches in each top cover half and universal
and ram-insert to allow the umbilical to pass through? Answer; See pictures; 21, 31, 71:
We do not forbid you to make the cut in the top-cover halves but we have some concerns about
it;
Cuts at the PS door-side straight above the space between PS door and side slips. National
Oilwell Varco warns for the increased risk of pinching due to the cut!
The centering rams plus centering cylinders are closing off this total space while centering the
pipe and will pinch everything in their way (your cable for instance). We question how you plan
to keep the rams from closing?
Even if the rams could be prevented from closing the space is very limited and very close to the
slips, which makes this not practical enforceable.

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Pic 21

Pic 31

Pic 71

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Assembly and dis-assembly

Safety
NOTE: All images in this chapter are for info only. Please
use the official drawings for reference

WARNING: Make sure that all hydraulic lines are

isolated before any work is performed on the PS.

Procedure prior to working on the PS or any of it’s parts

If the PS is connected to a power unit, bleed the system prior to repair.
To bleed the PS;
1. Shut the valve in the Pressure line
2. Shut off the power unit
3. Give command <slips up> and <slips set> a number of times

WARNING: When working on the PS, lock and tag the

controls in order to prevent unexpected movement of
the PS.

WARNING: Do not weld on PS or individual parts

NOTE: Prior to assembly or disassembly, clean the PS

thoroughly with a steam-cleaner in order to prevent the
parts from getting contaminated with dirt, mud etc.

Before (dis)assembly of the PS make sure:

1. All tools are at hand
2. Hoisting equipment is available
3. Lifting equipment is suitable for handling heavy parts (crane, lifting bands, chains, eyes
etc)
Torques
Use the proper torque for assembly parts. Applying too much torque easily could damage
cartridges. See the torque lists in this manual.

Required tools
For normal maintenance and repair, standard tools will be sufficient for all work. However, bigger
size spanners may be required for hydraulic tubes

Special tools
The removal of cartridges from the PS manifold block may require an extended socket be
modified. If required, the outside diameter of a 7/8”socket should be reduced (turned down) to
29 mm, 1.14”.

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Assembly of the PS
Follow the reverse order for disassembly of the PS
1. Changing centering device ram inserts
2. Close ball valve
3. Disengage the top cover lock and open the top covers.
4. Remove the lynch pin clip that locks the ram insert into the universal ram guide.
5. Replace the ram insert. Two threaded holes (1/2" UNC) for lifting eyes are provided in each
ram insert to ease handling.
6. Lock the new ram insert with the lynch pin clip.
7. Close and lock the top covers.
8. Open ball valve.

CAUTION: To prevent damage to the tool during

operation, never operate the PS without a ram insert
assembled into the universal ram c.q. without a centering
ram assembled. EXCEPTION: Drill collars will be run
without ram inserts installed in the universal ram.

Procedure changing the ram guides.

1. Open top covers.
2. Disconnect lynch pin from pin on guide half
3. Change out ram guide halves
4. Re-assemble lynch pin.
5. Close and lock top covers.

Procedure (dis)-connection of the hydraulic hoses.

See chapter operations.

Hydraulic actuators
NOTE: Prior to disassembly, clean the PS thoroughly with
a steam-cleaner to prevent the disassembled parts from
getting contaminated with dirt, mud etc.
Cylinder part numbers

Part Part number

Left hand cylinder 202203-55

Right hand cylinder 202204-55

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Disassembly of cylinder
1. Open up the PS top covers.
2. Ensure the slip lift levers are in halfway raised position.
3. Disconnect all 3 hydraulic tubes from the right hand cylinder.
4. Remove all 4 bolts that connect the cylinder barrel to the cylinder gear box.

5. Gently slide the barrel up until the barrel parts from the piston. No excessive force should
be needed to remove the barrel. Making a turning movement with the barrel while sliding
up eases the disassembly of the barrel.

Replacing of the RH actuator seals

These instructions lists the step by step procedure to replace the piston seals and/or piston
inside the right hand PS cylinder (= the cylinder with the signal port).
Procedure
1. Inspect the seals for any damages and/or scoring.
2. Determine the assembly position of the seals.
3. Warm up the 2 white outer rings of the piston seals in hydraulic oil with a temperature of
approx. 65°C (150° F)
4. First assemble the bottom piston seals, before the top seals.

NOTE: Never assemble the top seal first, as the top seal
will get damaged during assembly of the bottom seal.

NOTE: In order to allow the bottom seal to be assembled

first, the 2 half moon rings (delivered together with
replacement seals) have to be assembled in the top seal
groove.
5. Fit the bottom.

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6. Assemble the o-ring

7. Assembly of the white outer ring. The warmed-up outer ring needs to be stretched gently
BY HAND over the taper on the piston.

NOTE: Never apply brute force while assembling the

white outer ring. Sometimes the outer ring needs to be
warmed-up again during stretching.
8. When the outer ring is stretched beyond the taper on the piston, gently slide the outer ring
downwards until the ring falls into the bottom seal groove. The outer ring will shrink back
to its original diameter when cooling down.
9. Remove the 2 half moon rings from the top seal groove and assemble the top seal.

NOTE: Take care the seals are assembled in the correct

position. Once assembled the seals cannot be removed
again without damage.

Assembly of the barrel

1. Slide the barrel over the new piston seals.
2. Turn and slide the barrel to ease the assembly of the piston into the barrel.
3. Secure the barrel to the cylinder gear box using the 4 original bolts. Assemble the bolts
with blue Locktite and pre-torque the bolts properly.
Replacing of the LH actuator seals
See drawings.

Assembly of the levers.

1. Make sure the V-mark on the levers is lined up with the V-mark on the spline shaft of the
cylinders.
Assembly of the hydraulic cylinders into the PS
1. Put the hydraulic cylinders into position without tightening the bolts.
2. Insert from one side the synchronization shaft through both cylinders (Do not forget the 2
protection rings). In the new design only one key is present.

Synchronisation
shaft. New
design has 1 key

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3. Put the cylinders into position and assemble them with 8 bolts and washers on the sides.
Do not tight the bolts.
4. Assemble the 4 bolts and washers in the back.
5. Torque to 157 - 173 ft-lbs (213 - 235 Nm) when using anti-seize compound

NOTE: After all bolts are tightened, try to shift the

synchronisation shaft. Use a mallet to slightly tap the shaft
in order to check the alignment of the 2 cylinders. The
shaft must be tight but not clamped.

Torque the bolts (sides) + (back)

Assembly of the Hoisting Swivel Ring

Procedure
1. Hoist swivel rings pn 980473-2

WARNING: To avoid loads from slipping or falling,

always use the proper hoist ring assembly and folow
the lifting procedures.

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Hoist swivel
ring p/n
980473-2

2. Ensure there are no spacers (washers) used between bushing flange and the mounting
surface.
3. Verify threads on shank and receiving holes are clean, not damaged, and fit properly.
4. Apply locktite no. 243 to the thread.
5. Installation torque 2500 lbs SWL hoist ring: 28 ft/lbs (37 Nm)
6. Installation torque 5000 lbs SWL hoist ring: 100 ft/lbs (135 Nm)
7. After installation, always ensure free movement of bail. The bail should pivot 180º and
swivel 360º.
Assembly of the manifold block
Procedure
1. Put the manifold into position on the PS-body. Tighten the bolts and lock wire.
2. Use 3 o-rings on the bottom side of the block.
Assembly cover plate hinge pin assembly
NOTE: The hinge pin must be assembled with great care
to ensure functioning properly. Clean pin and hinge boss
hole and remove any sharp burrs that might damage the
seals during assembly. Clean the seals.
1. Apply a coat of hydraulic fluid to all pin surfaces.

NOTE: Take care all seals are mounted in the correct

position

2. Assemble O-rings, backup rings, lips seals and spacer rings.

3. Apply a grease coating to all hinge boss holes.
4. Gently assemble the pin with the seals.

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5. Gently assemble the hinge pin

Back up ring (1x)
Hinge pin

U cup Flow
seal ring
U cup Ring + Back
seal up o-ring (2
places)

NOTE: Do not forget the spacer ring between the hinge

pins

NOTE: Pull back the pin when resistance during assembly

is observed to prevent damage on the seal surfaces.

NOTE: Always change out seals when an hinge pin is

removed from the boss when it has been used!

Assembly centering device cylinder.

The knuckle is correctly mounted onto the cylinder piston rod when there is 0.125" space
between the knuckle and the piston rod shoulder.

Assembly of the PS
NOTE: Use the proper torque for assembly parts.
Cartridges easily could be damaged by applying too much
torque.

Assembly is the reverse procedure of disassembly.

1. Lock wire all parts as indicated on the assembly drawings.
2. Check the PS according the Test Procedure.

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Trouble shooting
Prior to trouble shooting, carry out the following checks. When problems cannot be solved,
please contact an authorized NOV repair facility.

WARNING: Make sure that all hydraulic lines are

isolated and the ball valve is closed before any work
is carried out on the PS

NOTE: When a solution is not available in the following

flowcharts, please contact an authorised NOV repair
facility for further information

Prior to trouble shooting a problematic PS

NOTE: When problems occur, carry out the following
checks according the PCLEFOS-rule. Solve discovered
problems first, than go to the trouble shooting flow charts.

Symbol Check

P Check available Pressure to Hook Up Manifold is 2300 psi (15,857

KPa) minimum read out pressure gauge near accumulator.

C Check that all hoses and quick disconnects are properly Connected
and the ball valve is open.

L Check Lubrication status of tool.

E Check whether Electrical power is available at the control panel
F Check if the flush valve handle is in Normal Operation Mode

O Check whether Oil leakage is visible at manifold block, Hook Up Kit,

Quick disconnects or hoses

S Is Signal slips set/up coming up correctly after setting/raising slips?

Trouble shooting Flowcharts

When no solutions available in the flow-chart, please contact an authorised NOV repair facility
for further information.

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1. Slipping pipe
The pipe is slipping through the inserts.

Problem Possible solution

Are teeth on inserts in slip or insert carrier are
worn? Status of inserts can be verified by Replace inserts. See chart on instruction sheet
conducting a slip paper test. See instructions on to verify correct insert part number for specific
special NOV Slip Test Paper paper 980303, test pipe size.
spec TSEL-0054 and manual.
Check and/or change out insert carriers. See
Wrong insert carriers used? chart on instruction sheet to verify correct insert
carrier part-number for specific pipe size.
Check size and/or change out inserts. See chart
Wrong inserts used in slip or insert carrier? on instruction sheet to verify correct insert part-
number for specific pipe size
Lack of grease on back of slips is preventing
Slips not setting correctly in clamping cones
slips to set correctly. Apply grease frequently as
inside body?
listed on instruction chart.
Built-up of dirt inside a slip cylinder is preventing
a full stroke of the cylinder. See instructions in
manual to inspect and assemble these
cylinders.
Check available pressure to HUK manifold is
Is lack of slips down force preventing insert
2,300 psi (15,857 psi) min. on pressure gauge
teeth from gripping the pipe. (Especially
near accumulator. Also check condition of
applicable when tripping high graded pipe in
accumulator. See instructions in manual to
combination with oil based mud).
check status of accumulator.
Is the PS (slip and body) modified with anti
Modify PS.
cocking-device (PS30 only)?

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2. The PS functions incorrectly.

Problem Possible solution
Check and/or change out insert carriers. See
Wrong insert carriers used? chart on instruction sheet to verify correct insert
carrier part-number for specific pipe size.
Check size and/or change out inserts. See chart
Wrong inserts used in slip or insert carrier? on instruction sheet to verify correct insert
partnumber for specific pipe size.
Is a strong radial or angular deviation of the pipe
towards the door side of the PS preventing the Rotate PS with center slip towards deviation
slips from setting correctly?
Is pipe not correctly clamped by slips because Check size and/or change out ram inserts. See
incorrect sized ram inserts in centering device chart on instruction sheet to verify correct ram
are used? insert partnumber for specific pipe size.
Solutions in logical order:
Lack of grease on back of slips. Apply grease
frequently as listed on instruction chart.
Slip hinge pins are not properly greased or have
broken/wrongly assembled torsion springs.
Rams closing/slip setting sequence is not
functioning properly. Slips set before rams are
completely closed. Check minimum pressure
differential between slips up and slips down
Are slips not setting correctly in clamping cones
hose of 2,100 psi (14,478 KPa).
inside body?
Dirt inside PS manifold may cause a
malfunctioning of the sequence valves. Flush
and/or clean PS manifold. Check proper
pressure setting of sequence valve inside PS
manifold. Valve should be set at 1,900 psi
(13,100 KPa).
Built-up of dirt inside a slip cylinder is preventing
a full stroke of the cylinder. Inspect and
assemble these cylinders.

3. Slips don’t work properly

The slips don’t retract / open up completely in raised position.

Problem Possible solution

Is there a built up of dirt inside the body and/or Take slips out of body regularly to clean slips
on top of the ribs on the backside of the slips? and body
Apply grease to hinge pins nipples on slips.
Check whether torsion springs on slip hinge
Do slip hinge pins have too much friction? pins are broken / worn / have been wrongly
assembled with the spring legs outside their
retaining holes.
Built-up of dirt inside a slip cylinder is preventing
a full stroke of the cylinder. Inspect and
Is the piston inside one of the slip cylinders not assemble these cylinders.
fully stroking up? Piston inside one of the cylinders has come
loose from the piston rod. Check correct internal
assembly of slip cylinders.

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4. The slips do not raise

Problem Possible solution
Pressure in slips up hose is min. 2,300 psi
(15,857 KPa). Back pressure in power down
hose may not exceed 200 psi 1,378 KPa).
Check pressure and back pressure in hydraulic
lines between Hydraulic Power Supply and HUK
manifold.
Is hydraulic pressure high enough to raise Check in-line filters in PS hydraulic system are
slips? not clogged up. Filters in HUK manifold must
be cleaned/replaced.
Check proper functioning of quick disconnects
in hydraulic lines between HUK manifold and
PS.
Return filter on HPU is clogged up. Replace or
clean.
Frequently grease back of slips as outlined on
instruction chart.
Is there lack of lubrication on clamping cones
Check proper and equal grease distribution over
resulting in too much friction on upward slip
all ribs/clamping cones inside body.
movement?
Check condition of grease supply and grease
outlets if applicable.
Check for dirt in hydraulic system that is causing
a malfunctioning of the valve.
Is directional control valve on HUK manifold Check for high back pressure in return line to
malfunctioning? HPU and/or in non-pressurized hose running to
PS that may cause a malfunctioning of the
valve.

5. The slips don’t move up or down

Problem Possible solution
Pressure in slips up hose should be 2300 psi
(15,857 KPa). Back pressure in power down
Is hydraulic pressure supplied to the PS? hose may not exceed 200 psi (1,378 Kpa)
Check hydraulic hoses are connected to PS.
Check ball valve in slips down hose is open.

6. Sagging slips
The slips sag when Hook Up manifold is isolated from power supply

Problem Possible solution

Are Non-Leaking seals in left hand slip cylinder
Replace piston seals in left hand cylinder.
are worn out?
Is Anti-sagging check valve malfunctioning? Replace check valve.
Tubing connection leaking? Tighten or replace.
Internal pressure relief valve inside LH actuator
Tighten or replace
leaking or defect

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7. Faulty signal
Incorrect (double, faulty, absent, continuous etc) slips down / slips up signal is observed while
slips are travelling up and down correctly

Problem Possible solution

In logical order:
Check condition of quick disconnects in signal
hose.
Check condition of accumulator
Is HUK manifold getting hydraulic signal from Check condition of inline filter in signal hose
PS? near HUK manifold.
Check whether middle barrel port in right hand
slip cylinder is not blocked.
Check condition of piston seals in right hand
cylinder. Replace seals if required.
Built-up of dirt inside HUK manifold may cause
a malfunctioning of the signal valves SV1 or
SV2. Clean/replace valves if applicable
Pressure setting of SV1 or SV2 may be higher
Is pressure switch getting signal from HUK than actual system pressure. Valves should be
manifold? set at 1,500 psi (10,342 KPa). Adjust if
applicable (OLD SYSTEM).
High back pressure in return line may cause
malfunctioning of SV1 or SV2.
Check DV3 (NEW SYSTEM)
Dirt inside pressure switch may cause
malfunctioning of switch.
Are pressure switches on HUK giving correct Setting of pressure switche(s) may be higher
signal? than actual system pressure.
Check if pressure switches are correctly wired
to control panel.
Is one of the slip set indicator valves
Replace malfunctioning valve.
malfunctioning

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8. The slips are travelling too slow

The slips are travelling up and/or down too slow. (Set/raise time should not exceed 6 seconds)

Problem Possible solution

In logical order:
Check inline filters in PS hydraulic system are
not dirty. Filters in HUK manifold must be
cleaned/replaced.
Check condition of accumulator.
Sequence valves inside PS are not opening
properly. Check minimum pressure differential
between slips up and slips down hose of 2,100
psi (14,478 KPa)
Hydraulic pressure supply to the PS sufficient?
Dirt inside PS manifold may cause.
Malfunctioning of the sequence valves. Flush
and/or clean PS manifold.
Check proper pressure setting of sequence
valve inside PS manifold. Valve should be set at
1,900 psi (13,100 KPa).
Check available pressure to HUK manifold is
2,300 psi (15, 857 KPa)min. on pressure gauge
near accumulator.
Check condition of quick disconnects in hoses
running to PS.
Check ball valve in slips down hose is fully
open.
Is the hydraulic flow supply to the PS sufficient?
Assemble flow meter in pressure line to HUK
manifold and check flow is 5 GPM (19 l/min)
minimum. A flow of 10 GPM (38 l/min) is
recommended.

9. Problems with rams

Rams inside top cover do not open or close properly

Problem Possible solution

Is the piston inside top cover cylinder fully Built-up of dirt inside top cover cylinder may
stroking? prevent a full stroke of the cylinder.
Is the knuckle on the top cover cylinder rod Check correct assembly of knuckle onto
properly connected? cylinder rod.

10. Problems with rams

Rams inside top cover does not open or close properly

Problem Possible solution

Disassemble top cover hinge pins (2 per hinge)
Is hydraulic oil leaking from top cover hinges? one at the time and check condition and replace
seals. if necessary

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11. Problems with insert carriers

The insert carriers are sliding inside the slips during tripping

Problem Possible solution

In logical order:
Built-up of dirt on stop pads of latches is
preventing the latches from falling properly over
the insert carriers. Latches engage properly
when their top surface it sitting horizontal after
engagement.
Is the latch spring in place or worn?
Built-up of dirt on top of insert carriers is
Are the insert carriers properly locked in place preventing the latches from properly falling over
by latches positioned on top of slips? the insert carriers.
Lifting hook on insert carriers is not falling down
on its seat after assembly of the insert carrier,
preventing the latch from falling properly over
the insert carrier.
Built-up of dirt on top of slip is preventing the
insert carrier from sliding down far enough,
preventing the latch from falling properly over
the insert carrier.

12. Problems with the insert carriers

The insert carriers are hard to assemble into or disassemble from the PS slips

Problem Possible solution

Clean outer contour and retainer slot on insert
Is built-up of dirt preventing insert carriers from
carrier.
assembly?
Clean inner contour and carrier retainer on slip
Remove burrs from retainer slot on insert
Is retainer slot on insert carrier matching with carrier.
carrier retainer on slip? Check condition of carrier retainer on slip and
replace if applicable
Check latches on top of slip can move freely.
Is the carrier quick release mechanism
Check lifting eye on top of insert carrier can
functioning?
move freely

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13. Problems with slips

The slips are hard to put in or out the PS

Problem Possible solution

In logical order:
Check sliding hole inside center slip is not
clogged up with mud or other debris.
Check condition of mud drain hole in bottom of
sliding hole.
Check pins are properly greased.
Are the slip mounting pins in center slip stuck? Check slip mounting pins are not bent.
Check if correct slip assembly procedure as
listed in manual is followed. The use of the ball
valve in the slips down hose during slip changes
is essential.
Check presence and functionality of ball valve in
slips down hose.
Ball headed grips on slip mounting pin handles
Are the handles on the slip mounting pins
must face towards the levers of the slip
preventing these pins from fully retraction?
cylinders.

14. Problems with the inserts

The bottom row of the inserts in the insert carriers are cracking frequently and/or the teeth on the
inserts are breaking off frequently

Problem Possible solution

Check only genuine NOV inserts are used. The
Are the inserts performing properly? use of non-NOV inserts may seriously affect the
functionality of the PS
Check insert carriers are dressed with bevelled
Check correct sized ram inserts are used. inserts in the bottom row at all times. This is
also applicable when non-reducing inserts are
used.

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15. The lifting eyes on the body bail

Problem Possible solution
Never lift complete PS with top cover lifting
eyes.
Always lift PS using all 4 lifting eyes on body
Have the lifting eyes been overloaded? simultaneously.
Only lift PS using dedicated NOV 4-way lifting
sling with curved spreader bar.
Replace the broken lifting eyes.
The lifting eyes on the body (hoist swivel rings)
are designed for hoisting only and are not
Have the lifting eyes been side loaded?
suitable to adopt side loads.
Replace lifting eyes.

16. Problems with tubing

The hydraulic tubing inside the PS starts to leak after extended operation

Problem Possible solution

Slip cylinders are not properly attached to PS
body. Regularly check pre-torque moments of
cylinder assembly bolts.
PS manifold is not properly attached to PS
Is the tubing moving during operation? body. Regularly check condition of manifold
assembly bolts.
Top cover hinge blocks are not properly
attached to PS body. Regularly check condition
of hinge block assembly bolts.

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Appendixes
Spare parts
NOTE: Please select below the appropriate valves and
parts, depending on the configuration.

General HUK
Part number Qty Description
980052-1 1 Replacement filter element 30p-2 media 40-w

50004442 Ass’y HUK manifold

Part number Qty Description
93548-1S30N 2 Check valve cartridge, CXCD-XCN
94817-2AN 1 Pressure reducing cartridge, PBFB-LAN
980016 1 Back connection pressure gauge:0-3500 psi
59000117-1 1 Flush valve, parker dm103ld cartridge
59000129 1 Hydr. pilot operated 4/2 cetop 03 valve, w/detend

50004511-1 Grease manifold ass’y

Part number Qty Description
94520-1CN 1 Cartridge relief valve, RPEC-LCN
94817-1AN 1 Cartridge pressure reducing valve, PBDB-LAN
Hydr. pilot operated 4/3 cetop 03 valve, w/o
979801-a6-2 1
detend
203016 1 Pressure switch,eexd

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Control valves
Part number Qty Description
112554-J2 1 24v/dc, eexd 4/3 valve, atos
112554-J3 1 110-120v/ac, eexd 4/3 valve, atos
112554-J4 1 220-240v/ac, eexd 4/3 valve, atos
979801-A4-3 1 Air pilot operated 4/3 valve, atos

Control box
Part number Qty Description
59000219-1 1 Logo! 24rc (ac), 24vdc 8 inputs & 4 outputs
Logo! expansion module dm8 12/24r,
59000220-1 1
24vdc 4 inputs & 4 outputs
59000219-2 1 Logo! 24rc (ac), 115-240vac 8 inputs & 4 outputs
Logo! expansion module dm8 12/24r,
59000220-2 1
115-240vac 4 inputs & 4 outputs
59000221 1 Logo! program module, yellow card

Spare parts Operational pn 202200-12

Part number Description Qty
202203-41 seal kit for l.h. actuator 1
202204-41 seal kit for rh actuator 1
202207 lock bar for stationary hinge pin 1
202209 synchronisation shaft 1
202219-11 hydraulic tube l-h slips up 1
202290 ring,centerslips 1
202308-1 hydraulic tube 1
202308-2 hydraulic tube 1
202308-3 hydraulic tube 1
30107236-1AN direct acting sequence valve 1
50004515 tube assy ps21 500 ton 1
50004516 tube assy ps21 500 ton 1
50004517 tube assy ps21 500 ton 1
50004518 tube assy ps21 500 ton 1
50004743 signal adapter block 1
50004745-1 hydraulic signal tube 1
50004745-2 hydraulic signal tube 1
50004745-3 hydraulic signal tube 1
50004745-7 grease tube assy right hand 1
51300-208-B o-ring id .604/.614 1

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Part number Description Qty

53000-2 plug,external pipe- countersunk hex 1
56507-4-4-S tee, branch 37' /37' /ext pipe 1
56700-6-4-S reducer, pipe-ext /int 1
947879-100 lock wire stainless steel 1
979504-5 male connector with o-ring 1
979504-6 male connector with o-ring 1
979504-7 male connector with o-ring 1
50104-3-C screw, cap-socket head (unc-2a) 10
53201 fitting,grease,straight 10
56519-6-6-S elbow, o-ring boss /37' 12
979512-2 plug 9/16-18 sae o-ring socket type 16
51010-C washer, lock-heavy 18
202210 key for synchronisation shaft 2
202226 cylinder protection ring 2
202226-1 cylinder housing protection ring 2
202249-11 grease nipple for hinge block 2
202263 knuckle, PS21 centering device 2
202266-100 knuckle pin 2
202269 backup ring hinge pin 2
202286 pin,centerslips 2
202289 handle,center slips 2
202292 slip spring 2
202292-1 slip spring 2
202294 compression spring ps21 2
202306 greasing sticker, warning 2
202388 ram hinge pin 2
202390 pin retainer 2
50004531 pin,cover plate lock 2
50004591 indicator valve right-hand 2
50004730 relief valve 2
50004744 slip indicator pin w. grease holes 2
50004748 plug ext. 1-1/4--11-1/2npt 2
50004749 indicator valve support 2
50004752 indicator trigger pin 2
50006-5-C8D screw, cap-hex hd (unc-2a) 2
50008-10-C8D screw, cap-hex hd (unc-2a) 2
50010-12-C8D screw, cap-hex hd (unc-2a) 2
50010-24-C8D screw, cap-hex hd (unc-2a) 2
50706-6-A-C screw, set-socket head (unc-2a) 2
51300-117-B o-ring i.d. .793/.805 thck 2
51403-20 pin, cotter 2
51506-26 pin, grooved taper 2
51606-12-C pin, roll 2
53203 fitting,grease,90 deg 2
53204 fitting,grease,straight 2
56501-2-4-S connector, ext pipe 37' 2
56506-2-4-S elb, 90' ext pipe /37' 2
56517-6-4-S reducer, int 37'/37' 2

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Part number Description Qty

56518-4-4-S elbow, 90' swivel int 37' /37' 2
56518-6-6-S elbow, 90' swivel int 37' /37' 2
59001008-5 chain, straight link, short,dia 5mm 2
93547-1B30N sun pilot to open check valve 2
948042-85 5 links-0.11m 2
948051-2 s-hook 2
979386-55 compression spring ps30/bx-elev. 2
979439-1 scraper type m12.20 2
979504-3 male connector with o-ring 2
979512-3 plug 7/16-20 sae o-ring socket type 2
979532-6-4 nipple, straight, bsp to jic 2
979935-6-6 elbow 90deg bsp to jic 2
979948-T13A sun cavity plug all 2
979966-1 relief valve 1/8"-27npt 2
980268 hose assembly for centering device 2
980269 hose assembly for centering device 2
50910-C washer, lock-regular 20
50906-C washer, lock-regular 24
202308-4 hydraulic tube 26
107629-160 pilot operated check valve 3
202349-15 grease restrictor 1.5mm 3
202349-25 grease restrictor 2.5mm 3
202349-50 grease restrictor 5mm 3
202416 plug for cac10 cartridge 3
51300-116-B o-ring id .732/.742 thck 3
7887 lynch pin 3
979455-10 expander 10mm 3
202203-43 roller bearing 4
202268 flow ring hinge pin 4
202410 cover plate hinge pin. 4
50006-14-C8D screw, cap-hex hd (unc-2a) 4
50006-4-C8D screw, cap-hex hd(unc-2a)drilled 4
50008-12-C8D screw, cap-hex hd (unc-2a) 4
50008-20-C8D screw, cap-hex hd (unc-2a) 4
50008-8-C8D screw, cap-hex hd (unc-2a) 4
50010-20-C8D screw, cap-hex hd (unc-2a) 4
50806-N-C washer, flat 4
51006-C washer, lock-heavy 4
56506-2-4-S elb, 90' ext pipe /37' 4
979485-15 lock washer s.s. din 432-17a2 4
979512-2 plug 9/16-18 sae o-ring socket type 4
979512-3 plug 7/16-20 sae o-ring socket type 4
979771-2225 trigger bushing manifold 4
979966-1 relief valve 1/8"-27npt 4
980473-2 hoist swivel ring adb, modified 4
51300-208-B o-ring id .604/.614 5
56518-6-6-S elbow, 90' swivel int 37' /37' 5
202283 latch-pin 6
50004742 hex. head shoulder screw 3/4-10 6

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Part number Description Qty

50006-10-C8D screw, cap-hex hd (unc-2a) 6
50006-8-C8D screw, cap-hex hd (unc-2a) 6
50010-10-C8D screw, cap-hex hd (unc-2a) 6
50914-C washer, lock-regular 6
51008-C washer, lock-heavy 6
979386-5 compression spring 6
50004-4-C8D screw, cap-hex hd (unc-2a) 8
50108-16-BD screw, cap-socket head drilled 8
50904-C washer, lock-regular 8
50908-C washer, lock-regular 1/2" 8
51108-C washer, lock-hi-collar 8
51302-223 ring, back up-o ring 8
56529-6-6-S connector, o-ring boss /37' 8
949708-223 o-ring id 1.599/1.619 thck 8
979962-2538 hydraulic u-cup seal 8
980267-8 rubber-lined hose clamp 8
53000-2 plug,external pipe- countersunk hex 9
53000-4 plug,ext. pipe- countersunk hex 9
202294 Compression spring ps21 2
202203-41 Seal kit for l.h. actuator 1
51506-26 Pin, grooved taper 2
202388 Ram hinge pin 2
202266-100 Knuckle pin 2
202210 Key for synchronisation shaft 2
202209 Synchronisation shaft 1
202292-1 Slip spring 2
202292 Slip spring 2
50010-20-C8D 5/8-11 UNC-2A grade SAE-8 8

Recommended commissioning spares pn 202200-11

Part number Description Qty
202539 Testkit bx elevator + ps 1
947879-100 Lock wire stainless steel 1
56501-8-6-S Connector, ext pipe 37' 2
56501-6-6-S Connector, ext pipe 37' 2
55909-4-4 Valved nipple, qck disc./int pipe 1
56501-4-6-S Connector, ext pipe 37' 2

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Insurance spares 202200-13

Part number Description Qty
202203-41 seal kit for l.h. actuator 1
202203-55 l.h. hydr. act ps-30 1
202204-41 seal kit for rh actuator 1
202204-55 r.h. hydraulic actuator ps-30 1
202209 synchronisation shaft 1
202228-101 l.h. hydr.cylinder with tab washers 1
202228-102 r.h. hydr.cylinder with tab washers 1
30107236-1AN direct acting sequence valve 1
55908-4-4 valved coupler, qck disc. int pipe 1
55908-6-6 valved coupler, qck disc. int pipe 1
55908-8-8 valved coupler, qck disc./int pipe 1
55909-4-4 valved nipple, qck disc./int pipe 1
55909-6-6 valved nipple, qck disc./int pipe 1
55909-8-8 male quick disconnect#10/int pipe 1
979504-5 male connector with o-ring 1
979504-6 male connector with o-ring 1
979504-7 male connector with o-ring 1
980268 hose assembly for centering device 1
980269 hose assembly for centering device 1
980473-2 hoist swivel ring adb, modified 1
202210 key for synchronisation shaft 2
202292 slip spring 2
202292-1 slip spring 2
202294 compression spring ps21 2
50004591 indicator valve right-hand 2
50004730 relief valve 2
50004744 slip indicator pin w. grease holes 2
50004748 plug ext. 1-1/4--11-1/2npt 2
50004749 indicator valve support 2
50004752 indicator trigger pin 2
51300-117-B o-ring i.d. .793/.805 thck 2
56517-6-4-S reducer, int 37'/37' 2
56518-4-4-S elbow, 90' swivel int 37' /37' 2
56518-6-6-S elbow, 90' swivel int 37' /37' 2
56519-6-6-S elbow, o-ring boss /37' 2
59000016-1 seal kit for cylinder rod 1" 2
59000016-2 seal kit for cylinder piston 2-1/2" 2
59000016-3 seal kit for cylinder body 2-1/2" 2
7887 lynch pin 2
93547-1B30N sun pilot to open check valve 2
979386-5 compression spring 2
979386-55 compression spring ps30/bx-elev. 2
979439-1 scraper type m12.20 2
979504-3 male connector with o-ring 2

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Part number Description Qty

979532-6-4 nipple, straight, bsp to jic 2
979935-6-6 elbow 90deg bsp to jic 2
979966-1 relief valve 1/8"-27npt 2
107629-160 pilot operated check valve 3
56529-6-6-S connector, o-ring boss /37' 3
202410 cover plate hinge pin. 4
50004-4-C8D screw, cap-hex hd (unc-2a) 4
50904-C washer, lock-regular 4
56518-6-6-S elbow, 90' swivel int 37' /37' 4
979771-2225 trigger bushing manifold 4
51300-208-B o-ring id .604/.614 5
51302-223 ring, back up-o ring 8
949708-223 o-ring id 1.599/1.619 thck 8
979962-2538 hydraulic u-cup seal 8
980267-8 rubber-lined hose clamp 8

Risk assessment
‰ Risk assessment according NEN-EN 1050
‰ The risk assessment showed is according standard NEN EN 1050.
‰ Determination the limits of machinery according to NEN-EN 1050 chapter 5 and NEN-EN
292-1 clause 5.1.
‰ Identification and noting hazards and hazardous situations was carried out according
NEN-EN 414.
‰ Estimating the risks according prEN 1050.
‰ Identify and note all hazards and hazardous situations by use of NEN-EN 414 Annex A.

NOTE: Below risk assessment is for information only. It is

the user’s responsibility to carry out risk assessments
when using the tool in a system like on a rig.

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Identified potential hazard

Ref Identified potential hazard Probable Risk
consequence/injury
Squeezing hand, finger or foot by PS Fractures of hand, finger or
1 5
during installation foot
Sharp corners may cause cuts, for
2 Cut of body parts 5
example while lifting slips.
3 Breaking of lifting sling. Cut of body parts 5
Get stuck under the PS during lifting
4 Loss of feet 3
operations.
Pinching fingers between body and door,
5 Fractures of fingers and hand 5
while opening door
Feet placed above the hole when the PS
6 Cut of feet 5
is lowered into the rotary table
Fingers between cover plates while Cut of fingers
7 5
closing them
Get stuck between slips and body during
8 Loss of fingers, hand 5
installation / removing of the slips
Get stuck between pipe and slips and / or
9 Loss of fingers, hand, feet 5
between pipe and guide ram
Get stuck between centering device rams
10 Loss of fingers, hand, feet 5
or between rams and pipe
11 Get hit by the PS during lifting operationsFractures of body 5
12 Get hit by spring during maintenance Bruise 3
Injection of oil into or through
13 Burst of hydraulic hose 4
the body
Rotating the rotary tabel and the PS with Grabbed by the hoses,
14 1
hydraulic hoses connected fractures and bruises
Tripping over the PS when PS is not flush
15 Bruises 3
with rotary table
Tripping over the hydraulic hoses lying on
16 Bruises 3
the work floor
Disable to talk to each other because of Misunderstandings and
17 3
the noise on the rig floor failures
Installing/removing of the insert carriers Excessive effort
18 5
by manual force
19 Drilling jobs are monotonous Carelessness during the job 3
Top covers not closed when there is no Get stuck in the hole of the PS,
20 3
pipe in the hole abrasions, bruises
Not reading the manual may result in
21 hazardous situations when described Several injuries possible 3
procedures are not carried out properly

Severity, Frequency, Probability

Severity, Frequency, Probability of occurrence of an event that can cause harm.
S = Severity of the possible harm:
1. Slight (normally reversible) injury or damage to health.
2. Serious (normally irreversible) injury or damage to health.
3. Death.
F = Frequency of exposure:

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1. Seldom to quite often.

2. Frequent to continuous.
P = Probability of occurrence of an event that can cause harm:
1. Low (so unlikely, it can be assumed occurrence may not be experienced).
2. Medium (likely to occur sometime in life of an item).
3. High (likely to occur frequently).
A = Possibilities of avoidance:
1. Possible under specific conditions.
2. Scarcely possible.
The values used for factor S are pessimistic. Although fractures are normally reversible, it can
be assumed that the person in question will not be able to perform his normal duties during a few
weeks. Thus absenteeism is used to measure severity of the possible harm more than
reversibility.
A possible division in acceptability of safety-levels is:
1 - 4 risk low
5 - 7 risk medium high
8 -10 risk high
11-14 risk very high

Evaluate risks and document the decisions taken.

Ref 1.This is a normal risk for all hoisting operations. Risk can be avoided by steering the
hoisted PS-from a distance with lines. Personal protection such as gloves and safety shoes
which are standard procedure on a rig can minimise the nature of the injury. Information
regarding this hazardous event, consequences and procedures for rigging up the PS are written
and emphasised in the operations manual.
Ref 2.Information regarding this hazardous event, consequences and procedures for operating
the PS-are written and emphasised in the operations manual.
Ref 3.While pulling up the PS out of the RST with the 4 way lifting sling it is strongly advised to
unlock the rotary table lock. Not doing so will cause the 4 way lifting sling to break prior to the
breaking of the rotary table locks. The breaking cables might injure the drilling crew.
Ref 4.Information regarding this hazardous event, consequences and procedures for rigging up
the PS are written and emphasised in the operations manual.
Ref 5.Information regarding this hazardous event, consequences and procedures for removing
the PS-are from the rotary table are written and emphasised in the operations manual.
Ref 6.Information regarding this hazardous event, consequences and procedures for rigging up
the PS-are written and emphasised in the operations manual.
Ref 7.To prevent this hazardous event NOV has provided a special lifting hook. Information
regarding this hazardous event, consequences and procedures for operating the PS are written
and emphasised in the operations manual.
Ref 8.Information regarding this hazardous event, consequences and procedures for installing /
removing of the slips are written and emphasised in the operations manual.
Ref 9.Information regarding this hazardous event, consequences and procedures for operating
the PS are written and emphasised in the operations manual.

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Ref 10. Information regarding this hazardous event, consequences and procedures for
operating the PS are written and emphasised in the operations manual.
Ref 11.Information regarding this hazardous event, consequences and procedures for
maintenance and repair of the PS are written and emphasised in the operations manual.
Ref.12.Information regarding this hazardous event, consequences and procedures for
maintenance and repair of the PS are written and emphasised in the operations manual.
Ref 13.Two situations are distinguished:
a) Operate with damaged hoses
b) Hose gets damaged by wrong hoisting procedure
Ad. a.Hoses have a burst pressure of 5.5 x working pressure and are protected by a stainless
steel coating.
Ad. b. The possible damage of hoses by wrong hoisting procedures is as far as possible
reduced by using quick disconnects. Information regarding this hazardous event, consequences
and procedures for operating and inspection of the PS are written and emphasised in the
operations manual.
Ref 14.Information regarding this hazardous event, consequences and procedures for
operation, inspection, maintenance and trouble shooting of the PS-are written and emphasised
in the operations manual.
Ref.15.Information regarding this hazardous event, consequences and procedures for
maintenance and repair of the PS are written and emphasised in the operations manual.
Ref 16.Information regarding this hazardous event, consequences and procedures for assembly
and inspection of the PS are written and emphasized in the operations manual.
Ref 17.On the rig floor it is very noisy so that it is difficult to communicate by talk. This can lead
to miss-understanding. NOV recommends the driller to be the operator of the PS.
Ref 18.During installing/removing the insert carriers with manual force this can apply excessive
effort to the human body. Therefore NOV recommends to use the insert lifting hook as much as
possible during installing / removal of the insert carriers of the PS.
Ref 19.Drilling jobs are monotonous so that there exists the danger of carelessness during the
jobs. This is hard to avoid and therefore the PS should be operated by instructed people only.
Ref.20.Information regarding this hazardous event, consequences and procedures for
operating, maintenance and repair of the PS are written and emphasized in the operations
manual.
Ref 21.Not reading of the manual may result in hazardous situations because dictated
procedures are not carried out properly. Every PS will have to be supplied with instructions for
safe operation. These instructions are written in accordance with the requirements of the
Machinery Directive. Information regarding hazardous events, consequences and procedures
for rigging up, assembly, operating, maintenance, inspection, trouble shooting and repair of the
PS are written and emphasized in the user’s manual.

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Fault Tree Analyses (FTA)

NOV has carried out a FTA. The full analyses is available on request from NOV
General
The fault tree itself is an organised graphical representation of the conditions or other factors
causing or contributing to the occurrence of a defined undesirable event, referred to as the “top
event”. The representation is in a form which can be understood, analysed and, as necessary,
rearranged to facilitate the identification of:
Factors affecting the reliability and performance characteristics of the system, for example
component fault modes, operator mistakes, environmental conditions, software faults;
Conflicting requirements or specifications which may affect reliable performance;
Common events affecting more than one functional component, which could cancel the benefits
of specific redundancies.
Fault tree analysis is basically a deductive (top-down) method of analysis aimed at pinpointing
the causes or combination of causes that can lead to the defined top event. The analysis is
mainly qualitative but, depending on certain conditions, it may also be quantitative.
Construction procedure:
To implement a systematic approach two concepts have to be understood and used
consistently. These are the concepts of immediate cause and basic unit.
‰ Immediate cause are the immediate necessary and sufficient causes for the occurrence of
the top event.
‰ Basic units are treated as if they were single units or components or dealt with separately.
Evaluation of the fault tree:
‰ Identify faults which can directly cause a system failure
‰ Ability to function even after a number of lower level failures or events contributing to the
occurrence of a system failure have happened
‰ Verification of the independence of failure of systems, subsystems or components
‰ Locating critical components and failure mechanisms
‰ Identify device failure diagnostics, inputs to repair and maintenance strategies etc.
Storage, transport & scrapping.
The following sections detail proper disassembly of the tool to comply with various
environmental requirements.

Storage
When the PS is not being used for a longer period then 3 days the following steps should be
carried out:
1. Remove the slip assembly.
2. Clean PS slip assembly.
3. Grease PS and slip assembly as described in checklist lubrication.
4. Place PS in closed position.
5. Grease all blank parts.

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6. Use an extreme pressure, multi-purpose, lithium based grease of No. 1 or No. 2

consistency and multi grade motor oil.
7. Grease trigger finger-shaft.
8. Clean and cap hydraulic Quick Disconnect Couplings.
Transport
1. Lift the PS by the lifting eyes only.
2. The best way of transporting the PSPS is in its original crate. Use oiled paper and seal the
box with plastic from leaking when stored outside. Secure the top.
Scrapping
1. The tool contains hydraulic fluids, grease, aluminium, steel, rubbers, plastic and several
assembled components from undefined consistency or mixtures. The tool can be
contaminated with mud.
2. When the tool is taken out of service it is recommended to disassemble the tool in a place
where drainage for waste fluids is possible.

CAUTION: Hydraulic fluids, mud and grease are unsafe

when touched by the skin. Always wear gloves and safety
goggles when disassembling the tool.
3. Hydraulic fluids, mud and grease are unsafe when touched by the skin. Always wear
gloves and safety goggles when disassembly the tool.
4. Remove all quick-disconnects, hoses, cylinders and manifold block and bleed off hydraulic
oil.
5. Clean the tool with a steam cleaner.
6. Remove the doors, latch, trigger valve, levers and remove all bronze wear parts.
7. Carry of to proper place for final storage or destruction.

NOTE: When the tool is taken out of service it is

recommended to disassemble the tool in a place where
waste fluids can be contained and properly disposed.

Lubrication before storage

Apply grease to all grease points according to the chapter “Maintenance”, prior to storage of the
tool.

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Torque values (US)

Bolts Lubricated with Light Bolts lubricated with Anti-
Machine Oil seize compound
Grade 8 Grade 8
Dia. Threads Min. Max. Clamp Min. Max. Clamp
per inch Torque Torque force Torque Torque force
(ft lb) (ft lb) (lb) (ft lb) (ft lb) (lb)
Coarse Thread Series, UNC
1/4” 20 11.4 12.6 2860 8.6 9.5 2860
5/16” 18 24 26 3720 17.8 19.7 3720
3/8” 16 43 47 7000 32 35 7000
7/16” 14 67 74 9550 50 55 9550
1/2” 13 105 116 12750 78 87 12750
9/16” 12 143 158 16100 107 118 16100
5/8” 11 209 231 20350 157 173 20350
3/4” 10 361 399 30100 271 299 30100
7/8” 9 570 630 41600 428 473 41600
1” 8 855 945 54500 641 709 54400
1 1/8” 7 1216 1344 68700 912 1008 68700
1 1/4” 7 1729 1911 87200 1297 1433 87200
1 3/8” 6 2261 2499 104000 1696 1874 104000
1 1/2” 6 3002 3318 126500 2252 2489 126500

Tensile Strength = 150,000 psi to 1” dia. Proof Strength = 120,000 psi

Bolts Lubricated with Light Bolts lubricated with Anti-

Machine Oil seize compound
Grade 8 Grade 8
Dia. Threads Min. Max. Clamp Min. Max. Clamp
per inch Torque Torque force Torque Torque force
(ft lb) (ft lb) (lb) (ft lb) (ft lb) (lb)
Fine Thread Series, UNF
1/4” 28 13.3189 14.7 3280 10 11 3280
5/16” 24 24 26 5220 17.8 19.7 5220
3/8” 24 48 53 7900 36 39 7900
7/16” 20 76 84 10700 57 63 10700
1/2” 20 114 126 14400 86 95 14400
9/16” 18 162 179 18250 121 134 18250
5/8” 18 228 252 23000 171 189 23000
3/4” 16 399 441 33600 299 331 33600
7/8” 14 627 693 45800 470 520 45800
1” 14 950 1050 59700 713 788 59700
1 1/8” 12 1368 1512 77000 1026 1134 77000
1 1/4” 12 1900 2100 96600 1425 1565 96600
1 3/8” 12 2584 2856 118400 1938 2142 118400
1 1/2” 12 3382 3738 142200 2537 2804 142200

Tensile Strength = 150,000 psi to 1” dia. Proof Strength = 120,000 psi

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Torque values (metric)

Bolts Lubricated with Bolts lubricated with Anti-
Light Machine Oil seize compound
Grade 8 Grade 8
Diamete Threads Min. Max. Clamp Min. Max. Clamp
r per inch Torque Torque force Torque Torque force
(Nm) (Nm) (N) (Nm) (Nm) (N)

Coarse Thread Series, UNC

1/4” 20 15.5 17.14 12870 11.7 12.9 12870
5/16” 18 32.6 35.4 16740 24.2 26.8 16740
3/8” 16 58.5 64 32500 43.5 47.6 31500
7/16” 14 91.1 100.6 42980 68 92.5 42980
1/2” 13 143 158 57380 106 118 57380
9/16” 12 195 215 72450 145.5 160 72450
5/8” 11 284 314 91580 213.5 235 91580
3/4” 10 491 542 135450 368 407 135450
7/8” 9 775 857 187200 582 643 187200
1” 8 1163 1285 245250 872 965 245250
1 1/8” 7 1654 1828 309150 1240 1370 309150
1 1/4” 7 2351 2598 382400 1764 1949 392400
1 3/8” 6 3075 3398 468000 2306 2549 468000
1 1/2” 6 4082 4512 569250 3062 3385 569250

Bolts Lubricated with Bolts lubricated with Anti-

Light Machine Oil seize compound
Grade 8 Grade 8
Diamete Threads Min. Max. Clamp Min. Max. Clamp
r per inch Torque Torque force Torque Torque force
(Nm) (Nm) (N) (Nm) (Nm) (N)

Fine Thread Series, UNF

1/4” 28 18.1 20 14760 13.6 15 14760
5/16” 24 32.6 35 23490 24.2 26.8 23490
3/8” 24 65.3 72 35550 49 53 35550
7/16” 20 103 114 48150 77.5 86 48150
1/2” 20 155 171 64800 117 129 64800
9/16” 18 220 239 82130 165 182 82130
5/8” 18 310 343 103500 232 257 103500
3/4” 16 542 600 151200 406 450 151200
7/8” 14 853 943 206100 639 707 206100
1” 14 1292 1428 268650 970 1071 268650
1 1/8” 12 1860 2056 346500 1396 1542 346500
1 1/4” 12 2584 2856 434700 1938 2128 434700
1 3/8” 12 3514 3884 532800 2635 2913 532800
1 1/2” 12 4599 5083 639900 3450 3813 639900

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Drawings + Test procedures

Test procedures
Drawing Name
number

Inspection criteria for PS 21 standard, PS21/PS30

TSEL 0035
TC+CD

TSEL 0050 Test Spec for HUK PS21/30

TSEL 0054 PS 21/30 Slip assembly test

TSEL 0067 Field commissioning procedure for PS21/PS30

TSEL 0127 Test spec hydraulic actuators

Dimensional drawings
Drawing number Name

DD-202200-200 PS21 EMSCO

DD-202200-300 PS21 VARCO

DD-202200-400 PS21 OILWELL

DD-202200-500 PS21 IDECO

DD-202250-5 Dimensional drawing slip assembly 103/4 “ -2 3/8”

DD-202250-2 Dimensional drawing slip assembly 123/4” -14”

DD-202253-2 Dimensional drawing slip assembly 113/4”

Assembly drawings
Drawing number Name

50004754-1 PS21 with slip indicator valve

202250-5 PS21 slip ass'y 2-3/8 - 10 3/4 inch

202250(-) PS21 slip ass'y 12-3/4 - 14 inch

202253(-) PS21 slip ass'y 11 7/8 - 11 3/4 inch

202220-100 PS21 Left hand cover plate ass'y

202221-100 PS21 Right hand cover plate ass'y

202203-55 Actuator LH

202204-55 Actuator RH

50004722 Piston rack assembly L.H.

50004727 Piston rack assembly R.H.

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Drawing number Name

202228-099 RAM cylinder assembly PS21 RH

202228-100 RAM cylinder assembly PS21 LH

50004746 Manifold PS21

50004550-21 Lift tool hand-slip bowl #1 PS21

50004551 Lifting tool for PS slip assembly

50004552 Operating tool for PS slip handles

50004600(-) Lifting-Hook Insert-carriers

200982-1 Four way lifting sling S.W.L 6.0 Ton

202458-10 Closed hatch plate PS21

202348 Bit breaker plate PS21

50004446 General HUK-drawing

50004726 Hydraulic schematic

50004750 Indicator valve left

50004751 Indicator valve right

50004525 Ram insert wear piece set

202346 Assembly ram insert

202346-775 Assembly ram insert

202369 Insert carrier assembly

202271 DC insert carrier assembly

204702 Inline filter

Critical area drawings

Drawing Name
number

CA-266 Critical area’s PS21 body

CA-256 Critical area’s doors PS21

CA-259 Critical area’s PS21 cover plate

CA-261 Critical area’s PS21 center slips

CA-262 Critical area’s PS21 side slips

CA-265 Critical area’s PS 21 insert carriers

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 TEST SPECIFICATION
Configuration :PS-21 T
:PS-30: T
:PS-21 Topcover assembly T
:PS-30 Topcover assembly T

Serial Number :______________________________

Part Number :______________________________

Part Description :______________________________

Shop order :______________________________

Test Technician :______________________________

Name, date, and signature

3rd Party Witness: :______________________________

Agency-Name, Name
Signature and date :______________________________

Final Inspection:
Inspectors: Name, signature
And stamp :______________________________

Remarks :______________________________
______________________________
______________________________
Contents:
1. General
2. Assembly
3. Hydrostatic testing
4. Functional testing
5. Traceability
6. Final Inspection

D 601078 C.d.L 29 April ’03 P.D.

Name: Date C 555003 H.v.R. 4 Dec. 98 H.T.
Prepared P.G. Frank Feb 4th 98 B 555002 P.G. Frank Mar 4th 98 C.de Laat
Checked C. de Laat Feb 16th 98 A 555001 P. G. Frank Feb 16th 98 C. de Laat
Approved H. Kamp Feb 16th 98 Rev. ECN Name Date Checked
THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:
INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR
ANY PURPOSE NOR USED FOR TSEL 0035 PS-21, PS-30 or PS-top- 1 of 8
MANUFACTURING PURPOSES WITHOUT cover assembly
THE WRITTEN PERMISSION OF THE
OWNER.
1.GENERAL;
This specification defines the production testing and inspection of the PS21,
PS30, PS21- or PS30- top-cover assembly. Each unit is to be tested and
inspected according to the following procedure. Any discrepancy is cause for
discontinuing the test until the discrepancy has been eliminated. In the event
of a major discrepancy whose repair would affect items previously inspected
or tested, the affected items shall also be re-tested or re-inspected after the
discrepancy has been eliminated.

Check all sharp corners are properly de-burred. T O.K.

Picture 1

Check if slip-path has been rounded, see picture 1 T O.K.

Check whether bore-cones are correctly buffed. No visible horizontal T O.K.
(turning or grinding) grooves may be visible after buffing.

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR
ANY PURPOSE NOR USED FOR TSEL 0035 PS-21 standard & PS-30 2 of 8
MANUFACTURING PURPOSES WITHOUT TC+CD
THE WRITTEN PERMISSION OF THE (Rev. D)
OWNER.
 2. ASSEMBLY

Check if all parts are present and assembled in accordance with the T O.K.
drawings
Check whether all bolts are on torque and lock-wired in accordance with the T O.K.
drawings.
Check removable door hinge pin can be replaced by hand and door can be T O.K.
opened 90° by hand.
Check position of top covers when opened (see assembly drawing). T O.K.

Check a proper functioning of the top cover lock (be aware: door must be T O.K.
lifted ! ).
Check the rotary table locks are functioning properly. T O.K.

Apply grease to all grease fittings until CLEAN grease (free of burrs, oil etc.) T O.K.
comes out on the appropriate surfaces.
Check whether grease is applied and devided properly to inner ribs of body T O.K.
and outer ribs of slips.
Check that Varco bit breaker plate is available and fits on top cover. T O.K.

3.HYDROSTATIC TESTING
Connect the PS21/PS30 with a hydraulic hook up kit (Preferably the T O.K.
dedicated hook up kit from the same sales).
Check the QD-sizes are present and assembled in accordance with the
Manifold drawing:
• Check QD-brand (Aeroquip) FD45.
• Check whether the QD’s are on the right port (up = up, down =
down).

Manifold PS-21/30: Adjust powerunit at 1500 psi./ 104 bar Increase power T O.K.
unit pressure and check at what pressure the sequence starts ( must start
at 1900 psi / 131 bar differential pressure between slips-down and slips-up
hoses). When setting is not correct, adjust the sequence valve on the PS-
manifold block:

• List actual pressure slips down hose:_________psi. ______bar

• List actual pressure slips up hose: _________psi. ______bar
Checks with a pressure gauge on the signal port of the PS-manifold block; T O.K.

-Check for the presence of a slip-set-signal when the slips are down set on
pipe and slip-set-indicator valves are triggered see picture 2.

-Check for the absence of a slip-set-signal when the slips are down and
tilted; thus slip-set-indicator valves are Not triggered. This can be obtained T O.K.
THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:
INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR
ANY PURPOSE NOR USED FOR TSEL 0035 PS-21 standard & PS-30 3 of 8
MANUFACTURING PURPOSES WITHOUT TC+CD
THE WRITTEN PERMISSION OF THE (Rev. D)
OWNER.
 by a wooden beam in between the side slips, see picture 3.

Picture 2 Picture 3

-Check for the presence of a slip-Up-signal when the slips are Up. T O.K.

-Check the operating sequence: Adjust the pressure of the Power Unit to
2500 psi/ 173 bar at 5 G.P.M./ 20 litres/Min.
T O.K.
Slips Set cycle; Rams close first, then the slips set
Slips Set cycle time:_____Seconds (max. 6 sec.)

-Check the operating sequence: T O.K.

Slips Up cycle; Slips raise first, then Rams open
Slips Up cycle time:_____Seconds (max. 6 sec.)
Make 5 slip-set- and 5 slip-up cycles. T O.K.
Open and close the top covers 5 times while under pressure (with 2500 T O.K.
psi./ 173 bar). No leakage shall occur.
Pressure proof test at 1.5 times the working pressure; T O.K.
Check whether no leakage occurs at 3750 psi / 258 bar when pressurized
for 5 minutes minimum.

Check if slips stay up for at least 8 hours without hydraulic pressure supply;
Raise the slips then disconnect the PS from the power-unit and connect a T O.K.
drainhose to the slips up port. Load up the slips with extra weight.

Oil cleanness test; Use the tapped oil for an oil cleanness test and verify it
copes with NAS class 8. T O.K.

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR
ANY PURPOSE NOR USED FOR TSEL 0035 PS-21 standard & PS-30 4 of 8
MANUFACTURING PURPOSES WITHOUT TC+CD
THE WRITTEN PERMISSION OF THE (Rev. D)
OWNER.
 4.FUNCTIONAL TESTING
Grease body- and slip-cones with Autol Top-2000 grease
Prepare the 1400 Mton press in Hall 6 with a mandrill matching
the diameter for which the slips/insert carriers are dressed. Then
place the body in the load test fixture and the whole set onto the
press table and connect to the hydraulic power supply. The
pressure of the power unit has to be set between 2000 and 2500
psi/138 and 173 bar.
Report: Mandrill diameter :__________ inch.

Install a set of Qualified slips (this is not necessarily the slip-ass’y which T O.K.
will be shipped together with this PS) into the PS21/PS30 and check for
flawless movement of the slips.
Check the slips are free from the rotary cylinders in the up position. T O.K.

Check the throat-opening “B” of the slips without insert-carriers when the T O.K.
slips are in the up position, ( is the biggest circular opening of the slip
without insert-carriers or with inserts)
Check the pipe-opening “A” at door-side, of the slips without insert-carriers
when the slips are up, see picture 4:
Slip-assembly: Throat-opening. “B” measured: Pipe-opening “A” “A” measured:
”B” minimum: minimum:
202433-1 ∅ 17.5 inch ∅ 13.5 inch
202250-1 ∅ 17.5 inch ∅ 14.25 inch
202250-2 ∅ 17.5 inch ∅ 14.25 inch
202253-2 ∅ 15.5 inch ∅ 12.75 inch
202430-1 ∅ 23.5 inch ∅ 16.50 inch
202430-2 ∅ 24 inch ∅ 20.25 inch
202430-3 ∅ 23 inch ∅ 18.38 inch
NL:
Picture 4

Note the
“NL number” of tested
slip here,

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR
ANY PURPOSE NOR USED FOR TSEL 0035 PS-21 standard & PS-30 5 of 8
MANUFACTURING PURPOSES WITHOUT TC+CD
THE WRITTEN PERMISSION OF THE (Rev. D)
OWNER.
Cycling-in Test.

Run the slips through the following load cycles. Hydraulically raise and set the
slips between every cycle. Hydraulic power down pressure has to be applied to
the cylinders at all times during load cycle. The slip assembly must pass all
cycles without sticking. In case of sticking, remove slips from body, clean body
and slip tapers, re-buff tapers, re-grease tapers and repeat test until slip
assembly passes all cycles successfully. If a slip assembly fails this test more
than 1 times, stop testing and inform NPD.

Cycle nr: Applied Load Load hold time Report completion:

Sh-Tons:/Mton: in seconds: Run1 Run2
1 275 / 250 30 T OK T OK
2 275 / 250 30 T OK T OK
3 275 / 250 30 T OK T OK
4 275 / 250 30 T OK T OK
5 330 / 300 30 T OK T OK
6 330 / 300 30 T OK T OK
7 330 / 300 30 T OK T OK
8 330 / 300 30 T OK T OK
9 385 / 350 30 T OK T OK
10 385 / 350 30 T OK T OK
11 385 / 350 30 T OK T OK
12 385 / 350 30 T OK T OK
13 385 / 350 30 T OK T OK
14 385 / 350 30 T OK T OK
15 385 / 350 30 T OK T OK

After completion of the cycles, the slips have to be removed from the body. In
case damages on the body or slip tapers are observed, rebuff the damaged
areas (and the damaged areas only).

Report: Final inspection body tapers. If applicable,

all cycling-in markings removed by buffing: T OK

Final inspection slip tapers. If applicable,

all cycling-in markings removed by buffing: T OK

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR
ANY PURPOSE NOR USED FOR TSEL 0035 PS-21 standard & PS-30 6 of 8
MANUFACTURING PURPOSES WITHOUT TC+CD
THE WRITTEN PERMISSION OF THE (Rev. D)
OWNER.
5.TRACEABILITY
REFERENCE SERIAL NUMBER:..................................................

PARTNUMBER FOUNDRY HEATNUMBER HEATCODE

BODY
DOOR
REM.HINGE PIN
HINGE PIN
MANIFOLD
LIFTING SLINGS
HOIST SWIVEL
RINGS

Hook Up Kit. n/a n/a

Manifold H.U.K. n/a n/a
LEFT HAND ACT.
RIGHT HAND ACT
CERT. CROSBY
HOOK

Prior to paintjob:
Check if body cones are covered by Autol Top-2000 grease prior to T O.K.
painting and shipment.
Check if all hoses and cylinder rods are protected against paint. T O.K.
Check if manufacture instructions at hoist swivel rings are protected T O.K.
against paint.
Check if all moveable parts are protected against sticking by paint. T O.K.
Check if the warning labels have been placed. T O.K.
Check presence and correctness of Serialnumber. T O.K.
Check presence and correctness of Partnumber. T O.K.
Check presence and correctness of CE marking T O.K.
Check presence and correctness of API marking T O.K.
Check presence and correctness of DNV marking if applicable T O.K.

INLINE INSPECTOR STAMP IN PS21/30. T O.K.

FINAL ACCEPTANCE INLINE INSPECTOR:

Signature and stamp.

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR
ANY PURPOSE NOR USED FOR TSEL 0035 PS-21 standard & PS-30 7 of 8
MANUFACTURING PURPOSES WITHOUT TC+CD
THE WRITTEN PERMISSION OF THE (Rev. D)
OWNER.
6.FINAL INSPECTION (after last paintjob)
Check whether all movable parts are not locked in place by paint, but T O.K.
greased with Autol Top-2000 grease.

• All grease fittings

• Internal bowl cones of body
• Hinge pins doors
• Door
• Topcover lock
• Topcover hinge pins
• Rams
• Centering cylinder
Check preservation according QAP 7.2 T O.K.
Check paintjob according QAW 7.2.1. T O.K.

FINAL ACCEPTANCE INLINE INSPECTOR / PAINTER:

Signature and stamp.

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR
ANY PURPOSE NOR USED FOR TSEL 0035 PS-21 standard & PS-30 8 of 8
MANUFACTURING PURPOSES WITHOUT TC+CD
THE WRITTEN PERMISSION OF THE (Rev. D)
OWNER.
 TEST SPECIFICATION
H.U.K. PS-21/30
Shop Order :______________________________

Part Number H.U.K. :______________________________

Part Description :______________________________

E-Serial Number control plate :______________________________

Test Technician Name :______________________________

3rd Party Witness Agency :______________________________

3rd Party Witness Name :______________________________

3rd Party Witness Signature :______________________________

Test Date :______________________________

Remarks :______________________________
______________________________
______________________________

ID SERIAL CODE HUK:

Name: Date G 601209 L. Sonneveld 22 aug. 03 R. Mulder

Prepared L.Sonneveld 30 june ‘98 B 546902 L. Sonneveld 01 june ‘99 H. Bakkers
Checked H. Bakkers 30 june ‘98 A 549601 L. Sonneveld 30 june ‘98 H. Bakkers
Approve H. Tiebout 30 june ‘98 Rev. ECN Name Date Checked
d
THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:
INFORMATION AND SUCH INFORMATION
MAY NOT BE DISCLOSED TO OTHERS FOR TEST SPEC.
ANY PURPOSE NOR USED FOR TSEL 0050 H.U.K. PS-21/30 1 of 5
MANUFACTURING PURPOSES WITHOUT
THE WRITTEN PERMISSION OF THE
OWNER.
This specification defines the production testing and inspection of the PS-21/30
H.U.K. The H.U.K. consist of a control plate, pressure filter, hoses and control box
for in drillers cabin. Each H.U.K. must be tested in combination with the PS-21/30.
Any discrepancy is cause for discontinuing the test until the discrepancy has been
eliminated. In the event of a major discrepancy whose repair would affect items
previously inspected or tested, the affected items shall also be re-tested or re-
inspected after the discrepancy has been eliminated.

1.0 INSTALLATION

Before you hookup the H.U.K. to a PS-21/30 first check to following items.

1) Are the pressure switches, solenoid valve and J-box electrical connected
according drawing 50004446. (additional DWG’s 203062, 50004453-4)
2) Are the tubing properly and tight enough connected.
3) Before you put on the Power-unit check if everything is properly connected.
4) Adjust the Pressure on the Power unit at 2500 PSI, and the flow at 10 GPM
(40 L/min.)
5) For connecting the “Control Console” see drawing 50004446.
Before you operate the Solenoid valve be aware that you ADJUST THE
CORRECT VOLTAGE ON THE “CONTROL CONSOLE”.

2.0 PRESSURE SETTING PC1 (SYSTEM PRESSURE)

The Pressure Reducing Valve PC1 (PBFB-LAN) is standard adjusted at 2500

PSI. Manifold 50004442.
This is MAXIMUM operating system pressure to control PS-21/30.
To adjust set HPU above 2500 PSI.
_________ OK

2.1 PRESSURE SETTING REDUCING VALVE (FLUSHING)

The Pressure Reducing Valve PC2 (PBFB-LAN) is standard adjusted at 1500

PSI. Manifold 50004442.
This is the pressure during flushing.
_________ OK

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION
MAY NOT BE DISCLOSED TO OTHERS FOR TEST SPEC.
ANY PURPOSE NOR USED FOR TSEL 0050 H.U.K. PS-21/30 2 of 5
MANUFACTURING PURPOSES WITHOUT
THE WRITTEN PERMISSION OF THE (REV.G)
OWNER.
2.2 PRESSURE SETTING RELIEF VALVE (GREASE PUMP)

Manifold 50004511-1.
The Pressure Relief Valve PR1 (RPEC-LCN) must be adjusted to approx.
1700 PSI. This is SAFETY for operating system pressure to control grease
pump.
To adjust the PR1, pressure reducing valve PC2 (PBDB-LBN) has to be set at
1700PSI. Turn PR1 fully in, than turn PR1 out, until you hear the oil release to
tank.
.
_________ OK

2.3 PRESSURE SETTING REDUCING VALVE (GREASE PUMP)

Manifold 50004511-1.
The Pressure Reducing Valve PC2 (PBDB-LAN) must be adjusted at
1500 PSI.
This is the MAXIMUM pressure to control the grease pump.
_________ OK

3.0 PRESSURE SETTING OF LOW ALARM PRESSURE SWITCH PS1

Pressure Switch PS1 (E12) is normally closed and set at 2000 PSI.
Start with a low pressure on the Power unit and raise the pressure slowly up
to 2000 PSI, than adjust the Pressure Switch PS1. The Pressure Switch PS1
has to give a signal when the System Pressure is below 2000 PSI.
_________ OK

3.1 PRESSURE SETTING OF SLIPS UP PRESSURE SWITCH PS2

Pressure Switch PS2 (E13) is normally open and set at 1600 PSI.
Verify 1600 PSI pressure setting of pressure switch PS2. Slips have to be
command to UP and pressure has to be provided to port S1.
If you don’t have a signal check first that you have a signal on the S1 port of
the PS-21/30 manifold. If yes than check the pressure off B1 (slips UP).
Still no signal check valve DV3 works properly.
_________ OK

3.2 PRESSURE SETTING OF SLIPS SET PRESSURE SWITCH PS3

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:
INFORMATION AND SUCH INFORMATION
MAY NOT BE DISCLOSED TO OTHERS FOR TEST SPEC.
ANY PURPOSE NOR USED FOR TSEL 0050 H.U.K. PS-21/30 3 of 5
MANUFACTURING PURPOSES WITHOUT
THE WRITTEN PERMISSION OF THE (REV.G)
OWNER.
 Pressure Switch PS3 (E11) is normally open and set at 1800 PSI.
Verify 1800 PSI pressure setting of pressure switch PS3. Slips have to be
command to SET and pressure has to be provided to port S1.
If you don’t have a signal check first that you have a signal on the S1 port of
the PS-21/30 manifold. If yes than check the pressure off A1 (slips SET).
Still no signal check valve DV3 works properly.
_________ OK

3.3 PRESSURE SETTING OF GREASE EMPTY INDICATION

PRESSURE SWITCH PS4

Pressure Switch PS4 (E17) grease empty indication is normally open and set
to accommodate grease empty indication: 1000-1200 PSI.
_________ OK

4.0 FUNCTIONAL TEST

Operate PS for 25 times minimum.

When the Control valve is a Solenoid valve than control the valve by using
“control-console”.

_________ OK

Verify that pressure gauge PG2 gives a reading only when slips are
UP and not when slips are SET.
Pressure read out is the same as system pressure (2500 PSI).

__________OK

Verify that pressure gauge PG3 gives a reading only when slips are
SET and not when slips are UP.
Pressure read out is the same as system pressure (2500 PSI).

__________OK

Verify that auto greaser starts pumping after 25 cycles slips up.

15 seconds to center slips __________OK

25 seconds to side (L/R) slips __________OK

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:
INFORMATION AND SUCH INFORMATION
MAY NOT BE DISCLOSED TO OTHERS FOR TEST SPEC.
ANY PURPOSE NOR USED FOR TSEL 0050 H.U.K. PS-21/30 4 of 5
MANUFACTURING PURPOSES WITHOUT
THE WRITTEN PERMISSION OF THE (REV.G)
OWNER.
 Verify operation of manual override to start pump cycle.
Indication light should not flash while pumping.

__________OK

Verify grease empty indication.

Indication light on when pressure in grease lines is to low, depending on
pressure switch setting.

__________OK

Verify operation flushing valve.

By reversing the flow to PS, signal and operating lines will be cleaned out.
(NO visual check possible)

__________OK

4.1 CYCLE TIME

The cycle time for Slips up and Slips set should NOT exceed 5 seconds.

Slips Up : __sec. __________OK

Slips Set : __sec. __________OK

5 CONTROL BOX DRILLERS CABIN

IF APPLICABLE: Verify functions and indications on control box.

Operational switches and/or indication lights according applicable DWG’s.

Part number:.__________
__________OK

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION
MAY NOT BE DISCLOSED TO OTHERS FOR TEST SPEC.
ANY PURPOSE NOR USED FOR TSEL 0050 H.U.K. PS-21/30 5 of 5
MANUFACTURING PURPOSES WITHOUT
THE WRITTEN PERMISSION OF THE (REV.G)
OWNER.
Configuration :SLIP ASSEMBLY
: 202250-5: 11 1/8”- 2 3/8” ‰
: 202250-2: 14” - 12 ¾” ‰
: 202253-2: 11 7/8” - 11 ¾” ‰
: 202430-5: 16”- 4 1/2” ‰
: 202430-2: 20” – 18 5/8” ‰
: 202430-3: 18” - ‰
: 202433-5: 11 1/8”- 2 3/8” ‰

Serial Number :_NL:__________________________

Part Number :_202__________________________

Part Description :______________________________

Shoporder no.: :______________________________

Test Technician “DOMINIAL”(Outside vendor);

Needs to fill out sheets 1 up to and incl. sht4.
Name, date, and Signature
:______________________________
Test Technician “VARCO”;
Name, date, and Signature
Needs to compleet all sheets,
:______________________________

Remarks :______________________________
______________________________
______________________________

TEST SPECIFICATION

E 601078 CdL 7 April ‘03 PD

D 600959 CdL 16 Dec.’02 P.D.
Name: Date C 600188 CdL 5 Dec..’01 A.K.
Prepared P. FrankJuly 8th B 568601 HvR 4 dec 98 H T
1998
Checked HvRijzingen Aug 3rd F 601099 N.d.K. 09-Apr-‘04 C.d.L.
1998
Approved H..Kamp Aug 3rd Rev. ECN Name Date Checked
1998
THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:
INFORMATION AND SUCH INFORMATION MAY NOT Inspection criteria for
BE DISCLOSED TO OTHERS FOR ANY PURPOSE
NOR USED FOR MANUFACTURING PURPOSES TSEL 0054 PS-21/PS-30 slip 1 of 16
WITHOUT THE WRITTEN PERMISSION OF THE assembly
OWNER.
1 Hardness check (DOMINIAL). Left-hand-slip:

X1 Hrc. X9 Hrc.
X2 Hrc. X10 Hrc.
X3 Hrc. X11 Hrc.
X4 Hrc. X12 Hrc.
X5 Hrc. X13 Hrc.
X6 Hrc. X14 Hrc.
X7 Hrc. X15 Hrc.
X8 Hrc. X16 Hrc.

Note:
Hardness measure of left-hand-slip:
For PS21 slips (PN;202250% and 202253%) measurement points ;X13,X14,X15,and X16
are not applicable.
Hardness must be from 50 Hrc up to 60 Hrc.

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR 2 of 16
ANY PURPOSE NOR USED FOR TSEL 0054 PS-21/PS-30 Slip (Rev. E)
MANUFACTURING PURPOSES WITHOUT Assembly
THE WRITTEN PERMISSION OF THE
OWNER.
Center-slip:
Center-slip

X1 Hrc. X9 Hrc.
X2 Hrc. X10 Hrc.
X3 Hrc. X11 Hrc.
X4 Hrc. X12 Hrc.
X5 Hrc. X13 Hrc.
X6 Hrc. X14 Hrc.
X7 Hrc. X15 Hrc.
X8 Hrc. X16 Hrc.

Note:
Hardness measure of center-slip:
For PS21 slips (PN;202250% and 202253%) measurement points ;X13,X14,X15,and X16
are not applicable.
Hardness must be from 50 Hrc up to 60 Hrc.

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR 3 of 16
ANY PURPOSE NOR USED FOR TSEL 0054 PS-21/PS-30 Slip (Rev. E)
MANUFACTURING PURPOSES WITHOUT Assembly
THE WRITTEN PERMISSION OF THE
OWNER.
Right-hand-slip:

X1 Hrc. X9 Hrc.
X2 Hrc. X10 Hrc.
X3 Hrc. X11 Hrc.
X4 Hrc. X12 Hrc.
X5 Hrc. X13 Hrc.
X6 Hrc. X14 Hrc.
X7 Hrc. X15 Hrc.
X8 Hrc. X16 Hrc.

Note:
Hardness measure of right-hand-slip:
For PS21 slips (PN;202250% and 202253%) measurement points ;X13,X14,X15,and X16
are not applicable.
Hardness must be from 50 Hrc up to 60 Hrc.
THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:
INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR 4 of 16
ANY PURPOSE NOR USED FOR TSEL 0054 PS-21/PS-30 Slip (Rev. E)
MANUFACTURING PURPOSES WITHOUT Assembly
THE WRITTEN PERMISSION OF THE
OWNER.
2 GENERAL.

Check for presence of part numbers, Heat codes and Serial numbers.
PARTNUMBER FOUNDRY HEATNUMBER HEATCODE T O.K.
Center slip
L.H. slip
R.H. slip
L.H. Hinge N.A.
pin
R.H. Hinge N.A.
pin
Serial-number of slip assembly: T O.K.
Part-number of slip assembly: T O.K.

Check all sharp corners are properly de-burred. T O.K.

Check whether slip-cones are correctly buffed. No visible horizontal (turning or T O.K.
grinding) grooves may be visible after buffing.

Check whether the mud drain hole (center-slip) is present and open see picture T O.K.
2.
Check whether the center-slip is machined with two rounds at the lowest rib see T O.K.
picture 1.
Check proper welding of center-slip torque-plates (sharp grind, removal of all T O.K.
material outside slip-cone contour). Check by using welding caliber, see picture
2. Grind flush or maximum 0.05” below slip cone.

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR 5 of 16
ANY PURPOSE NOR USED FOR TSEL 0054 PS-21/PS-30 Slip (Rev. E)
MANUFACTURING PURPOSES WITHOUT Assembly
THE WRITTEN PERMISSION OF THE
OWNER.
3 ASSEMBLY
Check if all parts are assembled in accordance with the drawing T O.K.
Check the correct assembly of slip hinge pins (UP/Part-Number visible on top). T O.K.
Check whether all bolts are lock-wired. T O.K.
Check the presence of all grease fittings, see picture 4. T O.K.

Check whether the springs around the hinge pins have a square cross section and T O.K.
not a cylindrical cross section and the spring legs fall back in the pockets below the
machined surface see picture 3. When slips are fully closed spring-legs should be
supported with a minimum of 0.25” in the pocket.
Check if all movable parts/hinges can move. T O.K.
THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:
INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR 6 of 16
ANY PURPOSE NOR USED FOR TSEL 0054 PS-21/PS-30 Slip (Rev. E)
MANUFACTURING PURPOSES WITHOUT Assembly
THE WRITTEN PERMISSION OF THE
OWNER.
4 LUBRICATION
Check Autol Top-2000 grease being applied to all grease fittings until grease comes T O.K.
out on all appropriate surfaces in equal amounts, see picture 4.

Check slip-cones are not painted but covered with Autol Top-2000 grease only, see T O.K.
picture 5.

5 FUNCTIONAL

Check a proper functioning of the pins that connect the slips to the actuator levers. T O.K.

Assemble the slip ass’y into a Qualified PS-21/30 (this is not necessarily the T O.K.
PS21/PS30 which will be shipped together with these slips) and check for a flawless
movement of the slips.
Check the throat-opening “B” of the slips without insert-carriers when the slips are in
the up position ( is the biggest circular opening of the slip without insert-carriers or
with inserts)
Check the pipe-opening “A” at door-side, of the slips without insert-carriers when
the slips are up, see picture 7:
Slip-assembly: Throat-opening. “B” measured: Pipe-opening “A” “A” measured:
”B” minimum: minimum:
202433-5 ∅ 17.5 inch ∅ 13.5 inch
202250-5 ∅ 17.5 inch ∅ 14.25 inch
202250-2 ∅ 17.5 inch ∅ 14.25 inch
202253-2 ∅ 15.5 inch ∅ 12.75 inch
202430-5 ∅ 23.5 inch ∅ 16.50 inch
202430-2 ∅ 24 inch ∅ 20.25 inch
202430-3 ∅ 23 inch ∅ 18.38 inch

Picture 7

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR 7 of 16
ANY PURPOSE NOR USED FOR TSEL 0054 PS-21/PS-30 Slip (Rev. E)
MANUFACTURING PURPOSES WITHOUT Assembly
THE WRITTEN PERMISSION OF THE
OWNER.
Check proper engagement of insert carrier latch: T O.K.
• No insert carrier fitted: The latch needs to tilt slightly forward (towards
center bore).
• With insert carrier fitted: The latch needs to move easily back and
forward as well as to slide over the insert carrier to a horizontal
position.

Check the insert carriers can be easily assembled and disassembled using the T O.K.
special insert-carrier lifting-hook (P.N.:50004600-1).

The intend of a paper test is to find anomalies in the machining, therefor one
needs to review the paper prints with this in mind.
Combinations of the given examples is also possible and are unacceptable
95 % contact is required.
For example one insert on a certain location could be of minimal height which
causes it to give bad paper-print

Conduct a paper test on a test mandrill / pipe applying test-loads from below
table.

Slip assembly With Insert- Test-load in Test-load in

carrier Short-tons M-ton
202250-5 202273-663 120 109
202250-5 202270-1075 175 159
202250-2 none 206 187
202253-2 none 175 159
202433-5 202273-663 120 109
202433-5 202270-1075 175 159
202430-5 202445-663 120 109
202430-5 202443-1075 236 214
202430-2 none 330 300
202430-3 none 316 287

Review results, using below described criteria

See pages 13,14 and 15 for Insert-contact-height of slips / insert-carriers.

Paper test acceptance criteria

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:
INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR 8 of 16
ANY PURPOSE NOR USED FOR TSEL 0054 PS-21/PS-30 Slip (Rev. E)
MANUFACTURING PURPOSES WITHOUT Assembly
THE WRITTEN PERMISSION OF THE
OWNER.
 L.H.-slip C.-slip R.H.-slip Top

1. 100% contact acceptable Bottom

L.H.-slip C.-slip R.H.-slip Top

2. Run out of bottom dovetails (all segments) or worn bowl/bushing

Not acceptable ( 80%< contact< 85%)

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR 9 of 16
ANY PURPOSE NOR USED FOR TSEL 0054 PS-21/PS-30 Slip (Rev. E)
MANUFACTURING PURPOSES WITHOUT Assembly
THE WRITTEN PERMISSION OF THE
OWNER.
L.H.-slip C.-slip R.H.-slip
Top

Bottom

3. Miss-machined middle column (too deep). Not acceptable

(≈90% contact)

L.H.-slip C.-slip R.H.-slip

Top

Bottom
4. Miss-machined side column. Not acceptable. (≈90% contact)

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR 10 of 16
ANY PURPOSE NOR USED FOR TSEL 0054 PS-21/PS-30 Slip (Rev. E)
MANUFACTURING PURPOSES WITHOUT Assembly
THE WRITTEN PERMISSION OF THE
OWNER.
 L.H.-slip C.-slip R.H.-slip Top

Bottom
5. Miss-machined middle column (not deep enough) Not acceptable
(≈80% contact)

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR 11 of 16
ANY PURPOSE NOR USED FOR TSEL 0054 PS-21/PS-30 Slip (Rev. E)
MANUFACTURING PURPOSES WITHOUT Assembly
THE WRITTEN PERMISSION OF THE
OWNER.
 L.H-slip C.-slip R.H.-slip Top

Bottom
6. About 80% contact most likely due to inserts worn / damaged or not made within the
tolerances.
This is Not acceptable

If results are not satisfactory please redo the test with maximum 50 short-tons extra load
Review results, using above described criteria
If still not satisfactory do a blue die test and contact a NPD (New Product Development
department) member

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR 12 of 16
ANY PURPOSE NOR USED FOR TSEL 0054 PS-21/PS-30 Slip (Rev. E)
MANUFACTURING PURPOSES WITHOUT Assembly
THE WRITTEN PERMISSION OF THE
OWNER.
 Insert contact height
for slip assembly;
202250-1400
202250-1363
202250-1338
202250-1275
202253-1188
202253-1175
=15.5”
Please note that the basic inserts will not give a print!

Insert contact
height for
slip assembly;
202430-2000
202430-1863
=21”

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR 13 of 16
ANY PURPOSE NOR USED FOR TSEL 0054 PS-21/PS-30 Slip (Rev. E)
MANUFACTURING PURPOSES WITHOUT Assembly
THE WRITTEN PERMISSION OF THE
OWNER.
 Insert-contact height
For insert-carriers; Insert-contact height
202270% For insert-carriers;
202279% 202369%
=15.50” 202273%
202274%
202277%
202278%
=13.75”

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR 14 of 16
ANY PURPOSE NOR USED FOR TSEL 0054 PS-21/PS-30 Slip (Rev. E)
MANUFACTURING PURPOSES WITHOUT Assembly
THE WRITTEN PERMISSION OF THE
OWNER.
 Insert-contact height
For insert-carriers;
202271%
202272%
202275%
202276%
=10.00”

Insert-contact height for insert-carriers;

202440%, 202441%, 202442%, 202443% Insert-contact height for insert-carriers;
=21” 202445%, 202446%, 50004569%
=20.65” with gap of 1.375”
THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:
INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR 15 of 16
ANY PURPOSE NOR USED FOR TSEL 0054 PS-21/PS-30 Slip (Rev. E)
MANUFACTURING PURPOSES WITHOUT Assembly
THE WRITTEN PERMISSION OF THE
OWNER.
6 FINAL INSPECTION.
Check whether all movable parts/hinges are greased with Autol Top-2000 T O.K.
grease;
• Slip-hinge-pins
• Slip mounting pins
• Latches
Check slip-cones are greased. T O.K.

Check presence and correctness of DNV marking if applicable T O.K.

Check for Inline inspector Stamp in the slip T O.K.

FINAL ACCEPTANCE INLINE INSPECTOR:

Signature and stamp.

7 FINAL INSPECTION (after last paintjob)

1. Check preservation according QAP 7.2 T O.K.

2. Check paintjob according QAW 7.2.1. T O.K.

FINAL ACCEPTANCE INLINE INSPECTOR / PAINTER:

Signature and stamp.

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR 16 of 16
ANY PURPOSE NOR USED FOR TSEL 0054 PS-21/PS-30 Slip (Rev. E)
MANUFACTURING PURPOSES WITHOUT Assembly
THE WRITTEN PERMISSION OF THE
OWNER.
 Rig name :_____________________________________

Part Description :_____________________________________

Part Number :_____________________________________

Serial Number :_____________________________________

Customer ref. Number :_____________________________________

Varco BJ sales order Number :_____________________________________

Varco BJ rep. Name/ Job title :_____________________________________

:_____________________________________

Varco BJ Witness Signature :_____________________________________

Reviewed manual revision/ Date :_____________________________________

Commissioning date :_____________________________________

Remarks :_____________________________________

_____________________________________

TEST SPECIFICATION
( Field Commissioning and
instruction procedure )

Name: Date C 700113 C. de Laat. 4 July 2005 A. Krijnen

Prepared C. de Laat. July30th 99 B 577402 H.v.Rijzingen 8 Aug. 1999 L.Sp.
Checked H. van Rijzingen July30th 99 A 577401 C. de Laat. July 30th 99 H. van Rijzingen
Approved A. Krijnen July30th 99 Rev. ECN Name Date Checked
THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:
INFORMATION AND SUCH INFORMATION MAY
NOT BE DISCLOSED TO OTHERS FOR ANY
Field Commissioning
PURPOSE NOR USED FOR MANUFACTURING TSEL 0067 procedure for 1 of 11
PURPOSES WITHOUT THE WRITTEN
PERMISSION OF THE OWNER.
PS 21 & PS 30
 ¾ During commissioning, as much as possible of the following rig personnel need to
be present for witnessing. Please check and have them signed for their presence
during the complete commissioning procedure.

Rig company man : .

Superintendent : .

Rig manager : .

Rig mechanic : .

Driller(s) : .

After completion of the commissioning procedure, the following people have to

sign for approval:

Rig company man : .

Superintendent : .

Rig manager : .

After final approval, hand over copies of the completed

TSEL to all attendees.

THIS DOCUMENT CONTAINS PROPRIETARY Document no.: Title: Sheet:

INFORMATION AND SUCH INFORMATION MAY NOT BE Field commissioning 2 of 11
DISCLOSED TO OTHERS FOR ANY PURPOSE NOR
USED FOR MANUFACTURING PURPOSES WITHOUT TSEL 0067 procedure for (Rev. C)
THE WRITTEN PERMISSION OF THE OWNER. PS 21 & PS 30
 General Warnings;
¾ MAKE SURE A SAFE WORKING ENVIRONMENT IS PROVIDED WHEN FIELD
COMMISSIONING THE PS.

¾ CLEANING REQUIREMENT OF THE HYDRAULIC SYSTEM BEFORE CONNECTING

SYSTEM 21 PRODUCTS.
Clean, purge and pickle all hydraulic piping after installation prior to hooking up to our
System 21 equipment. Verify oil quality meets NAS class 8 requirements. (E.g. this can
be reached by looping the hydraulic supply line from the hydraulic power unit to the
installation’s hydraulic return line back to the hydraulic power supply and hydraulic fluid is
to be run through this loop ).

¾ CHECK REQUIRED INTERLOCKS IN PLC SOFTWARE SUPPLIED BY DRILLERS

CONSOLE MANUFACTERER.
• In case the PS is installed into a Varco RST, the RST should not be rotated when the
RST slip ring ports are pressurized for raising or lowering the PS-21/ 30 slips. When
these ports are pressurized, additional force is put on the RST seals creating greater
friction between the seals and the rotating surface. This causes the seals to wear
more rapidly or even break. Therefor an interlock must be installed (PLC) that will
prevent the operation of the PS when rotating the RST (see RST Manual).
• The PS slips may only be raised if there is a positive signal that the elevator suspends
the string-load.
• The PS slips may never be set when the pipe to be clamped is rotating.
• Preferably do not set the PS slips when the string is still moving.

¾ REQUIRED PLC FUNCTIONS IN DRILLERS CONSOLE SUPPLIED BY DRILLERS

CONSOLE MANUFACTERER.
Operating the hydraulic PS cylinders.
• PS control and indication lights:
ƒ Slips set (down) switch and indication light for slips set.
ƒ Slips up (raise) switch and indication light for slips up.
ƒ Warning light for Pressure Low.
ƒ Warning light for grease bin empty.
• Formal mentioned interlocks in the PLC program.
See RST and PS manual.

If interlocks are not integrated this may cause severe

mechanical damage to the PS (and RST when
applicable), may lead to dropping of Pipe, and / or
injury to the Rig floor personnel.

THIS DOCUMENT CONTAINS PROPRIETARY Document no.: Title: Sheet:

INFORMATION AND SUCH INFORMATION MAY NOT BE Field commissioning 3 of 11
DISCLOSED TO OTHERS FOR ANY PURPOSE NOR
USED FOR MANUFACTURING PURPOSES WITHOUT TSEL 0067 procedure for (Rev. C)
THE WRITTEN PERMISSION OF THE OWNER. PS 21 & PS 30
 PROCEDURE
1. General.

• Go through PS manual with customer representatives, as mentioned on page 2, during

commissioning procedure. Get agreement on contents. OK

• Show the PS instruction chart in the driller’s cabin and get agreement
on the content. OK

• Show;
- PS 21/30 OK
- Slips, insert-carriers and ram inserts OK
- Hand-slip bowls OK
- Four way lifting sling OK
- Slip assembly lifting tool OK
- Insert carrier lifting tool (“pogo stick”) OK
- Slip handles operating tool OK
- Bit breaker plate OK
- Hook up manifold OK
- Automatic slip greasing system
(Not applicable for PS in combination with RST) OK
- Controls in driller’s cabin OK
- Ball valve in slips down hose (Not applicable for PS in combination with RST) OK
Purpose of the ball valve;
-Close off the hydraulic supply to the PS21/30 slip actuators to keep the
Levers in the right position for installing the slip assembly.
-When running hand-slips in the hand-slip bowls for PS21/30 after installing the
Hand-slip bowl set the slips, then put the PS21/30 pressure-less by the neutral
button and close the ball valve.
-When running hand-slips in the hand-slip bowls for PS21/30 in the RST after
installing the hand-slip bowl set the slips, then put the PS21/30 pressure-less by
the neutral button and disconnect the jumper-hoses to isolate the PS21/30
avoiding inadvertent opening of the slips.

2. Hydraulic controls:

• Explain general functioning of the PS and its controls using the Varco BJ installation
and hook-up drawings and general schematic inside manual. OK

• Verify that pressure, and tank lines from the Hook Up manifold are connected to the
hydraulic power unit. And verify that hydraulic lines from this manifold are connected the
right way with the correct Q.D’s to the PS according the Varco BJ installation-
and hook up drawings. Point out the items (valves, pressure switches/junction
boxes, etc.) shown in these drawings to driller, Tool pusher and rig mechanic. OK

THIS DOCUMENT CONTAINS PROPRIETARY Document no.: Title: Sheet:

INFORMATION AND SUCH INFORMATION MAY NOT BE Field commissioning 4 of 11
DISCLOSED TO OTHERS FOR ANY PURPOSE NOR
USED FOR MANUFACTURING PURPOSES WITHOUT TSEL 0067 procedure for (Rev. C)
THE WRITTEN PERMISSION OF THE OWNER. PS 21 & PS 30
 • Hand over these drawings to the rig mechanic and have him signed for receipt:

• Rig Mechanic drawing receipt: .

• Show the big inline filter and clean (green)/dirty (red) indicator OK

• Demonstrate how to clean hydraulic quick disconnects prior to connection.

Explain that non-removed dirt on the quick disconnects will enter the hydraulic
circuit and clog up the filters, resulting in a malfunctioning system. OK
• With complete system hooked up, check if all air is removed from the hydraulic
circuit by following this procedure, Precaution put the PS21/30 on an isolated floor to
avoid pollution by oil :
ƒ Cycle slips up and down 10 times. OK
ƒ Caution! Take safety measures when working on pressurized hydraulic systems
ƒ With slips powered down, slowly and slightly loosen the upper port tube nuts
from the rotary actuators in the PS body. Flush until only clean oil leaks out.
Then tighten the nuts again. OK
ƒ With slips powered up, slowly and slightly loosen the lower port tube nuts from
the rotary actuators in the PS body. Flush until only clean oil leaks out. Then
tighten the nuts again. OK
ƒ After following this procedure always conduct a leak test:
1. Hold pressure for five minutes at 2,300 psi minimum on slips up and
visually check for leaks. OK
2. Hold pressure for five minutes at 2,300 psi minimum on slips down
and visually check for leaks. OK

• Explain and demonstrate the Flushing procedure (see manual):

Note: PS21/30 inside an RST can only be flushed after the inline check-valve
in the signal jumper hose has been removed. OK

• Note that the required hydraulic flow to the hook up kit manifold is 5 Gpm or more with
a pressure between 2,300 psi and 3,000 psi. Also verify that the pressure difference
between pressure-line and tank-line (backpressure)
is 2100 psi minimum. write the actual values down in the table below:
Pressure is:………..……psi.
Backpressure is:………..psi

• Instruct the rig mechanic how to verify the pressure settings according to TSEL-0050
and schematics;
-50004442
-50004446
-50004453-4
-50004511-1
-203062
(see manual) write the read-out values down in the table below:
THIS DOCUMENT CONTAINS PROPRIETARY Document no.: Title: Sheet:
INFORMATION AND SUCH INFORMATION MAY NOT BE Field commissioning 5 of 11
DISCLOSED TO OTHERS FOR ANY PURPOSE NOR
USED FOR MANUFACTURING PURPOSES WITHOUT TSEL 0067 procedure for (Rev. C)
THE WRITTEN PERMISSION OF THE OWNER. PS 21 & PS 30
 PC 1 is set at:………….psi.
PC 2 is set at:………….psi. (only in combination with autom. slip greasing system)
PR 1 is set at:………….psi. (only in combination with autom. slip greasing system)
PRV 1 is set at:………….psi.
PS 1 is set at:………….psi.
PS 2 is set at:………….psi.
PS 3 is set at:………….psi.
PS 4 is set at:………….psi. (only in combination with autom. slip greasing system)

• Check all quick disconnects are opening easily and are not damaged or leaking. OK

3. Electrical controls.
• Let the rig mechanic/electrician verify that all electrical wiring is connected
according to the Varco BJ installation and hook-up drawings. OK

4. PS21 or PS30.
• Body and top covers.

While the PS is standing on the drill floor away from the hole and with the top
covers opened, point out the following components on the tool:

- Removable hinge pin. OK

– 4 big swivel eyes on top of body to lift the tool. OK

– 2 bars on the top covers to open/close these top covers. Emphasize

that these 2 small bars are not designed to lift the complete tool. OK

– Top cover lock. Emphasize that this lock must always be engaged and locked
when the top covers are closed. OK

– Rotary actuators inside body to raise/set slips. Point out in manual the correct
assembly procedure for these rotary actuators. Emphasize on pre-torque value for
cylinder bolts. OK

– Slip set indicator valves OK

– Cam-blocks and slip shaft (PS30 only) OK

– Hydraulic manifold inside PS. Point out the adjustment screw on the sequence
valve. Show the function of this valve on the hydraulic schematic (50004725 for PS30 and
50004726 for PS21). Emphasize that the setting of this valve may not be changed.
Changing the setting of this valve will result in an incorrect centering/slip setting sequence
thus creating a risk of dropping the pipe. OK

THIS DOCUMENT CONTAINS PROPRIETARY Document no.: Title: Sheet:

INFORMATION AND SUCH INFORMATION MAY NOT BE Field commissioning 6 of 11
DISCLOSED TO OTHERS FOR ANY PURPOSE NOR
USED FOR MANUFACTURING PURPOSES WITHOUT TSEL 0067 procedure for (Rev. C)
THE WRITTEN PERMISSION OF THE OWNER. PS 21 & PS 30
 – Hydraulic top cover hinge pins. Explain that the hydraulic oil operating the
centering device cylinders flows through these hinge pins. Point out in the manual
the cross section of these hinge pins and the position of the hydraulic seals around
these hinge pins. On the real pins point out the threaded disassembly holes.
Explain how the hinge pins can be removed from the hinge block by screwing
bolts into these threaded holes, thus pressing the hinge pins out. OK

– Centering device rams. Explain how the ram hinge pins are assembled. OK

– Centering device ram inserts. Show how they are inserted and locked into the
centering device ram. Point out on the plastic instruction sheet or manual
how to select the correct ram insert for a specific pipe size. OK

- Rotary table locks. Point out the arrow on top of the eccentric pins and demonstrate
how the position of the arrow correlates to the position of the rotary table lock.
Emphasize that these locks must be engaged at all time when the PS is placed into
the rotary table to avoid any unwanted lift of the tool during tripping pipe. OK

• Slips and insert carriers.

With the slips and insert carriers removed from the PS body, point out the following
components:

- Quick release pins in center slip to lock the slips into the body rotary actuator arms.
Show how they need to be slid out and locked. Point out the mud drain hole in the
bottom of the pin hole and emphasize on keeping this hole open in order to allow
mud to drain from the pin hole. OK

– Slip lifting eyes. OK

– Insert carrier lifting eye and latch on top of slip. Explain how the insert carrier
lifting hook automatically disengages the latch on the slip when the insert carrier is
lifted out. Emphasize upon that the latch must sit horizontal over the insert carrier
when installed. The latch may never be tilted backwards when falling over the
insert carrier. When the latch does not fall correctly over the insert carrier
there is a chance the latch disengages during tripping pipe. OK

– Point out on the plastic instruction sheet or manual how to select the proper insert
carrier for a specific pipe. Take caution when redressing insert-carriers for multiple sizes,
DO NOT redress insert-carriers;
202270-1113, 202271-950/-925, 202275-675, 202278-400
(They are machined different) OK

THIS DOCUMENT CONTAINS PROPRIETARY Document no.: Title: Sheet:

INFORMATION AND SUCH INFORMATION MAY NOT BE Field commissioning 7 of 11
DISCLOSED TO OTHERS FOR ANY PURPOSE NOR
USED FOR MANUFACTURING PURPOSES WITHOUT TSEL 0067 procedure for (Rev. C)
THE WRITTEN PERMISSION OF THE OWNER. PS 21 & PS 30
 5. Function test
• Clean any old grease and paint off the PS21/30 body cones, slip-body –cones, insert-
carriers, universal ram guide etc. Grease according to the manual prior to installing
slips insert-carriers and ram inserts. OK
• Connect PS to control manifold and operate the tool from the control panel in the
driller 's cabin and check for proper functioning: OK
• Check for a proper grease distribution inside the PS21/30 body either at manual-
or automatic slip greasing system. OK

• With the PS hooked-up to its controls, demonstrate how to assemble the slip into
the PS. Show that this need to be done with the rotary actuator levers locked into
half-way-down position. The levers can be locked into this position by closing the
ball valve in the slips down hose, for PS21/30 in an RST operate the slips and put
them into neutral position. For safety the jumper hoses must be disconnected from
the RST slip-ring.

• Explain that this ball valve will also protect the

man assembling the slips from any inadvertent slip movements. OK

• Connect the insert carrier lifting hook to a tugger line and assemble the insert
carriers into the slip using this lifting hook. Emphasize on the automatic locking
feature of this hook that will prevent any handled item from being dropped
inadvertently. OK

• Cycle slips up and down a few times and check for a correct centering/setting
sequence (slips and insert carriers installed). List down the cycle times. OK

Raising slips:
Function and sequence OK ‡
within:………….seconds. (6sec. Max.)
Slips up signal OK ‡

Setting slips:

Function and sequence OK ‡

within:………….seconds. (6sec. Max.)
Slips set signal OK ‡

• With the top covers still opened, point out on the tool all grease fittings listed on the
plastic instruction sheet and instruct on the greasing instructions as listed on this
sheet as well as in the manual. OK

THIS DOCUMENT CONTAINS PROPRIETARY Document no.: Title: Sheet:

INFORMATION AND SUCH INFORMATION MAY NOT BE Field commissioning 8 of 11
DISCLOSED TO OTHERS FOR ANY PURPOSE NOR
USED FOR MANUFACTURING PURPOSES WITHOUT TSEL 0067 procedure for (Rev. C)
THE WRITTEN PERMISSION OF THE OWNER. PS 21 & PS 30
 • Remove the removable hinge pin from the body by connecting the insert carrier
lifting hook to the hinge pin bail. Then gently pull the pin out with the tugger line.
Emphasize that the lock on the lifting hook will prevent the pin from being dropped
when the removable hinge pin is handled above open hole. OK

• Raise the slips and disconnect the hydraulic hoses. Check that the anti-sagging valve
inside the PS manifold block locks the slip in raised position. OK

• Install the special 4-way lifting sling to the 4 body swivel eyes and make sure the
curve in the spreader bar faces the manifold block inside the PS. Raise the tool,
open the door, move the tool towards well center and (in case applicable) around
the string. Close the door and lower the tool into the rotary table. OK

• Re-install the removable hinge pin, again using the insert carrier lifting hook. OK
• Close the top covers. Demonstrate that the safest way to handle the top covers is
by using again the insert carrier lifting hook attached to the top cover opening bars.
The lock on the lifting hook will prevent the top covers from being dropped, but
in the same time the lifting hook assures a quick handling. Also, without the need
to attach lifting shackles to the lifting eyes near well center, the chances of any
item being dropped down the well are minimized. OK

• Set the slips around a piece of pipe and check for a correct “slips set” signal inside
the driller’s cabin. OK

• Raise the slips and check for a correct “slips raised” signal inside the
driller’s cabin OK

Confirm that No slip set signal is available when slips are Not fully set on pipe. OK

• Check for the absence of a “low pressure” signal inside the driller’s cabin.
Bleed off the hydraulic pressure and check at which pressure the “low pressure”
signal comes on.
“low pressure” setting:_____ psi. (recommended 2000 psi.)

• Check if the jumper hoses between rig floor and PS manifold are long enough to
make at least a half turn clockwise and counterclockwise with the rotary table
when the jumper hoses to the PS are still connected. Reason: Of all slip segments
the center slip has the greatest setting force. In case of extreme weather conditions
or heavy rig movement the side slips might not have enough setting force to set
correctly. In that case the PS has to be rotated until the pipe is offset towards the
center slip. The slips will now set correctly. OK

THIS DOCUMENT CONTAINS PROPRIETARY Document no.: Title: Sheet:

INFORMATION AND SUCH INFORMATION MAY NOT BE Field commissioning 9 of 11
DISCLOSED TO OTHERS FOR ANY PURPOSE NOR
USED FOR MANUFACTURING PURPOSES WITHOUT TSEL 0067 procedure for (Rev. C)
THE WRITTEN PERMISSION OF THE OWNER. PS 21 & PS 30
 6. Advise the customer to Check for availability and proper fit of size components:

• Check that complete sets of slips dressed with inserts or insert-carriers and ram-
guides or ram inserts are present according to the tubular sizes to be handled, and
highlight them in the size components list in the manual and the plastic instruction
chart. OK

• Check for the right part- and size numbering in the size components. OK

• Check for the right inserts in slips by taking one insert out and compare the part
number on the back of it with the insert listed in the chart on the plastic instruction
sheet. OK

• Check for the right inserts in the insert-carriers by taking one insert out and compare
the part number on the back of it with the insert listed in the chart on the plastic
instruction sheet. OK

• Verify the bottom insert of each column of inserts in a slip/insert carrier is always
beveled unless there is a load-ring installed. OK

• Check that all individual size components can be assembled and locked easily into
the PS.
Note on insert carriers: Again check on each insert carrier the position of the
latch. The latch on top of the slip may NEVER tilt backwards when slid over the
insert carrier. OK

• It is recommended to have all matching size components, insert carriers as well as

the corresponding ram inserts, color-coded identically. This will minimize the risk
of handling pipe with the wrong size components. If no color-coding is present
on the size components, discuss the need for color-coding with the people attending
the commissioning procedure and apply a color-coding as discussed. OK

THIS DOCUMENT CONTAINS PROPRIETARY Document no.: Title: Sheet:

INFORMATION AND SUCH INFORMATION MAY NOT BE Field commissioning 10 of 11
DISCLOSED TO OTHERS FOR ANY PURPOSE NOR
USED FOR MANUFACTURING PURPOSES WITHOUT TSEL 0067 procedure for (Rev. C)
THE WRITTEN PERMISSION OF THE OWNER. PS 21 & PS 30
 7: Lessons Learned and Field Input.
• Avoiding the slips to stick: Besides all modifications done by Varco BJ to
prevent the slips from sticking, it is vital for the performance of the tool to
keep the tool in a well greased condition, as outlined on the plastic
instruction sheet and users manual. Especially greasing the back of the slips
(= grease points A on the plastic instruction sheet) once every 50 tripped
joints largely enhances the performance of the tool.

• The second important item in line to keep the PS in best performance is to

keep dirt and water out of the hydraulic circuit. Pollution in the hydraulic
circuit is likely to cause damage and/or corrosion to the hydraulic
components (valves, cartridges, cylinders, etc) inside the control manifold
and the PS, thus leading to a malfunctioning of the tool. Also keep your quick
disconnects clean.

• Despite of the presence of a centering device, extreme weather conditions

may cause problems with the setting of the slips. If such is noted during
tripping of pipe, always rotate the PS until the pipe is offset towards the
center slip. Beware of cutting/snapping your jumper hoses while
rotating the PS when the hoses are still connected! If the PS can not be
rotated far enough in one direction, rotate the tool around in the other
direction or disconnect the Q.D’s.

• A few occasions have been reported from the field whereby pipe has been
dropped because either none or a wrong sized ram insert/top guide has
been installed. Therefore make it a good practice to check all your size
components after every size change. The recommended color-coding
increases the speed and accuracy of your check.

• The PS21 and PS30 are heavy pieces of equipment. Please keep this in
mind while lifting & transporting the tools on the rig/ rig floor.

• One occasion in the field has been reported whereby hydraulic tubing inside
the PS started to leak because the rotary actuators to raise/set the slips were
not assembled tight enough to the body. Therefore make it a good practice
to follow the maintenance procedures described in the manual.

THIS DOCUMENT CONTAINS PROPRIETARY Document no.: Title: Sheet:

INFORMATION AND SUCH INFORMATION MAY NOT BE Field commissioning 11 of 11
DISCLOSED TO OTHERS FOR ANY PURPOSE NOR
USED FOR MANUFACTURING PURPOSES WITHOUT TSEL 0067 procedure for (Rev. C)
THE WRITTEN PERMISSION OF THE OWNER. PS 21 & PS 30
 TEST SPECIFICATION
Part Number: 202203-55 / 202204-55

Part Description: ACTUATOR with internal relief.

Serial Number: _NL_____________________________

Supplier: ______________________________

Country of origin: ______________________________

Test Technician: ______________________________

Name, date, and signature

Remarks: ______________________________
______________________________

This specification defines the production testing and inspection of the PS Actuator
assembly. Each unit is to be tested and inspected according to the following procedure. Any
discrepancy is cause for discontinuing the test until the discrepancy has been eliminated. In
the event of a major discrepancy whose repair would affect items previously inspected or
tested, the affected items shall also be re-tested or re-inspected after the discrepancy has
been eliminated.

D
Name: Date C
Prepared C.d.L Aug. 27 ‘03 B 601252 C.d.L Dec. 10 ‘03 P.D.
Checked P.D. Aug. 27 ‘03 A 600168 C.d.L Aug. 27 ‘03 P.D.
Approved A.K. Aug. 27 ‘03 Rev. ECN Name Date Checked
THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:
INFORMATION AND SUCH INFORMATION Inspection criteria for PS
MAY NOT BE DISCLOSED TO OTHERS FOR
ANY PURPOSE NOR USED FOR TSEL-0127 21 / PS30 Actuator 1 of 3
MANUFACTURING PURPOSES WITHOUT assembly
THE WRITTEN PERMISSION OF THE
OWNER.
Check:
If all parts are present and assembled according to the drawing (202203-55, Ok
Or 202204-55).
If the upper link arm position corresponds with the drawing Ok
If the lower link arm position corresponds with the drawing Ok
If the serial- and part-number are present corresponding with the drawing
If 55 is present on top of the barrel Ok
Ok

Cycle in;
Hydraulic oil used shall be according the following specification;
SAE class 3, ISO 15/12, Oil cleanness according to NAS class 8 Ok
Hook up the actuator, set the supply oil pressure at 2,500 psi. (17.3 MPa) de-
aerate. Then cycle the actuator 50 times up and down.
Ok
Check for signal pressure with a gauge on the signal port (port S1) when the
piston is up or down (only applicable to the right hand “202204-55” actuator).
Ok

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR
ANY PURPOSE NOR USED FOR TSEL-0127 PS21 / PS30 Actuator 2 of 3
MANUFACTURING PURPOSES WITHOUT assembly
THE WRITTEN PERMISSION OF THE (Rev. B)
OWNER.
Pressure test;
Set the piston / link-arm in the lower position by pressurizing port A1and build Ok
up pressure up to 3.750 psi. (25.9 MPa) keep this pressure on for at least five
minutes. No leakage or damage may occur.
Set the piston / link-arm in the upper position by pressurizing port B1 and
build up pressure up to 2.900 psi. (20 MPa) keep this pressure on for at least Ok
five minutes. No leakage or damage may occur.
Then increase the pressure and the internal relief should open, the reading Ok
on the signal port S1 gauge may not exceed 3,000 psi. (20.7 MPa)

Paint check;
Check for a nice Red (RAL3002) layer of paint according to paint Ok
specification P001

Clean;
Plug open ports, and Protect against damage,
Sign off this TSEL .

THIS DOCUMENT CONTAINS PROPRIETARY Document No.: Title: Sheet:

INFORMATION AND SUCH INFORMATION Inspection criteria for
MAY NOT BE DISCLOSED TO OTHERS FOR
ANY PURPOSE NOR USED FOR TSEL-0127 PS21 / PS30 Actuator 3 of 3
MANUFACTURING PURPOSES WITHOUT assembly
THE WRITTEN PERMISSION OF THE (Rev. B)
OWNER.