12K – OFFLINE ACTIVITY CRANE

Operation & Maintenance Manual

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SERVICE MANUAL1126253
REV. - DATE: 26-10-2015
 TABLE OF CONTENTS
Page

SECTION 1: INTRODUCTION .......................................................................................... 4

1.1 Name Plate Data ................................................................................................................................ 4
1.2 Intended Use ..................................................................................................................................... 4
1.3 Design Criteria .................................................................................................................................. 5
1.4 Symbol Naming Conventions .......................................................................................................... 5
1.5 Naming and Directional Conventions............................................................................................. 5
1.6 Operator Safety Instructions ........................................................................................................... 6

SECTION 2: UTILITY REQUIREMENTS AND DESCRIPTIONS ......................................... 7

2.1 Operator Safety Instructions ........................................................................................................... 7
2.2 Hydraulic ........................................................................................................................................... 8

SECTION 3: COMPONENT IDENTIFICATION ................................................................ 10

3.1 System ............................................................................................................................................. 10
3.2 Trolley .............................................................................................................................................. 11
3.3 Bridge............................................................................................................................................... 12
3.4 Mechanical Bridge Lock................................................................................................................. 13
3.5 Mechanical Trolley Lock ................................................................................................................ 14
3.6 Control Panel Assembly ................................................................................................................ 15
3.7 Main Control Center (1113077) ...................................................................................................... 16
3.8 Human Machine Interface (HMI) .................................................................................................... 18
3.9 Operator’s Podium (1112361, 1112094) ........................................................................................ 24

SECTION 4: OPERATIONS ............................................................................................ 27

4.1 Modes of Operation ........................................................................................................................ 27
4.2 Manual (Emergency) Operations .................................................................................................. 27
4.3 Normal (Electrical) Operations ...................................................................................................... 28
4.3.1 Individual Function Descriptions and Instructions ............................................................. 28
4.3.2 Normal Operating Procedures ........................................................................................... 30
4.4 Failure Mode Operations................................................................................................................ 35

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4.5 Zone Management (if applicable) .................................................................................................. 37

SECTION 5: MAINTENANCE ......................................................................................... 38

5.1 General Information ........................................................................................................................ 38
5.2 Periodic Checks .............................................................................................................................. 38
5.2.1 Bridge ................................................................................................................................. 38
5.2.2 Trolley, Hoist ...................................................................................................................... 39
5.3 General Electrical System ............................................................................................................. 39
5.4 Control Panel Assembly ................................................................................................................ 39
5.5 Lubrication ...................................................................................................................................... 39
5.6 Wire Rope ........................................................................................................................................ 41

SECTION 6: TROUBLESHOOTING................................................................................. 43
6.1 Problem Identification Flow Chart ................................................................................................ 43
6.1.1 Electrical Troubleshooting ........................................................................................................ 45
6.1.2 Hydraulic - Mechanical Troubleshooting ................................................................................. 47

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 SECTION 1: INTRODUCTION

1.1 Name Plate Data

CAPACITY: 12,000 POUNDS (5,440 KG) SAFE WORKING LOAD
WIRE ROPE: BRIDON ENDURANCE DYFORM 34LR/PI/MAX (LANG LAY, LEFT
HAND, GALV, 2160 – 18MM DIAMETER (OR EQUIVALENT)
VERTICAL HOOK TRAVEL: 138 FEET (42 M)
RATED SIDE LOAD: 1,000 POUNDS (454 KG)
HOISTING SPEED UP: HEAVY LIFT SPEED (OVER 5,000 LB) APPROXIMATELY
0-1.64 FT/SEC (0-0.5 M/SEC). LIGHT LIFT SPEED
APPROXIMATELY (UNDER 5,000 LB) 0-3.25 FT/SEC (0-1.0
M/SEC)
HOISTING SPEED DOWN: HEAVY LOAD SPEED (OVER 5,000 LB) APPROXIMATELY
0-1.64 FT/SEC (0-1.0 M/SEC). LIGHT LOAD SPEED
APPROXIMATELY (UNDER 5,000 LB) 0-3.25 FT/SEC (0-1.0
M/SEC)
CROSS TRAVEL SPEED: 0.82 FT/SEC (0.25 M/SEC)
LONG TRAVEL SPEED: 0.82 FT/SEC (0.25 M/SEC)

1.2 Intended Use

The 12K Offline Activity Crane (OAC) is a compact, fit-for-purpose derrick- or mast-mounted tool
that combines X-Y travel, a trolley system, and hoisting functions into a single, easily installed and
managed unit. It is designed to mount above the fingerboard of a derrick or mast drilling structure
to allow offline stand building, racking and tubular handling without interfering or delaying drilling
activities. It is a bridge style gantry hoisting and handling system with multi axis operations
described as Bridge, Trolley, and Hoist. The OAC has a trolley mounted winch that when used in
conjunction with a customer supplied single joint elevator, allows picking up of single joints of
drilling or completion tubulars at drill floor level and placing into a mouse hole located in the rig
floor. The process allows picking up additional single joints and making up at rig floor level into a
double, triple or quad stand. Once the stand is built, the OAC uses its X/Y motion to position the
stand into the appropriate storage position in the setback/fingerboard. Engagement of the single
joint elevator at the floor as well as at the fingerboard level is a manual operation performed by the
rig personnel.
The major components of the OAC system are the Bridge Travel Rails (2), the Bridge, and Trolley.
The Bridge Travel Rails provide the support and rolling surface for the Bridge which spans
between the two main rails. The Bridge Rails are custom designed to interface with each particular
drilling mast or derrick. This assembly includes the bridge rails but excludes the drilling mast
structure.

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 The bridge is supported at each end by the travel rails and moves laterally above the fingerboard
using a hydraulically powered rack and gear drive mechanism. The bridge supports and provides
a rolling surface for the trolley.
The trolley traverses the bridge using a hydraulic powered rack and gear drive. The trolley
contains a hydraulic powered winch and drum that hoists the drill pipe, tubing or casing. The winch
uses a wire rope on its drum to facilitate lowering and hoisting the customer supplied single joint
elevator vertically between the drill floor and the fingerboard. The winch is rated for 12,000 Lbs.
The drum of the winch is powered and supported by a planetary gearbox specifically designed for
a winch application.
The OAC system is controlled either from the drill floor, monkey board, or an optional casing board
or fingerboard using a combination of electric and hydraulic controls. An emergency mode of
operation and controls is available at the OAC level, directly from the OAC control panel.

1.3 Design Criteria

The 12K Offline Activity Crane is rated for a safe working load of 12,000 lbs under standard
operating conditions. Operating temperature is above 0 degree Celsius to 40 degree Celsius.
The allowable stress safety factor used in the design calculations and analysis are determined
according to the following code:
th
API Specification 2C (7 Edition, 2012). Specification for Offshore Pedestal Mounted Cranes
AISC, American Institute of Steel Construction, Latest Edition
AWS D1.1, American Welding Society, Latest Edition

1.4 Symbol Naming Conventions

WARNING: A Warning Symbol is used when failing to follow the direction can cause injury
or death to a person. This symbol will be placed with text describing the type of Warning that must
be observed.
CAUTION: A Caution Symbol is used when failing to follow a direction can cause equipment
failure. This symbol will be placed with text describing the type of Caution that must be observed.
NOTE: A Note Symbol is used before a step or procedure to describe special instructions
about the next step.

1.5 Naming and Directional Conventions

To prevent confusion, the names, titles and directions referenced in this document are described
as follow:
 MOUSEHOLE; The position of the hoist when it is parked over the centerline of the
mousehole opening.
 AFT; The movement of the trolley towards the aft portion of the rig when viewed from
above.
 FORWARD; The movement of the trolley towards the forwards the forward portion of the
rig when viewed from above.

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  PORT; The movement of the bridge towards the port portion of the rig when viewed from
above.
 STARBOARD; The movement of the bridge towards the starboard portion of the rig
when viewed from above.
 HOIST (UP or DOWN); The motion of the hoist winch raises or lowers the wire rope.

1.6 Operator Safety Instructions

WARNING: This unit must always be operated by an authorized and trained operator only.
Failure to follow these instructions can cause serious injury or death.
 Know the equipment limitations.
 Know and understand the operation manual.
 Know, understand, and follow the inspection plans.
 Know, understand, and execute routine maintenance procedures.
 Never operate or work on the unit without proper PPE (Personal Protective Equipment).
PPE required to operate the unit are as follow: hardhat, steel toes, safety glasses and ear
plugs.
 Do not permit people near the unit controls during inspections or repair unless they are
supervised or part of the inspection/repair team.
 Recognize all pinch points on moving components and maintain a safe distance from
them.
 Observe all jobsite rules; be in complete control at all times.
 Ample loose clothing, watches or bracelets can in some circumstances be dangerous.
Therefore, they are not recommended to be worn on the job.
 Prior to starting the unit and at the beginning of each shift, perform a visual inspection of
the unit.
 Unexpected movement, when raising or lowering the tubular product into place, could
result in a serious injury.
 When connecting hydraulic hoses to a coupling, make sure the circuit is not under
pressure or at high temperature.
 Take the necessary steps to prevent oil leakages when connecting or disconnecting the
system.

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 SECTION 2: UTILITY REQUIREMENTS AND DESCRIPTIONS

2.1 Operator Safety Instructions

Primary
Allowable Voltage Supply: 110 – 120 VAC / 220 – 240 VAC
Allowable Supply Frequency: 50 Hz / 60 Hz
Allowable Current Supply: 30 A continuous / 30 A In-rush
Normal Power Consumption: 600 watt
Secondary
Control Voltages: 24 volt DC
Normal Power Consumption @ 24 VDC: 480 watt
*Enclosure Classification
Main Control Enclosure (JB001) NEMA 4X/ IP66 (located on walkway at OAC
Bridge Junction Box (JB002) Level)
NEMA 4X/ IP66/ Ex „d‟
Suitable for use in Zone 1 hazardous areas
Trolley Junction Box (JB003) NEMA 4X/IP66/ Ex „e‟ & suitable for use in Zone
2 hazardous areas

Podium Interface Enclosure NEMA 4X/IP66/ Ex „e‟ & suitable for use in Zone
2 hazardous areas

*Podium Control Stations

Podium Control Stations NEMA 4X/ IP66/ Ex/NA

(Monkey Board) Suitable for use in Zone 2 hazardous areas
The operator controls how fast the motors move (located
(Casing Board) - Optional at drill floor,
using electrical finger
joysticks board and
mounted casing
in the podiums.
(Drill
The board)
Floor) can be on different podium and trade control by pressing a button on their console.
operators
A light is activated when that console is in control. Typically the operator on the drill floor will
control when the V-door or the mouse hole are being used, and the operator on the upper level will
control while sliding the tubular into or out of the rack and removing the elevator. The top drive
area is monitored by the encoders, and entry requires activating an override switch located on the
driller‟s cabin, which also flashes the warning lights at all consoles.
*Only CompEx trained personnel are to work inside of the electrical ATEX system.
The electrical measurement system consists of three encoders monitoring the Bridge, Trolley,
Hoist, and a hoist load cell. The measurement package provides the machine with limits to allow it
to slow down instead of hitting hard stops. Whenever the load cell detects a hoist load that is less
than 5,000 pounds normal setting but is adjustable, the operator is allowed to enter high speed
lifting through pressing the hoist joystick 75% from its neutral position, both directions. The load

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 cell monitors the weight on hook and the PLC turns on warning lights when the safe operating
limits are approached.

2.2 Hydraulic
o Hydraulic Operating Pressure (max) : 3000 psi, Closed Center
o Hydraulic Flow (max): 50 gpm
o Hydraulic Return (max): 200 psi @50 gpm
o Hydraulic Drain (max): 14.5 psi @5 gpm
o Equipped with onboard high pressure hydraulic filter system
The OAC hydraulic system is comprised of an integrated Hydraulic Valve Bank located on the
OAC control panel on the walkway. The individual functions of the valve bank are driven by the
control system but each section in the assembly is equipped with a removable handle that can be
used for emergency operation of the OAC.
This Valve Bank is comprised of the following:
 Hydraulic Enable; the first block in the assembly is a single acting, center return to tank
24 VDC solenoid. When control of the OAC is requested from either of the control station
the solenoid is activated. The OAC Emergency Stop system is also integrated into this
solenoid. Activation of an ESD from any of the control stations disables this solenoid and
prevents all movement of the OAC.
 Hoist Solenoid; a high flow proportional motor control solenoid with individual pressure
setting function and pressure sensing outlet.
 Trolley Travel Solenoid; a high flow proportional motor control solenoid with individual
pressure setting function.
 Bridge Travel Solenoid; a high flow proportional motor control solenoid with individual
pressure setting function.
 Hoist Speed Control Solenoid; a non-proportional low flow solenoid that enables high
speed, low torque function of the hoist system.
The Hoist has a spring applied brake to hold the load up, and a counterbalance valve (in the
“lower” direction) to stop the load before the brake engages. The Hoist uses a directional valve
with a relief. The motor is a two speed type that includes a directional control valve operating the
shift between speeds. The pressure is limited at the valve exit, not in the inlet, to allow more
pressure to be available to overcome valve stack internal pressure drops, and to avoid the
possibility of an inlet relief being set below pump compensator settings and roasting the valve
stack. Pump protection for the power supply is outside our scope of work and is the rig operator
responsibility. The relief valve placed on the hoist provides a nearly instant limit to the tonnage of
the hoist to avoid structural damage; an electrical Load Cell provides a more accurate limit set
below the hydraulic limit which then only acts if the electrical system fails. The hydraulic effort is
limited to a value which is lower than the maximum rating of the gear reducer, and the brake
capability. The brake will begin setting below the pilot pressure required to fully open the spring
applied brake. At such low pressures the counterbalance valve has removed the majority of the
load kinetic energy. A backstop device (brake) has been included in the winch gear reducer to
eliminate slippage during stops.

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 Hoist lifting and lowering are normally limited by a hoist encoder. During lifting, the hoist will stop
while it hits its upper encoder limit. There is a secondary safety stop for hoist lifting. The hoist is
equipped with a hoist gear reducer device with a cam set at the upmost limit of the hoist traveling.
The cam will depress a hydraulic flow control valve which will shut off hydraulic supply to the hoist
instantly. During lowering, the hoist will stop while it hits its lower encoder limit. To further
lowering the hoist, an operator must turn on the Hoist Override key switch located on the Drill
Floor Podium. An acknowledgement light will be flashing in other podiums when the hoist enters
the override zone. If the operator keeps on lowering the hoist, it will eventually stop while the wire
rope remains only seven wraps on the hoist drum. This is referred to the hoist absolute lower
limit.
The Bridge and Trolley have an independent valve control attached to the large hoist valve. The
travel axis forces and acceleration are limited by a pressure reducing section in the valve stack
which is adjustable. The valves in the travel section have pressure compensating spools under
each main spool allowing more than one travel action to occur at the same time. Travel is
restricted by encoders. When travel limits are reached, no further motion is allowed in the
direction of the set limit. The travel limits are meant to supplement human observation, not
replace it. The operator is responsible for watching the load and maintaining a safe move at all
times. Furthermore, the Bridge motors are equipped with spring applied brake that require
hydraulic pressure to release, whereas the Trolley drive has counterbalance valves to prevent
any mechanical movement while crane is non-functional. The Bridge travel is held parallel
through the use of an anti-crabbing wire rope system attached to the long travel rails and routing
through pulleys located on the bridge structure.
The motors provide driving force. Solid wheels made of high strength low friction plastic hold up
the crane and support the weight of the load. The rollers/wheels are connected to the pins
through maintenance-free plastic bushings. Proper alignment is required to ensure the pinions
remain sufficiently engaged and that the rollers remain centered on the rails. High strength crush
resistant bumpers provide end of travel protection.

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 SECTION 3: COMPONENT IDENTIFICATION

3.1 System

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3.2 Trolley

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3.3 Bridge

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3.4 Mechanical Bridge Lock

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3.5 Mechanical Trolley Lock

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3.6 Control Panel Assembly

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3.7 Main Control Center (1113077)

9 10 11

1 2 3 4

5 6 7 8

12 13

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 MAIN CONTROL CENTER
No. Description Function Type of Control
1 LIMIT SET SWITCH TURN TO RIGHT IN ORDER TO ENABLE 2 POSITIONE MAINTAINED
LIMIT SET MODE. SWITCH
2 LIMIT FUNCTION SWITCH SELECT WHICH AXIS TO SET LIMIT. 4 POSITION MAINTAINED
SWITCH
3 LIMIT SET A PUSH ONCE LIMIT HAS BEEN MOMENTARY
PUSHBUTTON REACHED. LIMIT SET SWITCH MUST PUSHBUTTON (SPRING
BE ENABLED. RETURN TO NEUTRAL)
4 LIMIT SET B PUSH ONCE LIMIT HAS BEEN MOMENTARY
PUSHBUTTON REACHED. LIMIT SET SWITCH MUST PUSHBUTTON (SPRING
BE ENABLED. RETURN TO NEUTRAL)
5 BRIDGE LIMITS SET GREEN ILLUMINATED INDICATOR THAT ILLUMINATED INDICATOR
(LIGHT) ACTIVATES WHEN BRIDGE LIMITS LIGHT (GREEN)
HAVE BEEN SET.
6 TROLLEY LIMITS SET GREEN ILLUMINATED INDICATOR THAT ILLUMINATED INDICATOR
(LIGHT) ACTIVATES WHEN TROLLEY LIMITS LIGHT (GREEN)
HAVE BEEN SET.
7 HOIST LIMITS SET (LIGHT) GREEN ILLUMINATED INDICATOR THAT ILLUMINATED INDICATOR
ACTIVATES WHEN HOIST LIMITS HAVE LIGHT (GREEN)
BEEN SET.
8 SLEW LIMIT SET (LIGHT) GREEN ILLUMINATED INDICATOR THAT ILLUMINATED INDICATOR
NOTE: This feature is not ACTIVATES WHEN SLEW LIMIT HAS LIGHT (GREEN)
available in the 12K OAC BEEN SET.
but the physical component
is still there.
9 E-STOP PUSHBUTTON PUSHBUTTON THAT ACTIVATES THE 2 POSITION MAINTAINED
(LIGHT) EMERGENCY STOP SYSTEM OF THE PUSHBUTTON AND
OAC AND RED ILLUMINATED ILLUMINATED INDICATOR
INDICATOR THAT INTEGRATED INSIDE LIGHT (RED)
THE PUSHBUTTON WHICH ACTIVATES
AS IT IS DEPRESSED.
10 HUMAN MACHINE DISPLAYS DIAGNOSTIC INFORMATION HMI
INTERFACE DISPLAY FOR SYSTEM.
11 POWER (LIGHT WITH GREEN ILLUMINATED INDICATOR THAT ILLUMINATED INDICATOR
GUARD) ACTIVATES WHEN POWER IS TURNED LIGHT (GREEN)
ON IN THE CABINET.
12 LOAD CELL OVERRIDE TURN TO RIGHT IN ORDER TO KEYED MAINTAINED
SWITCH (LIGHT) OPERATE CRANE WHEN LOAD CELL IS SWITCH AND
NOTE: Control light will flash NON-FUNCTIONAL. AMBER LIGHT ILLUMINATED INDICATOR
when activated. ILLUMINATES WHEN SWITCH IS LIGHT (AMBER)
ENABLED.
13 HOIST HIGH SPEED TURN TO RIGHT IN ORDER TO ENABLE KEYED MAINTAINED
SELECTOR (LIGHT) HOIST SPEED SHIFT WHILE LOAD CELL SWITCH AND
NOTE: Control light will flash IS NON-FUNCTIONAL. AMBER LIGHT ILLUMINATED INDICATOR
when activated. ILLUMINATES WHEN SWITCH IS LIGHT (AMBER)
ENABLED.

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3.8 Human Machine Interface (HMI)

MAIN (DEFAULT) SCREEN

No. Description Function
1 SETUP LIMITS PRESS TO DISPLAY SCREEN SHOWING ALL TRAVEL LIMITS AND
CURRENT POSITIONS/AXES OF THE CRANE. ALSO INCLUDES
THE BUTTON TO SET UP MAX HOIST LIMIT
2 SETUP PODIUMS PRESS TO DISPLAY SCREEN WHERE PODIUMS CAN BE
ACTIVATED OR DEACTIVATED
3 SETUP TRAVELS PRESS TO DISPLAY SCREEN WHERE TRAVEL DIRECTIONS CAN
BE CHANGED WITH RESPECT TO POLARITIES OF THE
JOYSTICKS‟ MOVEMENTS
4 OUTPUT OFFSETS PRESS TO DISPLAY SCREEN
5 OUTPUT RANGES PRESS TO DISPLAY SCREEN

6 COMPONENT STATUS PRESS TO DISPLAY SCREEN SHOWING COMMUNICATIONS

FROM/TO MAIN COMPONENTS
7 HOIST FEEDBACK PRESS TO DISPLAY SCREEN SHOWING HOISTING ISSUE(S) AND
ACKNOWLEDGEMENT
8 SLIPPAGE SENSORS PRESS TO DISPLAY SCREEN WHERE THE PROX SWITCH CAN BE
ACTIVATED OR DEACTIVATED
9 TRANSFER SOFTWARE PRESS TO TRANSFER HMI CONFIGURATION FROM COMPUTER
TO THE HMI UNIT

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 SLIPPAGE SENSORS
THIS SCREEN TO ADJUST THE PROX SWITCH FOR SLIPPAGE OF THE BRIDGE DETECTION.

****

SETUP LIMITS
THIS SCREEN DISPLAYS TRAVEL LIMITS AND CURRENT POSITIONS OF ALL TRAVEL AXES FROM THE
ENCODERS‟ FEEDBACK (COUNT) VALUES. THIS SCREEN ALSO ALLOWS YOU TO SET HOIST MAX LIMIT.

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 SETUP PODIUMS
ONCE A PODIUM IS DEACTIVATED FROM THE SYSTEM, THE DISPLAY OF THAT PARTICULAR PODIUM
WILL FLASH IN RED. ALL COMMUNICATIONS AND I/O, INDLUDING THE EMERGENCY STOP, FROM
AND/OR TO THE PODIUM WILL BE IGNORED.

SETUP TRAVELS
POLARITIES OF A JOYSTICK MOVEMENT AND RELATED TRAVEL DIRECTION OF THE TOOL CAN BE
CHANGED ON THIS SCREEN. THIS PROCESS IS APPLIED ONLY TO THE BRIDGE AND TROLLEY AXIS.
THIS PROCESS IS SEPARATELY APPLIED TO EACH PODIUM.

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 *OUTPUT OFFSETS
MOVEMENTS OF EACH AXIS (BRIDGE, TROLLEY AND HOIST) ON BOTH DIRECTIONS ARE DRIVEN BY A
DIRECTIONAL SOLENOID VALVE. THE STARTING SPEED ON EACH DIRECTION (OF EACH AXIS) CAN BE
ADJUSTED BY CHANGING THE RELATED OFFSET IN THIS SCREEN.
NORMALLY THE OFFSET IS AROUND 250-300. IF THIS OFFSET IS SET TOO LOW, A LARGER DEAD BAND
FROM THE JOYSTICK RESPONSE WILL BE SEEN. IF THE OFFSET IS SET TOO HIGH, A HIGH INITIAL
SPEED WILL BE SEEN FROM THE JOYSTICK MOVEMENT.
No. Description Function
1 BRIDGE PORT_A OFFSET APPLIED TO BRIDGE AXIS TRAVEL TO LIMIT A
2 BRIDGE PORT_B OFFSET APPLIED TO BRIDGE AXIS TRAVEL TO LIMIT B
3 TROLLEY PORT_A OFFSET APPLIED TO TROLLEY AXIS TRAVEL TO LIMIT A
4 TROLLEY PORT_B OFFSET APPLIED TO TROLLEY AXIS TRAVEL TO LIMIT B
5 HOIST PORT_A OFFSET APPLIED TO HOIST AXIS TRAVEL TO LIMIT A
6 HOIST PORT_B OFFSET APPLIED TO HOIST AXIS TRAVEL TO LIMIT B

*SLEW‟S OFFSET AND RANGE SETUP IS ONLY FUNCTIONAL DEPENDING ON THE TYPE
OF OAC SYSTEM.

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 *OUTPUT RANGES
ONCE THE OFFSET SPEEDS HAVE BEEN SET, RESOLUTION (RESPONSE FROM 0-100% MOVEMENT) OF
A JOYSTICK CAN BE MANIPULATED. NORMALLY THE RESOLUTION IS AT 100%. IF THE RESOLUTION IS
SET TOO LOW, THE MAXIMUM SOLENOID VALVE MOVEMENT WILL NOT BE SEEN EVEN THE JOYSTICK
IS AT 100%. IF THE RESOLUTION IS SET TOO HIGH, THE MAXIMUM SOLENOID VALVE MOVEMENT WILL
BE SEEN BEFORE THE JOYSTICK GETS TO 100%.

COMPONENT STATUS
THIS SCREEN DISPLAYS COMMUNICATIONS FROM/TO MAIN PLC RACK, ENCODERS AND LOAD CELL. IF
THE COMMUNICATION FAILS, THE DISPLAY FOR THAT PARTICULAR COMPONENT WILL FLASH IN RED.

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 HOIST FEEDBACK
THIS SYSTEM IS DESIGNED TO MONITOR THE HOIST TRAVEL. IF THERE IS AN ISSUE DETECTED, THE
SYSTEM WILL STOP ALL MOVEMENT AND THE HOIST BRAKE WILL BE APPLIED. TO CLEAR THE ERROR,
EACH STEP 1 TO 3 ON THE SCREEN MUST BE ACKNOWLEDGED IN SEQUENCE. THEN THE CRANE CAN
RESUME ITS NORMAL OPERATION.

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3.9 Operator’s Podium (1112361, 1112094)

Podium ‘B’ (Drill Floor) – 1112361

Finger Board / Monkey Board – 1112094

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 Foot Switch

*Image to show Foot Switch (Control Podium).

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 OPERATOR’S PODIUM
No. Description Function Type of Control
1 E-STOP (LIGHT) PUSHBUTTON THAT ACTIVATES THE 2 POSITION
EMERGENCY STOP SYSTEM OF THE OAC AND MAINTAINED
RED ILLUMINATED INDICATOR THAT PUSHBUTTON AND
INTEGRATED INSIDE THE PUSHBUTTON ILLUMINATED
WHICH ACTIVATES AS IT IS DEPRESSED INDICATOR LIGHT (RED)
2 * HOIST OVERRIDE TURN TO RIGHT IN ORDER TO ENABLE KEYED MAINTAINED
SWITCH – DRILL OVERRIDE MODE SWITCH
FLOOR PODIUM ONLY
3 OVERRIDE (LIGHT) LIGHT FLASHES WHEN THE BRIDGE ENTERS ILLUMINATED
OVERRIDE ZONE INDICATOR LIGHT
(YELLOW)
4 CONTROL PUSHBUTTON FOR TAKING CONTROL OF THE MOMENTARY
PUSHBUTTON (LIGHT) OAC FROM THAT PARTICULAR PODIUM. PUSHBUTTON (SPRING
GREEN ILLUMINATED INDICATOR THAT RETURN TO NEUTRAL)
ACTIVATES WHEN IT GAINS CONTROL AND ILLUMINATED
INDICATOR LIGHT
(GREEN)
5 LEFT JOYSTICK FWD/BACK – LABELED “BRIDGE,” BRIDGE PROPORTIONAL
MOVEMENT FWD OR AFT
LEFT/RIGHT – LABELED “TROLLEY,” TROLLEY
MOVEMENT STBD OR PORT
6 WEIGHT INDICATOR USER WEIGHT DISPLAY ANALOG DISPLAY

7 RIGHT JOYSTICK FWD/BACK – LABELED “HOIST,” HOIST UP OR PROPORTIONAL

DOWN
LEFT/RIGHT – NO FUNCTION

8 FOOT SWITCH REQUIRED TO BE DEPRESSED IN ORDER TO FOOT STEP PEDAL

MOVE ANY FUNCTIONS FROM THE JOYSTICKS (SPRING RETURN TO
NEUTRAL)

* Well Center not Functional on Key Switch

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 SECTION 4: OPERATIONS

4.1 Modes of Operation

There are three distinct modes of operation of the 12k OAC defined below:
 MANUAL OPERATIONS: This is defined as operating the OAC manually from the
hydraulic valve bank located on the OAC Control Panel. This mode is to be used in
emergency situations and/or while setting encoder limits only and the operator must use
extreme caution as this method of operation overrides any and all travel limits and safety
features.
 NORMAL OPERATIONS: This is the normal operation of the OAC from one of the three
Operator's Podiums when all functions of the OAC are working correctly and the travel
limits are set-up properly.
 MAINTENANCE MODE: This method of operation is defined as operating the OAC from
one of the three Operator's Podiums, however the OAC controls will have all travel
restricted to less than 50% of normal speed. This is an automatic feature of the OAC and
will occur when certain electrical issues are detected or when the OAC travel limits have
not been properly set-up.

4.2 Manual (Emergency) Operations

NOTE: Manual operation of the OAC overrides all safety features and travel limits
(electrical).
The main control hydraulic valve bank located on the OAC walkway is equipped with a handle on
each valve section. This allows the OAC to be operated manually and without any electrical
controls. Operation in this manner is designed for emergency use only and at no time should any
load be hoisted in this mode. Additionally, use extreme caution as all ESD, travel limits, safety
parameters, etc. are not active when the OAC is manually manipulated.
Refer to Control Panel Assembly (Section 3.6) for descriptions of the components. The handle and
corresponding valve located the farthest to the right (labeled HYDRAULIC ENABLE) is the main
supply function valve. This valve must be active for any function of the OAC to be active. In normal
operations, this valve is opened electrically provided at least one operator's podium has initiated
control and that there is no emergency stop active. Otherwise, the handle on this valve must be
manually pulled in order for the OAC to operate. Pull and hold this valve handle and follow the
instructions below for manual operation. Located farthest right of the Control Panel Assembly,
after the HYDRAULIC ENABLE section:
 HOIST: The second handle from the right is this Hoist Control Valve. Pushing or pulling
this handle raises and lowers the hoist. Pay careful attention to the position of the swivel
as manual operation allows the operator to pay out too much wire rope or otherwise hoist
too much resulting in contacting the fairlead rollers with the swivel.
 BRIDGE TRAVEL: This is the third handle from the right. This valve controls the
movement of the bridge. Pay careful attention to the position of the bridge as manual
operation will allow the operator to collide parts of the OAC and/or any traveling
equipment.

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  TROLLEY TRAVEL: This is the fourth handle from the right. This valve is used to control
trolley functions. Pay careful attention to the position of the trolley as manual operation will
allow the operator to collide parts of the OAC and/or any traveling equipment.
HOIST SPEED SELECTOR: This valve controls the speed of the hoist and should never
be used in emergency operations.

4.3 Normal (Electrical) Operations

The OAC is designed to be operated from any of the Control Podiums. The control system allows
only one podium to have control at a time. If the control button is pressed on a particular podium,
then that one is assigned control and the remaining podiums are disabled. When the OAC is not
in operation (no command from any joystick or section switch detected by the PLC) for five or
more minutes, the controls system disables all controls and the Hydraulic Enable solenoid is
deactivated. Control can be re-taken by pressing the CONTROL pushbutton on any of the
podiums.
The ESD on each podium remains active at all times and is not related to which podium has
control. Depressing the ESD on any podium, at any time, will immediately activate the emergency
stop system.

4.3.1 Individual Function Descriptions and Instructions

The following is a description of and instructions for operations of each individual function
of the OAC. These are based on normal operations and are not to be used for emergency
or manual operations. Refer to the emergency operating instructions if this mode is
required. Additionally, this section assumes that all travel limits have been properly set,
and all electrical and hydraulic functions are available. If this is not the case, refer to the
appropriate set up or trouble-shooting section.
Hoist:
The hoist SWL is 12,000 pounds.
Slack Wire Prevention:
The OAC control system measures the load on the swivel through the load cell. A
minimum load of approximately 100 lbs. is required in order to allow the hoist system to
lower the load/swivel. If it is detected that the load is below this minimum it is assumed
that the swivel is in contact with the drill floor, fingerboards, etc. and the lowering function
is disabled.
Normal (Low Speed - High Torque) Hoisting Operations:
To hoist or lower a load and/or the swivel depress the foot switch and maneuver the hoist
joystick in the direction required. Increasing the position of the joystick will increase the
speed of the operation.
High Speed Hoisting Operations:
Provided the conditions listed below, the hoist system will automatically shift into high
speed, low torque mode and the speed of hoisting and/or lowering will approximately
double.
 The detected load must be less than approximately 5,000 pounds.

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  The operator must position the joystick at least 90% of its full stroke.
 Reducing the joystick position below 75% will cause the OAC to automatically
default to the lower speed, higher torque, mode of operation.
When properly set up the OAC will limit travel of the swivel at upper and lower limits. The
upper limit is set to allow required hoisting elevations without colliding the swivel and the
fairlead rollers. The lower limit is set to allow the elevators to reach the drill floor or top of
the V-Door as needed.
 The upper limit is set to prevent collision between the OAC and the hoist swivel
(anti-tube lock). As the hoist approaches its upper limit the control system will
decelerate and then stop the hoist function despite joystick commands. Activating
the OVERRIDE function does not override this particular safety limit
 The operational lower travel limit is set according to rig operational requirements.
This point can be at or near the drill floor, the bottom of the V-Door, etc. provided
the limit does not exceed the usable wire rope length. As the OAC hoist
approaches the operational lower limit the control system will decelerate and then
stop the hoist function despite joystick commands. Activating the OVERRIDE
function does override this particular safety limit and allows the hoist to be lowered
beyond the operational lower limit until the absolute lower limit is reached
 The absolute lower limit is a limit that is set according to rig operational
requirements. This feature is designed to maintain, at all times, a minimum of five
wraps of wire rope on the drum. Activating the OVERRIDE function does not
override this particular safety limit
Bridge:
The bridge is controlled by a joystick on each operator‟s podium. Depressing a footswitch
and maneuvering the joystick in the direction required will cause the bridge to move in the
direction required. Increasing or decreasing joystick position will increase or decrease
travel speed.
When properly set, the OAC controls will limit the travel of the bridge on either end of the
Long Travel Rails to prevent high speed contact with the hard travel limit stops.
Trolley:
The trolley is controlled by a joystick on each operator‟s podium. Depressing a footswitch
and maneuvering the joystick in the direction required will cause the trolley to move in the
direction required. Increasing or decreasing joystick position will increase or decrease
travel speed.
When properly set, the OAC controls will limit the travel of the trolley on either end of the
bridge to prevent high speed contact with the hard travel limit stops.

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 4.3.2 Normal Operating Procedures
Setting Encoder Limits
Executing this procedure, it is recommended that the OAC be operated manually. There is
no requirement to set the axis limits in a particular order. For example, the hoist can be
set, followed by the trolley, etc. However, all axes‟ limits must be set before the crane can
be operated normally from the Control Podiums. For each axis, the “A LIMIT” must be set
prior to the “B LIMIT”. If needed, the “B LIMIT” can be set to a different position without re-
setting the “A LIMIT”. If the “A LIMIT” is re-set, then it is required to re-set the “B LIMIT” as
well.

AXIS LIMIT (A) LIMIT (B)

BRIDGE FORWARD SIDE AFT SIDE
TROLLEY STARBOARD SIDE PORT SIDE
HOIST SWIVEL APPROXIMATELY 1 METER DRILL FLOOR LEVEL CONVENIENT
BELOW TROLLEY FAIRLEAD ROLLERS FOR ATTACHING ELEVATORS

1 2 3 4

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 SETTING TRAVEL LIMITS

Instruction Results

1 Apply electrical power to the OAC Power supplied

2 Drive the bridge fully in the direction of BRIDGE “A LIMIT” Bridge at “A” position

3 Drive the trolley fully in the direction of TROLLEY “A LIMIT” Trolley at “A” position

4 Position the swivel approximately 1 meter (3 feet) below the Hoist at "A" position
fairlead rollers

5 On the main control center, locate the travel limit selector Switches accessible
switches and push buttons
The Switch and Buttons are labeled as follow:
1 – LIMIT SET DISABLE/ENABLE
2 – AXIS (BRIDGE/TROLLEY/HOIST)
3 – LIMIT SET A
4 – LIMIT SET B
6 Turn the switch 1 to ENABLE selection LIMIT SET ENABLE selected

7 Turn the switch 2 to BRIDGE selection BRIDGE selected

8 Press button 3 and monitor indication light to ensure the “BRIDGE LIMIT A” is set
display indicates that the limit is being written to the PLC

9 Turn the switch 2 to TROLLEY selection TROLLEY selected

10 Press button 3 and monitor indication light to ensure the “TROLLEY LIMIT A” is set
display indicates that the limit is being written to the PLC

11 Turn the switch 2 to HOIST selection HOIST selected

12 Press button 3 and monitor indication light to ensure the “HOIST LIMIT A” is set
display indicates that the limit is being written to the PLC

13 Drive the bridge fully in the direction of BRIDGE “B LIMIT” Bridge at “B” position

14 Drive the trolley fully in the direction of TROLLEY “B LIMIT” Trolley at “B” position

15 Lower the hoist until swivel is at its desired lower travel limit Hoist at "B" position

16 Turn the switch 2 to BRIDGE selection BRIDGE selected

17 Press button 4 and monitor indication light to ensure the “BRIDGE LIMIT B” is set
display indicates that the limit is being written to the PLC

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 SETTING TRAVEL LIMITS

Instruction Results

18 Turn the switch 2 to TROLLEY selection TROLLEY selected

19 Press button 4 and monitor indication light to ensure the “TROLLEY LIMIT B” is set
display indicates that the limit is being written to the PLC

20 Turn the switch 2 to HOIST selection HOIST selected

21 Press button 4 and monitor indication light to ensure the “HOIST LIMIT B” is set
display indicates that the limit is being written to the PLC

22 Drive the hoist fully in the direction of HOIST “MAX LIMIT” HOIST AT MAX LIMIT

23 IN THE HMI, NAVIGATE TO “SETUP LIMIT” AND PRESS “HOIST MAX LIMIT” is set
“SET HOIST MAX LIMIT”

24 Turn the switch 1 to DISABLE selection Travel limits are now set and
the OAC is ready to resume
normal operations

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 12K OAC NORMAL OPERATING
PROCEDURE
Instruction Results

This procedure describes building stands of tubulars. For laying out

tubulars, follow the instructions in the opposite direction.
1 With deck crane or other equipment, place at least three Tubulars in place
joints of tubulars in the V-Door with the bow end located
above the edge of the drill floor

2 Take control of the OAC from one Operator‟s Podium by Ownership established
pressing the CONTROL pushbutton
GREEN POWER light
illuminated on operator‟s
podium
RED ESD light extinguished
on podiums

3 Rig the required elevators to the OAC swivel Elevators installed

4 Drive the OAC into position where the elevators are OAC in position
located as close as possible to the top of the V-Door

5 Lower the elevators and latch onto first joint Elevators closed on joint

6 Hoist the joint until pin end is clear of drill floor Joint hoisted and suspended
above drill floor

7 Drive the OAC as needed to position the tubular over the Joint in position
mouse hole located nearest to the roughneck

8 Lower joint fully into mouse hole and unlatch elevators Joint located in mouse hole
nd
9 Repeat the above steps with the second joint but place it 2 joint located in mouse
in the second mouse hole hole
rd
10 Repeating the initial steps rig up to the third joint in the V- Rigged up to 3 joint
Door
rd
11 Hoist the third joint and position it over the first joint (in 3 joint stabbed
mouse hole closest to the roughneck)
st
12 Lower the OAC swivel and carefully stab the third joint 1 joint stabbed
into the first. Lower the elevators sufficiently to ensure
that the OAC is not suspending any of the weight

13 Using the roughneck make up the first connection Connection made

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 12K OAC NORMAL OPERATING
PROCEDURE
Instruction Results

14 Use the OAC to hoist the double clear of the mouse hole Double stabbed into single
and stab it into the single in the other mouse hole

15 Using the roughneck make up the second connection Triple made up

16 Hoist the triple clear of the mouse hole Pin end of triple clear of
mouse hole and drill floor

17 Drive the bridge of the OAC away from well center until Triple located just in front of
the triple is just in front of the first finger (far enough away the first finger
from well center to allow the tubular to pass between the
end of the diving board and the front of the top drive)

18 Drive the trolley until the triple is located in line with the Triple located in line with slot
slot on the side of the fiving board (on the side which the along diving board
racking is desired)
The next few steps assume that rotation of the slew is not required to allow the OAC to reach
the desired storage location.
19 Drive the bridge away from well center until triple is Triple aligned with finger
aligned with the slot along the desired racking finger

20 Drive the trolley until the tubular is located at the desired Triple in desired storage
storage location location

21 Lower the OAC until the trip is resting on the drill floor Triple stored and elevators
and supported by the fingerboards. Unlatch the elevators unlatched

22 Drive the trolley and/or bridge until the OAC is again OAC in position to start next
positioned over the V-Door and then lower the elevators triple
as needed
If the storage location is in a position that will require rotation of the slew, the following steps are
required.
23 Make sure that the OAC is in position to allow rotation on Triple located in between
the desired side of the diving board fingers and diving board
ROTATION light illuminated
on operator‟s podium

24 Drive the trolley until the tubular is located at the desired Triple in desired storage
storage location location

25 Lower the OAC until the triple is resting on the drill floor Triple stored and elevators
and supported by the fingerboards. Unlatch the elevators unlatched

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 12K OAC NORMAL OPERATING
PROCEDURE
Instruction Results

26 Drive the trolley and/or bridge until the OAC is again OAC in position to start next
positioned over the V-Door and then lower the elevators triple
as needed

4.4 Failure Mode Operations

In the case of a machine that has not been set up or has lost communication with one of the
encoders, the OAC will stop running. An "ERROR" message will be displayed on the LCD main
control console screen, indicating which particular encoder is busted.
If there is a failure in the load cell or the load cell receiver, the OAC control system will shut down
the OAC and movement will cease. Located inside the main control center (Section 3.5) will be
two selector switches that, when active, will allow the OAC to continue operation without the load
cell being active.
Activating the Load Cell OVERRIDE switch will allow the OAC to resume normal operations
without referencing the load cell. When active, the readouts on the operator‟s podiums will be
inactive. Additionally, the Slack Line Prevention feature and the two speed hoist function will be
inactive. In this case, the default hoist setting will be high torque, low speed. All other OAC
functions will be active and will operate at normal speeds.
There is a Hoist High Speed selector switch beside the Load Cell OVERRIDE switch. The default
or “OFF” position of this selector switch will keep the OAC hoist operating at high torque with a
slower speed. Turning this selector ON will switch the system into high speed, low torque. This
switch is only active when the Load Cell OVERRIDE switch is also active. Caution should be used
when selecting the High Speed function and no loads over approximately ½ the SWL should be
handled. In high speed mode the OAC controls will still allow proportional control of the hoist
system but the resolution will be reduced.
In the event that hydraulic power is lost to the OAC there are methods available to move the OAC
to a safe location. Both of the horizontal travel axis (Bridge and Trolley) are equipped with a
feature built into the hydraulic manifold for each of these travel functions that will allow the tool to
be manually moved if needed. A cartridge valve (stamped and labeled on each individual manifold
as “FREEWHEEL”) in each manifold can be opened. This function will bypass the counterbalance
system and allow the trolley and/or bridge to be moved with a tugger or other means to a safe
location.

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 The following procedure describes preparation of the OAC for service or maintenance.

12K OAC EMERGENCY OPERATING

PROCEDURE
Instruction Results

1 Position personnel as need to be sure the load, swivel, and all Personnel in place
parts of the OAC can clearly be seen.

2 Establish communication with spotters and the person Communication established

operating the OAC from the emergency panel.

3 Pull the HYDRAULIC ENABLE handle out toward the operator. HYDRAULIC ENABLE engaged

NOTE: The previous step is implied throughout the remainder of this portion of the procedure.
The HYDRAULIC ENABLE must be engaged and maintained when all other functions are to be
operated.
4 Move the BRIDGE and/or TROLLEY handle as needed to Load moved to safe location
position the BRIDGE and/or TROLLEY to a safe location
where it can be lowered and removed from the OAC.

5 If required, move the HOIST handle and lower the load. Load secured and disconnected
Disconnect the elevators from the load.

6 Move the HOIST handle and raise the swivel/elevators to a Swivel located above the finger
point clear of the fingerboards. boards

7 Move the BRIDGE and/or TROLLEY handle as needed to OAC is prepared for service or
move the OAC into a safe storage position. maintenance

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4.5 Zone Management (if applicable)
The Forum OAC Control system can be configured to interface with the rigs existing zone
management system. This interface is done through a passive DP coupler that establishes a
communication signal between the OAC PLC and the rigs zone management system.
The DP Coupler shall communicate with the Drilling Control System DCS and will transfer data
related to:
 OAC Bridge Position– data value will be a 16bit word from 0-100%, 0 being the “A” limit
and 100 being the “B” limit. This data will be an input to the rig DCS.
 OAC Trolley Position – data value will be a 16bit word from 0-100%, 0 being the “A” limit
and 100 being the “B” limit. This data will be an input to the rig DCS.
 OAC Hoist Position – data value will be a 16bit word from 0-100%, 0 being the “A” limit
and 100 being the “B” limit. This data will be an input to the rig DCS.
 OAC Lifted Load – data value will be a 16 bit word from 0-120 in 100X lbs. This data will
be an input to the rig DCS.
 OAC Enable Bit– Enable bit monitors to ensure operator is depressing footswitch prior to
allowing operation. This value will be a 1bit binary number, 0 represents no user present,
1 represents presence of user. This data will be an input to the rig DCS.
 OAC interlock confirm – data value will be a 1bit binary number, 0 represents that the
OAC is in interlock, 1 represents that the OAC is NOT in interlock. This data will be an
input to the rig DCS.
 OAC Heartbeat – data will be a 1 bit binary number with a rising edge 1 per second. This
data will be an input to the rig DCS.
 OAC Well Center Override – data will be a 1 bit binary number, 0 represents that the
OAC is in well center override, 1 represents that the OAC is NOT in well center override.
This data will be an input to the rig DCS.
 DCS interlock request – data value will be a 1bit binary number, 0 represents that the rig
DCS is requesting OAC to interlock, 1 represents that the rig DCS is NOT requesting
OAC to interlock. This data will be an output from the rig DCS.
Control system interlocks protect machine and operator from potentially hazardous conditions:
 When DCS sends interlock request, the OAC will not allow user requests to operate the
bridge, trolley, slew or hoist and will send an interlock confirm bit to the DCS.

Page 37 of 51
 SECTION 5: MAINTENANCE

5.1 General Information

The 12k OAC has three main systems:
 Electrical
 Hydraulic
 Mechanical
The electrical system interacts with the operator, supervises the hydraulics, and monitors the
crane mechanical position. The interface between the electrical system and the hydraulic system
is accomplished using a bank of proportional controlled electro-hydraulic valves. The interface
between the mechanical position and the electrical controls is provided by absolute rotary
encoders.
For safety, the mechanical system should be checked frequently to make sure the racks are clear
of debris, encoder are serviceable, the horizontal wheels have the proper clearance, and the wire
rope is suitable for service. Hydraulic filters and hoses should be replaced periodically as required
by service conditions. The electrical system has no scheduled maintenance required after
calibration and initial construction.

5.2 Periodic Checks

5.2.1 Bridge
 Ensure nothing is blocking the bridge rails.
 Inspect rollers/wheels for cracks, tread and sidewall wear.
 Inspect travel pinions and racks for wear.
 Manually operate the bridge from end to end using the valve handles, watch to
make sure the wheels are tracking true and listen for scraping or popping sounds
which can indicate rack damaged spots.
 Ensure the bridge encoder is functional.
 Visually monitor the hose carrier during the test move and make sure none of the
hoses are leaking.
 Ensure there is oil in the gear reducers, periodically (once a month) replacing the
gear oil in the reducers.
 Ensure there is oil in the brakes, periodically (once a month) replacing the brake
oil in the brakes.
 Inspect the Anti-Crabbing system.

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 5.2.2 Trolley, Hoist
 Ensure nothing is blocking the trolley travel.
 Check drum flanges for distortion, bending, weld cracks.
 Inspect rollers/wheels for cracks, tread and sidewall wear.
 Visually confirm that the fairleads have not been damaged.
 Inspect sheaves for tread wear or cracks.
 Inspect travel pinions and racks for wear.
 Test hoist brake against full system pressure.
 Ensure there is oil in the gear reducers, periodically (once a month) replacing the
gear oil in the reducers according to the manufacturer's recommendations in
attached documents.
 Ensure there is oil in the hoist brake, periodically (once a month) replacing the
brake oil in the hoist brake.
 Ensure the trolley and hoist encoder is functional.
 Manually operate the trolley from end to end using the valve handles, watch and
listen carefully for unusual sounds which may indicate wear or misalignment.
 Operate the hoist up and down approximately ten feet while listening to the
reducer. The wire rope must be inspected and replaced at an interval appropriate
to its use AND when kinks, abrasion, corrosion, or broken wires become visible.

5.3 General Electrical System

 Check that the cables/wires are undamaged, and that the podiums are clean and dry.
 Test emergency stops.
 Check paint that keeps metals from rusting; if the paint is damaged, repair it.

5.4 Control Panel Assembly

 Filter element should be changed at least annually (depend on the volume of OAC usage),
and within six months of a start-up.
 Visually inspect for loose fittings and fasteners.

5.5 Lubrication
The only component of the OAC that require daily lubrication is the Swivel body (1016459). Be
sure that the swivel is greased daily or more often during constant operation.
Additionally, the OAC drive train components shall be inspected and lubricated monthly (refer to
Chapter 3 for Component Identification).

Page 39 of 51
 Each Total
Lubricant OEM Recommended
Component Qty Amount Amount Remark
Type Brand & Type
(liter) (liter)
Hoist Inspect &
1 Gear Oil TOTAL GEAROIL EP 85W 140 5.50 5.50
Gearbox replace monthly
CALTEX TEXAMATIC 1888 or Inspect &
Hoist Brake 1 Brake Oil 0.30 0.30
DEXRON ATF replace monthly
Trolley Inspect &
1 Gear Oil TOTAL GEAROIL EP 85W 140 0.37 0.37
Gearbox replace monthly
Bridge Inspect &
2 Gear Oil TOTAL GEAROIL EP 85W 140 2.00 4.00
Gearbox replace monthly
Bridge CALTEX TEXAMATIC 1888 or Inspect &
2 Brake Oil 0.20 0.40
Brake DEXRON ATF replace monthly

These lubricants can be used as alternatives:

LUBE CODE AND DESCRIPTION

General Purpose Grease Motor Grease Hydraulic Oil
Ambient
Above Below All o o o o
Temperature o o o o -10 to 85 C -15 to 75 C
-4 F (-20 C) -4 F (-20 C) Temperatures
Range

Castrol MP Grease - - Hyspin AWS-46 Hyspin AWS-32

Chevron Avi-Motive Avi-Motive W - AW Hyd Oil 46 AW Hyd Oil 32

Exxon Lidok EP2 Lidok EP1 Andox BR Nuto H46 Nuto H32

Gulf Gulf Crown EP32 Gulf Crown EP31 - Harmony 46AW Harmony 32AW

Mobil Mobilux EP2 Mobilux EP1 - DTE 25 DTE 24

Shell Alvania EP2 Alvania EP1 Cyprina RA Tellus 46 Tellus 32

Statoil Uniway EP2N Uniway EP1N - Hydraway HMA 46 Hydraway HMA 32

Texaco Multifak EP2 Multifak EP1 Regal AFB-2 Rando Oil HD46 Rando Oil HD32

Total Multis EP2 Multis EP1 - Azolla ZS 46 Azolla ZS 32

Union Unoba EP2 Unoba EP1 - Unax AW46 Unax AW32

Page 40 of 51
 Gear Oil

ISO VG ISO VG ISO VG ISO VG ISO VG ISO VG ISO VG ISO VG ISO VG

150 220 320 150 220 320 150 220 320
Alpha SP Alpha SP Alpha SP Alphasyn Alphasyn Alphasyn Alphasyn Alphasyn Alphasyn
Castrol 150 220 320 EP 150 EP 220 EP 320 PG 150 PG 220 PG 320

Tegra Tegra Tegra

Ultra Gear Ultra Gear Ultra Gear HiPerSYN HiPerSYN HiPerSYN
Chevron 150 150 320
Synthetic Synthetic Synthetic
150 220 320
Gear 150 Gear 220 Gear 320

Omala Omala Omala Omala HD Omala HD Omala HD Tivela S Tivela S Tivela S

Shell 150 150 320 150 220 320 150 220 320

Meropa Meropa Meropa Pinnacle Pinnacle Pinnacle Synlube Synlube

Texaco 150 150 320 EP 150 EP 220 EP 320
-
CLP 220 CLP 320

5.6 Wire Rope

Wire rope is a complex assembly of carefully arranged, precisely assembled parts. The wire rope
chosen should not be changed without consulting Forum. The wire length stored, the lifting ability,
and the wear rate of the rope are all optimized to the specific application, this is a closely matched
highly engineered system and the wire rope is the most critical part. The wire rope is an anti-rotation
type since there is no block and tackle to keep the rope from spinning, and spinning weakens a rope
drastically. The rope is formed or compacted to a smoother outside which increases the ease with
which the rope can slide past itself on the drum reducing self-abrasion, and smooth rope helps keep
the wear on the drum to a minimum. The width of the drum was chosen so the wire does not have
enough space between the last full wrap and the flange to jam/bind. The manufacturer maintenance
and inspection schedules are included to help make sure the operation of the rope is safe. API
specifies that the rope minimum breaking strength must be 5 X safe working load, and required that
five wraps be left on the drum. The rated lifting distance allows for the five wraps, and we suggest
that the customer never set the encoder up to allow less than five wraps.

WARNING – The operator should NEVER lift loads with a damaged wire rope. The wire rope
should be replaced on the manufactures recommended schedule since internal damage may not be
visible.

Wire rope maintenance should follow API 2D section 5, API 9A and API 9 B for classification the
OAC Hoist is a Heavy Use Crane and should be inspected on the monthly basis in detailed per the
table with daily checks including rope review by the operator, and periodic lubrication as
recommended by the rope manufacturer.

Page 41 of 51
 Replacing a wire rope:
 Lower the hoist wire rope sufficiently to allow the swivel and load cell to be disconnected
on the drill floor
 Guide the swivel and load cell end of the rope out the V-Door or to the desired location
 Once the swivel is disconnected, replace new swivel wire ropes and shackles
 Using manual operating procedures (from the valve bank) lower the hoist until only one full
wrap remains on the drum
 Loosen and remove the hoist wire rope button
 Attach hemp rope or other lower mechanism to drum end of hoist wire rope
 Lower the hoist until there are no wraps remaining on the drum
 Lower the hoist wire rope to drill floor using the hemp line
 Attached hemp line to new hoist wire rope. Ensure that the hemp is properly routed to the
slot in the drum
 Raise new hoist wire rope onto drum slot
 Attach the hoist wire rope button
 Slowly hoist the OAC until the swivel end is in a position to attach the swivel. Be sure to
keep the hoist wire rope lying tight and properly during this stage
 Attach the swivel and load cell
 Raise the swivel until it is near the upper travel limit
NOTE: The travel limit will not be active therefore the operator must use caution
during this step.
 Inspect the drum and ensure all fasteners are installed and that the hoist wire rope is lying
properly in the drum
 Reset hoist upper and lower encoder limits

Page 42 of 51
 SECTION 6: TROUBLESHOOTING

6.1 Problem Identification Flow Chart

It is possible to determine if a problem is caused by hydraulic/mechanical or electrical issues by
attempting to operate the desired axis of the OAC manually at the valve stack. If the OAC does not
function manually, then the issue is likely to be hydraulic/mechanical. If the OAC functions
manually, but not from the podium, then the issue is likely to be electrical.

Page 43 of 51
Page 44 of 51
6.1.1 Electrical Troubleshooting
If the machine will operate by the valve handles but does not run correctly from the podium, then
use this chart.

Page 45 of 51
Page 46 of 51
6.1.2 Hydraulic - Mechanical Troubleshooting
First verify that a hydraulic or mechanical issue is the cause of the problem by attempting to
operate the desired axis of the OAC manually at the valve stack. If the OAC will not function
properly, then follow the steps below.
NOTE: The first handle must be pulled to allow fluid into the valve stack, and then
another valve can allow fluid out to the crane.
The use of several stauff test kits may be required to complete this section.

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 INDIVIDUAL AXIS TROUBLESHOOTING

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