knight oil tools pipe straightening machine

Revision: 1 Date: 9.24.14

KTM-011-1 (2005-Present) of 14

Operation and Maintenance Manual

PIPE STRAIGHTENING

MACHINE

Customer: Location: Job #: Local Rep: Rep Phone # Document #

Knight Oil Tools, Manufacturing 700 E Texas Ave. Rayne, LA 70578 Phone: (337) 334‐6969 Fax: (337) 365‐6565 www.knightmanufacturinginc.com



Table of Contents Introduction ...................................................................................................................................................... 3 Safety .................................................................................................................................................................. 3 Machine Specifications .................................................................................................................................... 4

Standard Features ................................................................................................................... 4 Optional Features ................................................................................................................... 4 Specifications ......................................................................................................................... 4 Pipe Plant Requirements ........................................................................................................ 4

Machine Setup .................................................................................................................................................. 5 Controls ............................................................................................................................................................. 5

Standard PSM-75/125 Controls ............................................................................................. 5 Equipment Layout ........................................................................................................................................... 7 Trouble shooting guide ................................................................................................................................... 9 Daily Preventative Maintenance .................................................................................................................... 9 Intermediate Preventative Maintenance ....................................................................................................... 9 Parts List .......................................................................................................................................................... 10

Ball Transfer Jack Stand ...................................................................................................... 10 Roller Assembly................................................................................................................... 11 On Board Jack Stands .......................................................................................................... 12

Schematics ....................................................................................................................................................... 13 Hydraulic Schematics .......................................................................................................... 13 Electrical Schematics ........................................................................................................... 14

Service Call: 337.857.5309

Email: [email protected]

Spare Parts

Call: 337.334.6969 Visit: www.knightoiltools.com/HCIW

Sales

Call: 337.334.6969 Email: [email protected]



Introduction

PIPE STRAIGHTENING MACHINE Knight’s pipe straightener is a manually controlled machine designed to efficiently bring pipe back to an acceptable straightness. This manual will cover both 75 and 125 ton machines, with and without optional jack stands. Designed with cost effectiveness in mind, Knight’s PSM couples performance with value.

Safety Knight has provided operating procedures and safety information to ensure the wellbeing of both the operator and the equipment.

This operating manual contains important safety information - please read it thoroughly. Safety Features Include:

Mechanically active components are painted safety yellow. Safety guards Equipment safety labels.

DO NOT ATTEMPT TO DEFEAT ANY OF THE INSTALLED SAFETY FEATURES ON THIS

MACHINERY

IMPROPER USE OF THIS MACHINE CAN CAUSE SEVERE INJURY OR DEATH



Machine Specifications

Standard Features

Included hydraulic power supply Multiple ranges 75 ton electrically operated system

Optional Features

Hydraulically operated mobile jack stands for positioning bends. Hydraulically operated rollers for loading, unloading and positioning. 75 ton Diesel operated system 125 ton electrically operated system

Specifications

2-3/8” through 6-5/8”diameter Test module

o Length 50’ 6” o Width 6’ 4” o Height 77.9”-86” o Ship Weight 4,000 lbs

Jack stands spread out a maximum distance of 50’

Pipe Plant Requirements

Electrical 230/480V, 3 Ph, 60 Hz 48 Kw (Others available upon request)

Rack height 37”-45” adjustable



Machine Setup

1. Machine is to be placed on a level, stable surface. A concrete slab is highly recommended. 2. Rack height can be field adjusted. Support top structure with overhead lifting and remove

the 4 pins in the legs. Very carefully lift or lower top assembly to desired height. Replace pins. Set jack stands about 5 1/2” below the height of the straightener.

3. Wiring is to be connected by a qualified electrician. 4. Plumb jack stands, if equipped, according to hose length. 90 degree crimp fittings connect

to the higher fittings while straight connectors connect to the bottom. Motor hoses and corresponding fittings are to be marked with matching numbers.

5. Check oil level in reservoir. Level should be on the upper end of the sight gauge as oil level is expected to drop during bleeding. Fill as required.

6. Remove case drain line from pump and fill case with hydraulic oil. Reinstall line. 7. Start the unit by moving switch to the on position. Monitor oil level in the reservoir

constantly during the next steps as oil level may drop unpredictably. 8. Set compensator to lowest pressure. Set jack stands on their side with connections facing

upward. Cycle each cylinder several times so that all air is evacuated out of the system. If it is apparent that not all air can be purged in this manner, it may be necessary to reposition jack stand so that the air can better escape.

Controls Standard PSM-75/125 Controls



(Standard Control Layout – Specific Control Locations May Change)

Function Description

1 Pressure Compensator

Adjusts pressure output at the pump. Indirectly affects flow. The Higher the pressure, the slower the flow.

2 Pressure Indicator Visual indication of system pressure.

3 Main cylinder Pressing down on handle lowers the main cylinder. Pressing up raises the main cylinder.

4 Left Onboard Jack Stand Cylinder Pressing down lowers the left cylinder, Pressing up raises the left cylinder

5 Right Onboard Jack Stand Cylinder Pressing down lowers the right cylinder, Pressing up raises the right cylinder

6 Left Outer Jack Stands Pressing down lowers the left jack stands, Pressing up raises the left jack stands

7 Rolling Jack Stands Pressing down lowers the rolling jack stands. Pressing up raises the rolling jack stands

8 Right Outer Jack Stands Pressing down lowers the right jack stands, Pressing up raises the right jack stands

9 Motor Controls Pressing down moves pipe left Pressing up moves pipe right.



Equipment Layout

Function Description 1 Roller pins Holds

2 Power switch Turns unit off and on.

3 Die A cradle for the pipe to sit in during straightening.

4 Ram Cylinder Main cylinder that performs straightening.

5 Operator Station Controls to operate mechanics of the machine.

6 On-board Jack Stands Moves up and down and allows pipe to spin. Moves independent of each other.

7 Roller Jack Stands Moves up and down and transverses pipe in and out of the machine.

8 Left Outer Jack Stands Moves up and down and allows pipe to spin. Moves independent of right jack stands.

9 Right Outer Jack Stands Moves up and down and allows pipe to spin. Moves independent of left jack stands.



Process Setup

1. Straightening pipe takes a practiced hand and is best left to only a few select individuals to operate the equipment. New operators should be allowed to practice on scrap joints before straightening repairable pipe.

2. Back the pressure off system with compensator knob. Leaving the pump set at a high pressure, while not under load, may cause system to halt and damage to the equipment may occur.

3. Select the correct die required for the pipe to be straightened. The die should be the smallest die that easily fits over the bent section.

4. Set roller adjustment according to the radius of the bend. The larger the radius of the bend, the farther out the rollers will need to be. Jack stands can be moved in and out to better suit the individual pipes need.

5. Load pipe into machine. 6. Position the bend directly under hydraulic ram. Use available controls to help position

pipe as required. Jack stands may be moved up and down to help hold the pipe in position. Raise the jack stands so that pipe can spin freely by hand. The peak of the bend should be the highest point and directly under the ram cylinder. A dial indicator can be used to find the high point if bend is slight. Mark high point. Lower pipe onto rollers.

7. Actuate the main cylinder control downward until die comes in contact with the bend and the die no longer moves.

8. Assuming that the pipe still has a bend in it, and while the main cylinder spool is still depressed, slowly turn the pressure compensator knob until the ram moves desired distance. Allow spool valve to reset to center position. Back off the compensator. Press up on the main cylinder control to raise cylinder.

9. Lift pipe off of pins so that it rests only on ball transfers. Spinning the pipe by hand will allow the operator to visually see if the deviation is within an acceptable range. A dial indicator can also be used to give a visual indication of deviation.

10. Repeat steps 5 through 8 until the pipe is acceptably straight. 11. Drift the pipe with the appropriate drift as per API.

.



Trouble shooting guide Straightener fails to turn on Check breaker/fuse box for blown fuse or tripped

breaker. Check that diesel and oil are present in diesel powered units. Call for a Knight technician to service equipment.

Pipe is hard to rotate Check that power roller is not in contact with pipe during rotation Check that pipe is completely off roller pins. Check that ball transfers spin freely. Replace ball transfers. Call for a Knight technician to service equipment.

Jack stands will not synchronize lift Check that there are no leaks in any of the hoses. Replace or tighten leaky hoses. Check fluid level in the machine. Work cylinders in and out to remove any air that may be in the system. See machine setup for tips on how to remove air. Call for a Knight technician to service equipment.

Machine kills when ram cylinder is moved Compensator is set too high for no load. Set compensator to lowest setting. Call for a Knight technician to service equipment.

Machine fails to bend pipe that is within specified limits

Compensator set to low. See operating instructions on how to adjust compensator while bending. Air in hydraulic system. Check oil level in machine. Work cylinder in and out to evacuate air. Call for a Knight technician to service equipment.

Daily Preventative Maintenance

1. Check oil level daily. Fill as required. 2. Check hoses and fittings, cylinders, etc for leaks daily. Leaks may cause machinery to

not operate as designed and can cause a low oil condition. 3. Check wiring for kinks, frays, and stripped insulation. Repair and replace as necessary.

Intermediate Preventative Maintenance

4. Hydraulic reservoir should be drained and cleaned with a suitable solvent every 2 years. When the tank is drained, remove the suction strainer and clean with solvent.

5. Change hydraulic filters on machine yearly. 6. All electrical control boxes should be opened and wires should be inspected thoroughly

*** This should not be done unless the machine is off and is properly locked out/tagged out.***

7. Check high stress areas for cracks in welds and base metals annually.



Parts List

Ball Transfer Jack Stand

ITEM NO.

PART NUMBER DESCRIPTION

1 14248 BALL TRANSFER 2 125-700-012-00 BALL TRANSFER MOUNT 3 27881 FLAT HEAD SOCKET CAP SCREW 4 125-100-005-018 JACK STAND BRACKET 5 125-100-006-025 JACK STAND SLIDE BAR 6 17730 SHAFT WIPER 7 125-100-028-XXX BUSHING 8 29119 RETAINING RING 9 14502 SOCKET HEAT CAP SCREW 10 14140 LOCK WASHER 11 17649 FLAT WASHER



Roller Assembly

ITEM NO.


1 13896 V ROLLER 2 14615 BEARING 3 27881 FLAT HEAD SOCKET CAP SCREW 4 125-100-005-018 JACK STAND BRACKET 5 125-100-006-025 JACK STAND SLIDE BAR 6 17730 SHAFT WIPER 7 125-100-028-XXX BUSHING 8 29119 RETAINING RING 9 14502 SOCKET HEAT CAP SCREW 10 14140 LOCK WASHER 11 17649 FLAT WASHER 12 125-100-036-018 V ROLLER BRACKET 13 004-206-003-018 SPACER 14 16391 MOTOR 15 14000 COUPLING



16 17163 SET SCREW 17 16487 NUT 18 17656 FLAT WASHER 19 14145 LOCK WASHER 20 14312 BOLT 21 14140 LOCK WASHER 22 17649 FLAT WASHER 23 006-700-006-00 MOTOR BRACKET

On Board Jack Stands

ITEM NO.


1 14494 FLAT HEAD SOCKET CAP SCREW 2 21602 BALL TRANSFER 3 104-700-021-00 BALL TRANSFER BRACKET 4 15150 CYLINDER



Schematics

Hydraulic Schematics



Electrical Schematics

knight oil tools pipe straightening machine

Documents

machine specifications

daily preventative maintenance

machine setup

present page

standard features

rep phone

local rep

standard psm