peart - peart 150 drilling machine operating … · • ensure that drilling machine is supported...

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OPERATING INSTRUCTIONS

FOR

Peart 150 Branch

Drilling Machine

1. Machine to be operated by trained personnel.

2. Instructions to be read before use.

Hy-Ram Mansfield Pelham Street Mansfield Nottinghamshire NG18 2EY Tel: 01623 422982 Fax: 01623 661022

Hy-Ram Bury 9 Portland Industrial Estate Portland Street Bury Lancashire BL9 6EY Tel: 0161 7641721 Fax: 0161 7620577

Hy-Ram Enfield Unit 2, Riverwalk Business Park Riverwalk Road Enfield EN3 7QN Tel: 0208 805 8010 Fax: 0208 805 6010

Hy-Ram Livingston 18 Napier Square Houstoun Road Trading Estate Livingston West Lothian EH54 5DG TEL: 01506 440233 Fax: 01506 440266

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Hyram recommend that a pressure test is completed prior to making new connections. The following test pumps are available for hire and purchase.

Important! This manual forms a part of the product to which it relates. It should be kept for the life of the product. Any amendments issued by Hy-Ram Engineering Co Ltd should be incorporated in the text. The manual should be passed to any subsequent holder or user of this product. Safety Information The Peart 150 Drilling Machine should only be used by trained and competent operators. As an operator, always ensure that you fully understand how the equipment functions and that you are fully aware of the dangers. Always wear the necessary protective clothing including adequate eye protection, hard hat, gloves, overalls, protective boots etc.

Prior to commencing work, always ensure that the drill kit is complete and fully serviceable. If in doubt replace.

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Technical Descriptions Specification Nominal branch drill and tap size 50mm (2”) to 150mm (6”) as standard. Can be upgraded to drill 200mm (8”) Maximum working pressure 16 bar. Maximum working temperature 200 c. Boring bar travel 500mm. Power Supply Hydraulic or pneumatic motor suitable for connection to site services. Hand: by ratchet wrench supplied. Speeds Boring bar rotational speed free from load: 28rev/min with air or hydraulic motor. Boring bar automatic feed 0.15mm/rev for cutting. 2.31mm/rev for tapping (11 TP1). Description The Peart 150 underpressure drilling machine is designed to work on gas, water, oil or chemical pipelines up to the specified pressure and temperature limits. The machine is supplied in a wooden box complete with boring bar extension ratchet, wrench, spanner, hexagon wrench (allen key), machine adaptor gaskets and spare seal kits. Cutters, adaptors, motor kits etc, if required are supplied in separate boxes. Weight Basic machine 78kgs.

Do’s and Don’ts Before attaching machine to valve fitting: Do:

• Ensure that pressure and temperature of fluid in pipeline is within machine specification. • Ensure that cutters and pilot drills are sharp and in good condition. • Ensure that the valve gate is fully open. • Ensure that cutter will pass through valve. • Ensure that cutter and pilot drill are securely fastened to the boring bar. • Ensure that cutter can be fully retracted into flange adaptor. • Prior to installation of the drilling machine the operator shall check the traverse of the

boring bar and the indicator scale. • Note the position of the boring bar and record from the indicator scale. • Using the handle provided activate the hand feed mechanism to traverse the boring bar

through a distance between 300mm and 500mm. • Measure the physical distance travelled by the boring bar.

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• Record the indicator scale reading with the boring bar extended. • Check that the physical traverse of the boring bar and the displacement from the change

in indicator readings correspond. • Any difference in between the indicator scale reading and the distance travelled is an

indication that the indicator gearing mechanism is slipping and the indicator scale is providing inaccurate information.

• Drilling MUST NOT be undertaken until the indicator scale is proven to provide accurate positional information.

• The machine MUST Not be allowed to travel beyond the limited 500mm traverse. Don’t:

• Fit blunt or damaged cutters. • Attempt to drill into pipelines containing fluids at higher pressure or temperature than the

machine design allows ( see specification). Fluid must not be capable of corroding machine components. With machine attached to valve flange Do:

• Check that screws on flange are tight. Use the correct number of screws. • Check that the valve can be closed with the cutter fully retracted. • Ensure that drilling machine is supported by suitable packers at gearcase end. • Ensure that the area around the machine is clear and allows easy access to the machine

controls. • Ensure that machine can successfully complete the intended cut without reaching the end

of the boring bar travel. • Ensure valve is fully open before starting to drill.

Don’t

• Allow machine to “hang” on valve flange when drilling horizontally. • Damage pilot drill point by feeding towards pipe to fast. During Drilling Do

• Remove feed handle during automatic feed. Don’t

• Leave the machine unattended whilst drilling. • Allow machine to continue to feed past end mark on indicator. • Feed by hand so fast that the machine stalls. • Put machine into reverse unless removing tap. • Reverse a cutter will damage the teeth.

Stop drilling operation once pilot drill has broken through the main. Interrupt drilling operating between pilot drill breaking through and cup drill commencing its cut this could provide an overload condition on the cup drill causing severe damage.

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After Drilling Do

• Ensure that boring bar is fully retracted before attempting to close valve. • Ensure that pressure in adaptor is release before loosening flange screws. Don’t

• Attempt or close valve with boring bar extended. After removal from Valve Do

• Clean machine and all separate parts and replace in boxes. • Clean, lightly oil and retract machine boring bar. • Leave automatic feed lever off. • Check cutters for damage and obtain replacements if necessary. Unpacking Check that all parts are to hand and in good condition. Cutters and pilot drills should be inspected for chipped or broken cutting edges. Replace any damaged cutters or drills. The detent on the pilot drill should be free to move and shown on signs of damage: faulty detent will result in the coupon being lost during drilling. Assembling machine, motor and cutters Assemble correct machine adaptor to the front flange of drilling machine using correct gasket. A plug or valve should be fitted into the tapped hole on the side of the adaptor flange. Advance boring bar by rotating feed handle anti-clockwise so that it protrudes beyond the adaptor flange. Check that cutter will pass through the open branch valve. Fit cutter and pilot drill to boring bar using the correct cap screw and ensure that the screw is tight. Withdraw cutter into adaptor. Using the correct number and type of flange screws, fit the machine to the valve. We strongly recommend that the branch connection and valve are checked at this stage to ensure that:

• The valve opens and closes satisfactorily. • The connection is pressure tight.

Check the valve is open, fit motor to machine drive spindle.

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IMPORTANT SAFETY NOTICE: Hydraulic and pneumatic motors should be fitted with the correct adaptor sleeves and torque tubes (see drawing). Failure to do so will cause damage to the machine and injury to the operator. Drilling: Disengage automatic feed and wind cutter forward until it touches pipe wall. Note position of indicator on scale to determine break through point. Mark this point on the scale. Start machine and start automatic feed. Machine will be heard to cut. The machine should never be allowed to drill unattended and a close watch should be kept on its progress. In case of trouble, stop the machine and refer to fault finding chart. After machine has reached break through point and cutting has ceased stop automatic feed. Withdraw cutter into adaptor flange with the crank handle: do not attempt to exceed travel of indicator. Close Valve, Bleed excess pressure from adaptor flange by removing plug on side of adaptor Remove machine (reverse of assembly). Tapping The Peart 150 underpressure drilling machine is capable of tapping steel, cast grey and ductile iron with threads of 11 threads per inch. Note: Always ensure that there is end float on the tap. The tap should be capable of being moved along the adaptor approximately 0.5mm with the pilot drill tightened into its socket. If there is no end float, see the fault chart. The procedure is similar to drilling (including checking that the tap will pass through the valve) until the machine is wound forward so that the point of the pilot drill touches the pipe wall. With the pilot drill touching the pipe wall, fit the tapping indicator (UP3641) to the machine scale with the set notch in line with the red indicator. Start machine until the indicator is adjacent to the start tap notch. Stop machine – turn off the automatic feed. Fit lock plate (part number UP3637) to feed spindle.

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Start machine. The indicator scale must be watched continually as the tapping procedure only takes a few minutes. The fitting of the backstop plate (UP3641) will ensure that the tap does not pass right through the pipe wall. When stop tap is reached reverse rotation of the machine to withdraw tap, Continue until indicator is back to start tap. Stop machine remove lock plate and withdraw boring bar by hand. Remove machine from valve as before. Hydraulic drive The hydraulic motor is supplied complete with all necessary valve, adaptors and connectors to enable it to be fitted to the 150 machine. Flow and pressure controls on the manifold block are factory set to give the correct speed and torque characteristics despite variation in the delivery of the power supply. As a minimum the motor requires oil at 136 kg/cm2 (2000psi) and 20 1/min delivery. Any excess from the pump unit is automatically bypassed. Instructions Installation The hydraulic motor should be assembled and installed as shown on drawing (UP3989/B). The torque tube (part number U3780) and the sleeve (part number UP2954) are essential to prevent damage to the machine and injury to the operator: they should NEVER be omitted. The pipe coupling faces should be cleaned before the hoses are connected. Operation The motor is controlled by the lever operated valve mounted on the manifold block. The valve is fitted with a reverse catch which will prevent the valve being accidentally reversed. UNDER NO CIRCUMSTANCES MUST REVERSE BE ENGAGED WHEN DRILLING. Reverse, obtained by simultaneously operating lever and pressing reverse catch, is only to be used for extracting taps. Pneumatic Drive Air motor type CR3270-R-100 is strongly recommended for use with this machine. Please contact Hyram Engineering before attempting to use any other motor. The air motor drive is assembled and installed to the machine drive spindle. As with the hydraulic drive, it is essential or damage to the machine will result. The motor should only be reversed (by operating the catch and twisting the handle) when extracting a tap.

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UNDER NO CIRCUMSTANCES MUST REVERSE BE ENGAGED WHEN DRILLING Air Conditioner Unit Ensure conditioner unit is fitted correctly with the bowls upright and that the lubricator is filled with light machine oil. The filter should be empty before drilling is started. An air supply of 6 to 7 bar (90-100 lb/inc2), 2.32 cu m/min (82 cu ft/min) FAD is sufficient to drive the motor. Oil type

• Airolene. • Shell Tellus 32.

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Certificate of Calibration.

• This product has been inspected and tested in accordance with the ISO9001 quality

control systems and procedures in place at Hyram Engineering Co Ltd.

• This product has no calibration period, periodic, safety inspections should be carried out by the operator if in any doubt please contact the manufacturer for further information

Decommissioning & Disposal Instructions

These give the instructions for decommissioning and disposal of the equipment and confirm how it is to be taken out of service safely, in respect of the Essential Health

and Safety Requirements.

• If a Hyram tool has reached the end of its useful working life and cannot be

refurbished it must be disposed of through a licensed scrap or waste disposal facility. Alternatively, a reverse engineering company could be used to strip the equipment for recycling purposes.

• Disposal is the responsibility of the Customer this can also be achieved by returning the product back to the manufacturer.

Warranty Information. 1. Extent of Warranty. (a) Hy-Ram Engineering Co Ltd warrants to the end-user customer that its products will

be free from defects in materials and workmanship, for six months after the date of purchase by the end-user customer, subject to providing proof of purchase.

(b) If Hy-Ram Engineering Co Ltd receives, during the warranty period, notice of a defect in product which is covered by this warranty, Hy-Ram Engineering Co Ltd shall either repair or replace the product, at its option. Any replacement product may be either new or like-new, provided that it has functionality at least equal to that of the product being replaced.

(c) All warranty work will be carried out by Hy-Ram Engineering Co Ltd unless otherwise agreed. On-site warranty and repair or replacement services are available from authorised Hy-Ram Engineering Co Ltd service facilities world-wide.

(d) Customers shall prepay shipping charges for products returned to Hy-Ram Engineering Co Ltd for warranty service, and Hy-Ram Engineering Co Ltd will charge for return of the products back to the customer.

(e) This warranty statement gives the customer specific legal rights. The customer may also have other rights which vary from country to country in the world.

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Pre-conditions for Warranty Application. Hy-Ram Engineering Co Ltd’ warranty covers only those defects which arise as a result of normal use of the product, and this warranty shall only apply in the following circumstances:

(a) All the instructions contained in the operating manual have been complied with (b) And none of the following apply:

(i) Improper or inadequate maintenance; (ii) Physical abuse; (iii) Unauthorised modification, misuse or any use not in accordance with the

operating manual and good industry practice; (iv) Operation outside the products specifications; (v) Improper site preparation or maintenance; and (vi) Faulty pipe or fittings.

Limitations of Warranty.

(a) Hy-Ram Engineering Co Ltd does not warrant the operation of any product to be uninterrupted or error free. (b) Hy-Ram Engineering Co Ltd makes no other warranty of any kind, whether express or implied, with respect to its products. Hy-Ram Engineering Co Ltd specifically disclaims the implied warranties of satisfactory quality and fitness for a particular purpose. (c) To the extent that this warranty statement is inconsistent with the law of the locality where the customer uses the product, this warranty statement shall be deemed modified by the minimum necessary to be consistent with such local law. (d) To the extent allowed by local law, the remedies provided in this warranty statement are the customer’s sole and exclusive remedies. (e) This tool has been designed for the range of fittings available at the time of its design and development. Hy-Ram Engineering Co Ltd can accept NO liability for the unit’s ability or otherwise to work with new or different fittings that subsequently appear in the market place.

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Please complete this information and keep it safely with your proof of purchase receipt. You will require it for any warranty claim.

Where purchased ...................................................................................

Date of purchase ................................................................................... Name & address ................................................................................... Of purchaser ................................................................................... ................................................................................... Type of tool ...................................................................................

Serial number ...................................................................................

For Service and repair please contact:

Hy-Ram Mansfield Pelham Street

Mansfield Nottinghamshire

NG18 2EY Tel: 01623 422982 Fax: 01623 661022

peart - peart 150 drilling machine operating … · • ensure that drilling machine is supported...

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