Revision: 1 Date: 9.24.14
PIPE STRAIGHTENING MACHINE Operation and Maintenance Manual
Hub City Iron Works 700 E Texas Ave. Rayne, LA 70578 Phone: (337) 334-6969 Fax: (337) 365-6565 www.hubcityironworks.com
KTM-011-1 (2005-Present)
Customer: Location: Job #: Local Rep: Rep Phone # Document #
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Revision: 1 Date: 9.24.14
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: 337.334.6969 Email: servicerequest@hubcityironworks.com Spare Parts Call: 337.334.6969 Visit: www.hubcityironworks.com Sales Call: 337.334.6969 Email: sales@hubcityironworks.com
KTM-011-1 (2005-Present)
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Revision: 1 Date: 9.24.14
Introduction
PIPE STRAIGHTENING MACHINE Hub City Iron Works’ 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, Hub City’s PSM couples performance with value.
Safety Hub City 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
KTM-011-1 (2005-Present)
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Revision: 1 Date: 9.24.14
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
Rack height
KTM-011-1 (2005-Present)
230/480V, 3 Ph, 60 Hz 48 Kw (Others available upon request) 37”-45” adjustable
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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
KTM-011-1 (2005-Present)
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Revision: 1 Date: 9.24.14
(Standard Control Layout – Specific Control Locations May Change)
KTM-011-1 (2005-Present)
Function
Description
1 2
Pressure Compensator Pressure Indicator
Adjusts pressure output at the pump. Indirectly affects flow. The Higher the pressure, the slower the flow. Visual indication of system pressure.
3
Main cylinder
4
Left Onboard Jack Stand Cylinder
5
Right Onboard Jack Stand Cylinder
6
Left Outer Jack Stands
7
Rolling Jack Stands
8
Right Outer Jack Stands
9
Motor Controls
Pressing down on handle lowers the main cylinder. Pressing up raises the main cylinder. Pressing down lowers the left cylinder, Pressing up raises the left cylinder Pressing down lowers the right cylinder, Pressing up raises the right cylinder Pressing down lowers the left jack stands, Pressing up raises the left jack stands Pressing down lowers the rolling jack stands. Pressing up raises the rolling jack stands Pressing down lowers the right jack stands, Pressing up raises the right jack stands Pressing down moves pipe left Pressing up moves pipe right.
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Equipment Layout
KTM-011-1 (2005-Present)
Function
Description
1 2
Roller pins Power switch
Holds
3
Die
4
Ram Cylinder
5
Operator Station
6
On-board Jack Stands
7
Roller Jack Stands
8
Left Outer Jack Stands
9
Right Outer Jack Stands
Turns unit off and on. A cradle for the pipe to sit in during straightening. Main cylinder that performs straightening. Controls to operate mechanics of the machine. Moves up and down and allows pipe to spin. Moves independent of each other. Moves up and down and transverses pipe in and out of the machine. Moves up and down and allows pipe to spin. Moves independent of right jack stands. Moves up and down and allows pipe to spin. Moves independent of left jack stands.
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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. .
KTM-011-1 (2005-Present)
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Revision: 1 Date: 9.24.14
Trouble shooting guide Straightener fails to turn on
Pipe is hard to rotate
Jack stands will not synchronize lift
Machine kills when ram cylinder is moved Machine fails to bend pipe that is within specified limits
Check breaker/fuse box for blown fuse or tripped breaker. Check that diesel and oil are present in diesel powered units. Call for a Hub City technician to service equipment. 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 Hub City technician to service equipment. 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 Hub City technician to service equipment. Compensator is set too high for no load. Set compensator to lowest setting. Call for a Hub City technician to service equipment. 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 Hub City 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.
KTM-011-1 (2005-Present)
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Revision: 1 Date: 9.24.14
Parts List Ball Transfer Jack Stand
ITEM NO.
PART NUMBER
DESCRIPTION
1
14248
BALL TRANSFER
2
125-700-012-00
3
27881
4
125-100-005-018
JACK STAND BRACKET
5
125-100-006-025
JACK STAND SLIDE BAR
6
17730
7
125-100-028-XXX
8
29119
RETAINING RING
BALL TRANSFER MOUNT FLAT HEAD SOCKET CAP SCREW
SHAFT WIPER BUSHING
9
14502
SOCKET HEAT CAP SCREW
10
14140
LOCK WASHER
11
17649
FLAT WASHER
KTM-011-1 (2005-Present)
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Revision: 1 Date: 9.24.14
Roller Assembly
ITEM NO.
PART NUMBER
DESCRIPTION
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
7
125-100-028-XXX
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
KTM-011-1 (2005-Present)
SHAFT WIPER BUSHING
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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.
PART NUMBER
1
14494
2
21602
3
104-700-021-00
4
15150
KTM-011-1 (2005-Present)
DESCRIPTION
FLAT HEAD SOCKET CAP SCREW BALL TRANSFER BALL TRANSFER BRACKET CYLINDER
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Schematics Hydraulic Schematics
KTM-011-1 (2005-Present)
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Electrical Schematics
KTM-011-1 (2005-Present)
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