kg act 3121269

Operator's ManualKellyguard™ Actuator, PN 3121269

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Manual 9602B

KELLYGUARD™ ACTUATORPART NO. 3121269

OP

ER

ATOR

'S M

AN

UA

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Pressure Control Equipment


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CONTENTS

PAGESECTION 1.0 OPERATION AND INSTALLATION

1.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 2.0 PHYSICAL DATA

2.1 Actuator Operating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.2 Wrench Size and Torque Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.3 Lubrication Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.4 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION 3.0 MAINTENANCE

3.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION 4.0 ASSEMBLY AND DISASSEMBLY

4.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SECTION 5.0 TROUBLESHOOTING

5.1 Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SECTION 6.0 DRAWINGS AND PARTS

6.1 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216.2 Top Drive Conversion Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Please contact Hydril Pressure Control Equipment for any assistance or questions concerning the information in thismanual. All information contained in this manual is the exclusive property of Hydril Company.

HYDRIL COMPANY/P.O. BOX 60458/HOUSTON, TEXAS 77205TELEPHONE: (281) 449-2000FAX: (281) 985-2828

© 2001 Hydril Company Printed In The USA, March 2001. All Rights Reserved.


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SECTION 1.0 OPERATION AND INSTALLATION

1.1 Features

▼ The HYDRIL® Kellyguard™Actuator sets a newstandard for safety, performance, and ease ofmaintenance. The pneumatically operatedKellyguard™ Actuator remotely operates upperIBOP valves on top drives and power swivels. Thedesign also allows manual operation with theactuator in place. Moving linkages are totallyenclosed within the rotating body. It is also theideal actuator for upper kelly cocks for kelly drillingand ball valves with cylindrical bodies for produc-tion manifolds.

▼ Provides 600 lb-ft of torque, more than anyother IBOP actuator. This power provides sureclosure of the Kellyguard™ against powerful kicks,substantially improving rig safety over earlier ac-tuator designs.

▼ The HYDRIL® Actuator is easy to maintain.Very few parts are subject to wear. The simpledesign saves time during removal and disassem-

Figure 1-1. HYDRIL® Kellyguard™ Actuator System

bly operations. Removal requires about 15 min-utes, and replacement of piston seals requiresabout an hour. The actuator can be overhauled onthe rig floor with common hand tools by installingthe replacement seal kit.

▼ Fits most top drives and power swivels. Thesmall outside envelope completely encloses allmechanisms.

▼ Powered by normal rig air pressure, 90 - 125psi. The low pressure requirement allows use ofexisting pneumatic systems on virtually every drill-ing rig.

▼ Keeps Kellyguard™ open during drilling op-erations. The weight of the piston and the frictionof the piston seals keeps the Kellyguard™ openduring rough, jarring drilling such as surface holeand air drilling.

Kellyguard™

Actuator


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1.2 Principle of OperationThe HYDRIL® Kellyguard™ Actuator (refer to Figure1-2) provides pneumatic and manual operation of aHYDRIL® Kellyguard™ valve that is installed in a topdrive application. Connected to the top drive struc-ture by means of four tie-back blocks, the upper andlower stators remain stationary as the body of theactuator turns with the Kellyguard™.

Operation of the Kellyguard™ valve occurs whenair pressure enters the Open or Close ports of theactuator. When the air pressure enters the Open portinto the Open operating chamber, the piston movesdown and opens the Kellyguard valve by means of alink connected between the piston and the crank(refer to Figure 1-3). Air in the Close operatingchamber vents out the Close port. When the airpressure enters the Close port into the Close operat-ing chamber, the piston moves up and closes theKellyguard™ valve by movement of the link and crankin the opposite direction (refer to Figure 1-4). Air in the

Figure 1-2. Kellyguard™ Actuator Operation

Open PortOpen OperatingChamberCrank

Link

Piston

Close OperatingChamber

Close Port

Kellyguard™ Valve

Stationary

Stationary

Tie-Back BlocksUpper Stator

Lower Stator

Open operating chamber vents out the Open port.NOTE: The service life of the rotating seals isreduced significantly if air pressure to the actua-tor is maintained while rotating at drilling RPMs.With no pressure on the actuator, only the weightof the piston is required to hold the valve in theopen position. Therefore, it is important to mountthe actuator onto the Kellyguard™ valve in thepreferred upright position as shown in Figure 1-2).

The preferred pneumatic control circuit (refer toFigure 1-11) supplies air to the actuator only when rigpersonnel maintain operation by means of a springcenter control switch or valve. When the switch orvalve is released, the control circuit returns to aneutral or vented condition. Optimum operation isachieved when the pneumatic control valves andquick exhaust valves are located as close as possibleto the actuator.

CLOSE

OPEN

Rotates


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OpenAir Out

CloseAir In

Figure 1-3 . Kellyguard™ Actuator In Open Position,and Kellyguard™ Valve Open.

Figure 1-4 . Kellyguard™ Actuator in Close Position,and Kellyguard™ Valve Closed.

CloseAir Out

OpenAir In


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CLOSE

OPEN

Figure 1-6. Sleeves resting on Kellyguard™ splinewith retainer ring installed.

SleeveHalves

RetainerRing

Spline

IndicatorMark

CLOSE

OPEN

1.3 Installation

Figure 1-7. Kellyguard™ in close position. Indica-tor mark points to the right.

Refer to Figure 6-1 in Section 6 and Figures 1-5through 1-10 while following this procedure. CAU-TION: Installation onto a VARCO Top Drive requiresinstallation of a spacer ring in the link adaptor beforeinstalling the Hydril® Kellyguard™ actuator (refer toFigure 1-5). The spacer ring is contained in the HydrilConversion Kit (kit contains two different size spacerrings that correspond to the respective top drive) .Refer to the Conversion Kit Parts list in Section 6.2 forthe part number.

1.3.1 Spacer Sleeve Installation1. Place the two halves of the mounting sleeve (item

128) around the Kellyguard™. The groove on theoutside diameter of the sleeve must be on top.Line up the groove. Refer to Figure 1-6.

2. Install the retaining ring (item 131) into the grooveon the sleeve. Refer to Figure 1-6.

3. Rotate the mounting sleeve until the large holesalign with the Kellyguard™ cranks. Allow thesleeve to slide down and rest on the splines.

1.3.2 Actuator Preparation1. Close the actuator. Refer to Figure 1-7.2. Remove the two crank retainer lock nuts (item

136), lock washers (item 137), and the crankretainer (item 129) from the actuator assembly.Remove the crank shafts.

3. Back out the two locating pins (item 138) farenough so as not to obstruct the inner bore of theactuator.

Kellyguard™

Top Drive Stem

Link Adapter

Landing Collar

Hydril Spacer Ring

Figure 1-5. Hydril Spacer Ring Installation


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OPEN

CLOSE

Witness mark

Figure 1-8. Actuator crank in Close position.

OPEN

CLOSE

Witness Mark

Figure 1-9. Kellyguard™ crank in Close position.

1.3.3 Kellyguard™ Preparation1. Close the Kellyguard™. Refer to Figure 1-7.

1.3.4 Actuator Installation1. Orient actuator (tie rod nuts up) to the

Kellyguard™. Note the rotation of the Kellyguard™and actuator cranks. The witness marks on theends of the cranks of both the Kellyguard™ andthe actuator should be pointing in the same direc-tion. If they are not, rotate the actuator 180degrees relative to the Kellyguard™. Refer toFigures 1-8, 1-9, and 1-10.

2. Slide the actuator up onto the mounting sleeve(item 128). The retaining ring (item 131) shouldrest on the upper rotor (item 105).

3. Makeup the two locating pins (item 138) until theybottom on the Kellyguard™ body, then back outapproximately one-half turn.

4. Slide the actuator up until the two locating pinscan be made up into the receiving holes in theKellyguard™. Makeup the two locating pins intothe receiving holes.

5. Slide the crank shafts (item 106) into theKellyguard™ cranks with the keys aligned withthe slots in the crank arms and the witness markpointing to Close. The crank shafts may berotated slightly to align the male hex on the crankshafts with the receiving female hex on theKellyguard™ cranks.

6. Install the crank retainers (item 129), lock wash-ers (item 137), and lock nuts (item 136).

7. Secure the actuator to the top drive structure withthe four stator tie-back blocks (item 121). Theapparatus used to secure the actuator shouldhave 1500 pound tension load capacity. Provideenough slack to allow for movement of the drivestructure relative to the actuator/drill stem as-sembly. Refer to Figure 1-10.

8. Connect 125 psi maximum air supply to the 3/8-inch NPT Open and Close ports.

9. Cycle the Kellyguard™ actuator assembly fromclose to open several times to verify proper op-eration.

1.3.5 Break-In PeriodThe new rotating inner seals (item 109/111) should berun-in before using the assembly. Rotate the drillstem at no more than 50 RPM for l0 minutes with noair pressure applied to the actuator.

CLOSE

OPEN

Figure 1-10. Actuator in upright position.

StatorTie-BackBlocks

Spline

Tie RodNuts

Kellyguard™

Actuator

CrankRetainer

Nuts andWashers


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Figure 1-11 . Preferred Pneumatic Control CircuitControl Switch on Driller's Panel: 3-Position, Spring-Centered

OPEN

CLOSE

RIG AIR IN

VENTCLOSE OPEN

Quick Exhaust

Quick Exhaust

CLOSE

OPEN

1.4 RemovalRefer to Figure 6-1 in Section 6 while following thisprocedure.

1.4.1 Actuator Removal1. Turn off the air supply and bleed the air pressure

from the actuator.2. Disconnect the air supply lines from the actuator.3. Remove the apparatus that is used to secure the

actuator to the top drive structure from the fourstator tie-back blocks (item 121).

4. Remove the nuts (item 136), lock washers (item137), and crank retainers (item 129).

5. Slide the crank shafts out of the Kellyguard™cranks. NOTE: A 1/4-20UNC internal thread isprovided at the bottom of the female hex on thecrankshaft for a pulling tool.

6. WARNING: SUPPORT THE ACTUATOR BE-FORE CONTINUING. Back out the two locatingpins (item 138) from the receiving holes in theKellyguard™ far enough so that they do notcontact the mounting sleeve (item 128). Slide theactuator down until it is off of the sleeve.

7. Remove the retaining rings (item 131) from themounting sleeve and remove the sleeve halvesfrom the Kellyguard™.


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2.1 Actuator Operating Data

SECTION 2.0 PHYSICAL DATA

2.2 Wrench Size and Torque DataTable 2-2

ITEM PART THREAD WRENCH TORQUE NO DESCRIPTION NUMBER SIZE SIZE LB-IN (N•m)

Table 2-1

Bore 8 1/2 In

Operating Pressure 125 PSI Air

Tension Load Capacity of Securing Apparatus 1500 Lb

Open/Close Air Supply Port Size 3/8" NPT

Operating Torque 600 Lb-Ft

Operating Temperature Continous Service –20o to 180o F/–29o to 82o C

Storage/Handling –40o to 212o F/–40o to 100o C

Weight-Single (Approximate) 150 Lb

a Item number refers to parts list and Figure 6-1 in Section 6.

Internal/External Surfaces Teflon® Base Grease

Seals Teflon® Base Grease

Threadsa Never Seezb

2.3 Lubricant DataTable 2-3

a For screw and nut threads requiring torque.b A thread lubricant with a coefficient of friction of 0.069 may be substituted.

111 Button Head Cap Screw 1900388-0303 10-24 1/8 Hex Key Tight

115 Hex Nut 1900389-5020 1/2-20 UNF 3/4 Hex 320 (36)

114 Hex Head Cap Screw 1900044-04014 1/4-20 UNC 7/16 Hex 32 (3.6)

122 Hex Head Cap Screw 1900186-06012 3/8-16 UNC 9/16 Hex Tight

136 Lock Nut 40-507033 3/8-24 UNF 3/8 Hex Tight


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2.4 Dimensional Data

Figure 2-1

A Actuator Width, Rotating 14 3/4

B Actuator Width, Non-Rotating 13 11/16

C Actuator Height, Non-Rotating 13 7/32

D Actuator Height, Rotating 8 9/32

E Crank Centerline 8

F Bore, Rotating (Not Shown) 8 1/2

DimensionSize(In)

Table 2-4

E

CD

A

B


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SECTION 3.0 MAINTENANCE

a Refer to Figure 6-1. b Paragraph where maintenance procedure is located. c Lubricate only whendisassembled.

3.1 Maintenance SchedulePeriodic maintenance is a very important part ofkeeping the HYDRIL® Kellyguard™ Actuator in goodoperating condition. Not only will regular mainte-nance extend the service life of the equipment, but itwill also help to eliminate unnecessary down time.This section contains a maintenance schedule (Table

3-1) that is designed to help maintain the Kellyguard™Actuator by displaying in tabular form the recom-mended service interval for each required mainte-nance operation. In addition, the paragraph wherethe maintenance procedure can be found in thissection is also included.

3.1.1 Six Week MaintenanceInspect and lubricate the upper and lower stators ofthe Kellyguard™ Actuator after six weeks of opera-tion.

A. Materials Required1. Teflon® base grease2. Standard U.S. handtools

B. Procedure1. Disassemble the upper and lower stators.2. Lubricate the upper and lower stators with a small

amount of grease. CAUTION: Do not applyexcessive amount of grease to stators. Ex-cessive grease may cause heat buildup anddamage seals.

3. Assemble the stators.4. Operate and observe for air leaks. If air leaks are

present, refer to troubleshooting information inthis manual.

3.1.2 One Year MaintenanceInspect the seals and bearings after one year ofoperation.

A. Materials Required1. Teflon® base grease2. Standard U.S. handtools3. Replacement seals and bearings

B. Procedure1. Disassemble the actuator.2. Clean thoroughly.3. Inspect seals and bearings. Replace as neces-

sary.4. Assemble the actuator. Apply a small amount of

grease to upper an lower stators upon assembly.CAUTION: Do not apply excessive amount ofgrease to stators. Excessive grease maycause heat buildup and damage seals.

5. Operate and observe the actuator for air leaks. Ifair leaks are present, refer to troubleshootinginformation in this manual.

TABLE 3-1MAINTENANCE SCHEDULE

Maintenance OperationsI = Inspect; L = Lubricate;

R = Replace

Item No. a Equipment/Component Service Interval & Maintenance Operations Ref. b

Six Weeks One Year

126 Upper & Lower Stators I,Lc 3.1.1

109/101-109/113 Seals I,R 3.1.2

118,132,133 Bearings I,R 3.1.2


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4.1 DisassemblyRefer to Figure 4-1 while following the proceduresbelow.

4.1.1 Tools and Materials Required.1. 5/16" hex key wrench2. 7/8" hex key wrench3. Puller tool with 1/4"-20 UN thread, Hydril Part No.

31173594. 3/4" hex wrench5. 7/16" hex wrench6. 9/16" hex wrench7. 1/8" hex key wrench

4.1.2 Disassemble Into Subassemblies1. Remove the upper rotor subassembly from the

actuator as follows:a. Unscrew the tie rod nuts (item 115) as far as

possible.b. Lift the upper rotor subassembly up as far as

possible.c. Continue steps a and b until the subassembly

is free of the actuator.2. Remove the lock nuts (item 136), lock washers

(item 137), and the crank retainers (item 129)from the crank shaft openings.

3. Pull the crank shafts (item 106) from the actuatorusing the puller tool.

4. Unscrew the locator pins (item 138) from theactuator.

5. Remove the outer cylinder (item 103) and theinner cylinder (items 102).

6. Unscrew the tie rods (item 117).7. Remove the piston subassembly (item 101).

4.1.3 Disassemble the Piston Subassem-bly1. Remove the dowel pins (item 116) and the crank

arms (item 107) from the links (item 108).2. Remove dowel pins (item 116) and the links from

the piston (item 101).3. Remove the bearings (item 133) from the links.4. Remove the retaining rings (item 120), piston

guide bushings (item 112), tie rod bearings (item132), and the T-seals (item 109/106) from thepiston (item 101).

4.1.4 Disassemble the Upper Rotor Sub-assembly1. Remove the tie-back blocks (item 121) from the

stator (item 126) by removing the screws (item122).

2. Remove the screws (item 114) and washers (item113) from the bearing retaining ring (item 127).Allow the ring to rest on the upper rotor (item 105).

3. Remove the stator from the upper rotor.4. Remove the bearing retaining ring from the upper

rotor.5. Remove the retaining ring (item 130) and the

bearing (item 118) from the upper rotor.

4.1.5 Disassemble the Lower Rotor Sub-assembly1. Remove the tie-back blocks (item 121) from the

stator (item 126) by removing the screws (item122).

2. Remove the screws (item 114) and tab washers(item 125) from the bearing retaining ring (item127). Allow the ring to rest on the lower rotor (item104).

3. Remove the stator from the lower rotor.4. Remove the bearing retaining ring from the lower

rotor.5. Remove the retaining ring (item 130) and the

bearing (item 118) from the lower rotor.

SECTION 4.0 ASSEMBLY AND DISASSEMBLY


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Figure 4-1 . Actuator Assembly, Part No. 3121269

104

107

106

114 113

111

108

116

116132

118130

114

126

127128

129

105

103

101

125

138

121122

131

134

133

112

120

117

102

115

110

135

136

137

109/111

109/101

109/106

109/102 109/103

109/108

109/107109/105 109/104

109/110

109/113

109/112


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RetainingRing

Bearing

Rotor

Rotor

Figure 4-3

Figure 4-2

4.2 AssemblyRefer to Figures 4-1 through 4-18 while following theprocedures below. NOTE: The item numbers refer tothe assembly drawing, Figure 4-1.

4.2.1 Tools and Materials Required.1. Any Teflon® base grease2. Never-Seez thread lubricant (coefficient of fric-

tion is 0.069) or equivalent3. 1/8" hex key wrench4. 5/16" hex key wrench5. 7/8" hex key wrench6. 3/4" hex wrench7. 7/16" hex wrench8. 9/16" hex wrench9. Pipe wrench

4.2.2 Lubrication1. Lubricate all internal surfaces, external surfaces,

and seal surfaces with a Teflon® base greaseupon assembly. CAUTION: Do not applyexcessive amount of grease to stators (item26). Excessive grease may cause heat buildupand damage seals.

2. Lubricate all seals with a Teflon® base greaseupon assembly.

3. Lubricate capscrew threads requiring torque withNever-Seez thread lubricant (coefficient of fric-tion is 0.069) or equivalent.

4.2.3 Assemble Upper and Lower RotorSubassembliesNOTE: The upper and lower rotor subassemblies areassembled in the same manner. Follow the proce-dure that follows for each subassembly.

1. Place the bearing retainer ring (item 127) in theinside diameter of each rotor. Install the bearing(item 118) into each rotor (items 104 and 105).Refer also to Figure 4-2.

2. Install the retaining ring (item 130) into each rotor(items 104 and 105). Refer also to Figure 4-3.

BearingRetainerRing


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Stator

Figure 4-6

Figure 4-5

Figure 4-4

3. Install the seals (item 109/111) into each stator(item 126). The cups or lips of the seals must faceinward toward each other. Refer also to Figure 4-4.

4. Install the stators onto the rotors, being careful notthe damage the seals. With the stators in place,lift each retainer ring up and install it onto thestator, using the lock washers and the screws(items 113 and 114) for the upper stator and thetab washers and screws (items 114 and 125) forthe lower stator. (NOTE: the lower stator is theone installed on the rotor with threaded holes forinstallation of the tie rods.) Tighten the screwsusing 32 lb-in (3.6 N•m) torque. Refer also toFigure 4-5.

5. Install the inner O-ring seal (item 109/104) and theouter O-ring seal (item 109/105) into the seal ringgrooves in each rotor (items 104 and 105). Referalso to Figure 4-6

RetainerRing

Screw

Stator

Seals

Bearing

Rotor

Rotor

Outer Seal

Inner Seal


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Retaining Ring

4.2.4 Assemble the Piston Subassembly1. Install the piston inner seals (item 109/107) into

the seal grooves in the inside diameter of thepiston (item 101). Install the piston outer seals(item 109/108) into the seal grooves in the outsidediameter. Refer to Figure 4-7 for seal orientation.

2. Press two bearings (item 133) into each of the twolinks (item 108).

3. Install the links into the two slots in the piston byinserting dowel pins (item 116) through the bodyof the piston. NOTE: Orient each link so that it canconnect to the crank arms (item 107).

4. Install the crank arms, one on each side, onto thelinks by inserting a dowel pin (item 116). Allow thecrank arms to rest on the piston for now as shownin Figure 4-8.

5. Install a tie rod bearing (item 132), T-seal (item109/106), piston guide bushing (item 112), andretaining ring (item 120) into each tie rod bushingbore in the piston as shown in Figure 4-9.

6. Turn the lower stator and rotor assembly so thatthe bottom of the rotor is face up.

7. Position the piston on the rotor so that the tie rodbores in the piston align with the threaded holes inthe rotor.

8. Install the tie rods (item 117) through the bushingsinto the rotors and make up tight. CAUTION: Donot use a wrench on the small diameter.

Figure 4-7

Figure 4-9

Figure 4-8

Bushing

Bearing

Piston

Lower Rotorand Stator

Link

Crank ArmLink

DowelPins

Piston

Tie Rod

Bearings

Dowel Pin

Piston

InnerSeals

OuterSeals

T-Seal


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4.2.5 Assemble the Actuator Assembly1. Install the tie rod seal (item 109/101) into the

groove on the end of each tie rod (item 117). Referalso to Figure 4-10.

2. Install the outer crank seals (item 109/103) intothe groove in each crank opening in the outercylinder (item 103). Refer also to Figure 4-11.

3. Install the inner crank seals (item 109/102) intothe grooves in each crank opening in the innercylinder (item 102). Refer also to Figure 4-12.

Figure 4-10

Figure 4-12

Figure 4-11

InnerCylinder

Seal

CrankOpening

Seal

Tie Rod

CrankOpening

Seal

OuterCylinder


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Inner CylinderOuter Cylinder

LocatingPin

Figure 4-15

Figure 4-14

4. Install the locating pin seals (items 109/110; 109/112; and 109/113) onto each locating pin (item138). Refer also to Figure 4-13.

5. Install the dowel pin (item 135) into the hole in theinner cylinder. Refer also to Figure 4-14.

6. Install the inner cylinder (item 102) through thepiston and onto the lower rotor (item 104) so thatthe dowel pin in the cylinder aligns with the dowelpin locating groove in the rotor. Push the cylinderdown until the dowel pin is engaged fully.

7. Install the outer cylinder (item 103) over the pistonand onto the lower rotor so that the groove in theouter cylinder mates with the orienting key slot.

8. Inspect the inner and outer cylinders to ensurethat the crank openings and the locating pinopenings are aligned.

9. Install the orienting key (item 110) onto the lowerrotor using the button head screw (item 111).

10. Install the locating pins (item 138) through thelocating pin holes in the inner and outer cylinders.Screw in the pins until tight. Refer also to Figure4-15.

Inner Cylinder

Outer Cylinder

Dowel Pin

Orienting Key

Rotor

Figure 4-13

Locating Pin

Seal (109/110)

O-Ring Seal (109/113)

Backup Ring (109/112)

Locating Pin


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11. Hold the crank shaft (item 106) with the male hexfacing the crank opening in the outer cylinder.With the witness mark pointing up, insert theparallel key (item 134) into the slot. If positionedwith the link on the left, insert the key into the slotpointing down and to the left. Refer also to Figure4-16.

12. Insert the crank shaft (item 106) through theopening. Pickup the crank arms (item 107) andslide the crank shaft through. Continue to pushthe crank shaft through until the crank shaft bot-toms. Repeat for the other side.

13. Install the crank retainers (item 129), the lockwashers (item 137), and the lock nuts (item 136)on both sides. Refer also to Figure 4-17.

14. Install the dowel pin (item 135) into the hole in theinner cylinder (item 102). Refer also to Figure 4-18.

15. Install the upper stator and rotor subassemblywith the upper rotor (item 105) down onto thecylinders (items 102 and 103) so that the dowelpin groove in the upper rotor aligns with the dowelpin. Position the hex tie rod nuts (item 115) in theopenings where the tie rods (item 117) will fitthrough prior to final positioning of the rotor. Startthe nuts onto the tie rods. Finally, push the rotordown into position on the cylinders. Tighten the tierod nuts.

16. Install the orienting key (item 110) and the buttonhead screw (item 111) into the upper rotor. Thekey should mate with a slot in the outer cylinder.

17. Install the stator tie-back blocks (item 121) andscrews (item 122).

18. Manually function the actuator with a 7/8" hexwrench in the female hex in the crank (item 106)several times. NOTE: It may be necessary to usetwo wrenches.

Figure 4-16

Crank Arms

Key

Retainer

Crank Shaft

Upper Stator & Rotor

Key

Dowel Pin

Tie Rod & Nut

Outer Cylinder

Inner Cylinder

StatorTie-Back

Figure 4-18

Figure 4-17

CrankRetainer

Nuts

Lock Washer


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SECTION 5.0 TROUBLESHOOTING

Problem Probable Cause

1. Actuator fails to operate in either direction. Inadequate air supply to actuator.

Actuator installed on IBOP 180o out of proper

orientation.

Crank arms or keys are not engaged with crank

shafts.

Links and crank arms are not oriented correctly

inside actuator.

2. Actuator opens but only closes half way. Crank shaft is not installed through at least one

crank arm.

3. Motion is erratic or slow. Exhaust on opposing chamber is restricted.

Inadequate air supply to actuator.

Excessive operating torque required by IBOP.

4. Motion stops before reaching full open or Excessive operating torque required by IBOP.

full close.

5. Air Swivel requires excessive torque to New rotating seals need to be "run in."

rotate or runs hot.

Air is maintained on chamber.

Interference exists in swivel rotating elements.

Bearings are worn.

6. Link adapter on top drive stem hitting Hydril spacer ring not installed in link adapter of

top of actuator. top drive stem (see Figure 1-5).


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PAGE21

SECTION 6.0 DRAWINGS AND PARTS

Part NameItemNo.

No.Req.

PartNumber

6.1 Parts List – Refer To Figure 6-1.

Actuator Assembly 1 3121269

101 Piston 1 3116041

102 Inner Cylinder 1 3120337

103 Outer Cylinder 1 3123289

104 Lower Rotor 1 3116044

105 Upper Rotor 1 3116045

106 Crank Shaft 2 3117773

107 Crank Arm 4 3124238

108 Link 2 3115116

▼109 Seal Kit 1 3123112

▼109/101 Tie Rod Seal, O-Ring 4 1900002-112

▼109/102 Inner Crank Seal, O-Ring 2 1900002-024

▼109/103 Outer Crank Seal, O-Ring 2 1900002-031

▼109/104 Inner Cap Seal, O-Ring 2 1900002-373

▼109/105 Outer Cap Seal, O-Ring 2 1900002-381

▼109/106 Tie Rod Seal, T-Seal 4 1920070-208

▼109/107 Piston Inner Seal 2 1920701

▼109/108 Piston Outer Seal 2 1920702

▼109/110 Locating Pin Seal, O-Ring 2 1900002-016

▼109/111 Rotating Inner Seal, Polypak 4 1920635-1

▼109/112 Back Up Ring 1 1920012-013

▼109/113 Inner Cylinder Pin Seal, O-Ring 2 1900001-013

110 Orienting Key 2 3116432

111 Screw, Button Head 2 1900388-0303

112 Piston Guide Bushing 4 3116433

113 Washer, Lock 8 1900296-09

114 Screw, Hex Head 16 1900044-04014

115 Nut, Hex, Tie Rod 4 1900389-5020

116 Pin. Dowel 4 1900151-1224

117 Tie Rod 4 3115119

118 Bearing, Ball 2 1920574-13

119 Nameplate 1 3108362-03

120 Ring, Retaining 4 1900103-125

121 Block, Stator Tie-Back 4 3116436

122 Screw, Hex Head 8 1900186-06012


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Part NameItemNo.

No.Req.

PartNumber

(Parts List Continued. Refer To Figure 6-1.)

6.2 Conversion Kits

Kellyguard Description 5 1/4-10,000 5 1/4"-10,000 5 1/4"-15,000 5 1/4"-15,000

With Without With Without

Load Shoulder Load Shoulder Load Shoulder Load Shoulder

Conversion Kit* 3116102 3116104 3116103 3116105

1 Plate Mods, VARCO TD S-3 3115324 3115324 3115324 3115324

2 Spacer Ring- 7.5" ID VARCO SP 3116999 3116999 3116999 3116999

3 Spacer Ring- 9.1" ID VARCO TD 3117554 3117554 3117554 3117554

4 Kellyguard Actuator Assembly 3121269 3121269 3121269 3121269

5 Kellyguard Actuator Seal Kit 3123112 3123112 3123112 3123112

6 Kellyguard Assembly 3109790 3116090 3116080 3116100

7 Repair Kit for 5.25"-15M Top Drive 3109779 3109779 3109779 310779

8 Installation Kit for Kellyguard Top 3116229 3116229 3116229 3116229Drive VARCO

* Items 1 through 8 are contained in coversion kit.

123 Plug, Hex Socket (Not Shown) 4 1900126-04

124 Screw, Drive 9 1900061-06

125 Washer, Tab 8 1920638-1

126 Stator 2 3116042

127 Ring, Bearing Retainer 2 3116043

128 Sleeve, Mounting 1 3115244

129 Crank Retainer 2 3123297

130 Ring, Retaining 2 1900135-196

131 Ring, Retaining 1 1900133-180

132 Bearing, Tie Rod 4 3117715

133 Bearing, Spherical 4 1900362-04

134 Key, Parallel 2 1900161-0812

135 Pin, Dowel 2 1900151-0507

136 Locknut, Crank Retainer 4 40-507033

137 Lockwasher, Crank 4 1920638-2

138 Locating Pin 2 3123237

▼ Recommended Spare Parts for 1-Year Service. Seal Kit 3123112 Contains

Items (109/101-109/113)


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PAGE23

Figure 6-1 . Actuator Assembly, Part No. 3121269

104

107

106

114 113

111

108

116

116132

118130

114

126

127128

129

105

103

101

125

138

121122

131

134

133

112

120

117

102

115

110

135

136

137

109/111

109/101

109/106

109/102 109/103

109/108

109/107109/105 109/104

109/110

109/113

109/112


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Pressure Control Equipment

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Documents

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