Operators Manual

Operators Manual

1 Thunderstorm 1

Operators Manual

2 Thunderstorm 1

Thunderstorm 1 Operators Manual Rev. 14.3

2765 Florance Rd. P. 940-479-2200 Thunderproducts@wyoben.com Ponder, TX. 76259 F. 940-479-2210

Operators Manual

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Operators Manual

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Table of Contents:

Lifting Your Thunderstorm 1……………………………………...……………………………………… 5

When First Receiving Your Thunderstorm 1 …......………………………………………………………. 5

Tether Option ……………………………………………………………………………………………. 9

Getting Started ………………………………………………………………………...…………………11

Grounding the Thunderstorm 1...…………………………………………………………………...…… 12

Mixing Bentonite ……………………………………………………………………………………...… 15

Send Fluid to Rig ……………………………………………………………………………………..…. 16

Fluid Level ……………………………………………………………………………………………… 16

Send Fluid to Shaker ……………………………………………………………………………………. 17

Cleaning ………………………………………………………………………………………………… 18

Screens ………………………………………………………………………………………………….. 18

Lift Pump/Pit Pump ...………………………………………………………………………………….. 19

Cones …………………………………………………………………………………………………..... 20

Generator Service ……………………………………………………………………………………….. 21

Main Electrical Box ……………………………………………………………………………………... 22

Daily Maintenance ………………………………………………………………………………………. 22

Weekly Maintenance …………………………………………………………………………………….. 23

Using Information from Testing Fluid ………………………………………………………………… ... 23

Winterizing ……………………………………………………………………………………………… 24

End of Crossing ………………………………………………………………………………………… 26

* Subject to change without notice.

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Lifting your Thunderstorm 1: CAUTION: The Thunderstorm 1 is left side heavy (generator side), use the lifting D-rings provided only.

When first receiving your Thunderstorm:

Check oil, fuel and coolant/anti-freeze levels in generator.

Clean leaves and any debris out of tanks and off of hopper.

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Make sure the 2” pipe plugs (tank drains) have Teflon tape, are installed and tightened.

Inspect screens for holes, check wedges on shaker and tighten using the wedges prying supports or rubber mallet as needed (Be Careful! Do not poke a hole in the screens).

Remove the two sets of transport lock-pins on the side of the shaker. Fill air bags on shaker. Side air bags: 10 - 25 PSI. Front air bag: 10 - 25 PSI (Pressure not important as long as there is no metal to metal contact). Always transport unit with air bags deflated and both transport Lock-pins installed.

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Verify the generator’s fuel valve is open (bottom of fuel tank near radiator).

Turn on the generator’s Battery Disconnect Switch (located below the Main Electrical Box) and switch the main breaker to the “ON” position, Pull E-STOP button out and ensure all electric motors Start/Stop buttons are in “Stop” position.

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To start the generator, push and release “AUTO” button, then push and release “RUN”

button. It will take a few seconds to preheat and then it will start.

Starting with the shaker, test each function for 3 seconds then shut off each function. When shutting generator off, you must press and release the generator control panel

“OFF” button.

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Note: The E-stop will stop all motors immediately and turn off the generator after 3 seconds.

Note: All of our generators run on clean fuel only! Make sure you have additional fuel filters on hand. Your fuel has to be kept clean! If you are fueling from a transfer tank (make sure transfer tank has fuel filter), change inline filter every 250 hrs. Part # 108 or equal.

Tether Option: The tether option allows the operator to control the “MIX/RIG” and “PIT” pumps from the

operator’s seat. There are two modes: In Platform Mode, all operations are conducted from the reclaimer’s platform. In Tether Mode, the “Mix & Rig” and “Pit” pumps are operated from a Tether Control away from the reclaimer.

Note: It is advisable for personnel to inspect the unit often when using the Tether Control.

Note: If the reclaimer is in Tether Mode and Tether Control is not connected, the generator will activate the E-Stop and will not start unless the Tether Control gets connected or you switch the reclaimer to Platform Mode.

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In Tether Mode:

A. The Generator can be started only from the Platform. B. E-Stops on the Platform and on the Tether Control will shut off all motors instantly

and turn OFF the generator after 3sec. C. “Mix/Rig” and “Lift/Pit” pumps can be operated from the Tether Control ONLY.

Those pumps CAN NOT be operated from the Platform. D. “Shaker” and “Cones” pumps can be operated from the Platform only not from the

Tether Control. In Platform Mode:

A. The Generator can be started only from the Platform. B. E-Stop on the Platform will shut off the pump’s motors instantly and turn OFF the

generator after 3sec. The E-Stop on the Tether Controller will not work. C. All pumps and motors can be operated from the Platform only, the Tether Control

will not operate any function.

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Getting started:

Find a level area or level an area to locate the Thunderstorm. Setup the Thunderstorm so Lift/Pit Pump hose will reach the return pit and you are able to see drill but away of the driller’s work area. The solids come off of rear of unit. If you are reclaiming from the exit pit, you will need a vacuum truck or a transfer pump to send the spoils back to the reclaimer.

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Grounding the Thunderstorm: Caution: The unit is a 480 volt system! Don’t skip this step! Locate the “Ground Plate” on the pump side of the Thunderstorm and verify the length of the attached ground wire. Dig a 24” X 24” X 24” deep hole within the reach of the attached ground wire. Set the Ground Plate at the bottom of the hole and cover it up with the dirt.

Add fuel to the Fuel Tank if required. If you add fuel out of a transfer tank, you may have to change fuel filters more often.

Remove the shaker’s transport pins and fill all air bags on the shaker with air. Side air bags: 10 - 25 PSI. Front air bag: 10 - 25 PSI. The front air bag is used to increase the shaker’s angle (Air pressure is not important as long as there is no metal to metal contact. However, with more air pressure in the front air bag, the angle on the screens will be less, and consequently, the spoils will run across the screens faster).

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Always transport the unit with air bags deflated.

Lower the spoils chute by unhooking the spoil chute’s chain from the shaker and carefully lower the spoils chute. It is required that you air up the side air bags first before unhooking the spoil chute’s chain. To transport the reclaimer, use the reverse order: Hook the spoil chute’s chain first, then deflate the airbags second.

Grease Lift/Pit pump bearings and place it in the return pit (Do not submerge electrical motor in fluid). Attach the 3” hose and power cord. Keep electric motor above ground level. If the centrifugal pumps has a grease fitting in the packing glands, you will need to grease them. If the centrifugal pumps have a plug instead of a grease fitting, then you do not need to grease the packing gland, since they are mechanical seals.(Pictures on the next page)

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If Thunderstorm is trailer mounted, lower jacks and level before filling with water. Mixed

bentonite weighs about 9.5lbs per gallon, plus the weight of Thunderstorm (6,800lbs/3,090Kg), plus the weight of the trailer. You could get up to 20,000lbs/9,090Kg.

Open all inlet/outlet valves to the centrifugal pumps except the “TO RIG” outlet valve. Fill Thunderstorm with water. Always fill over shaker screens in the dirty tank. Check PH of water. Stabilize if over 9 by adding soda ash. Recheck PH every time you

change your water source. If you are filling from a water truck the first tank may be influenced from your last job. It is best to check PH daily.

Turn generator’s Battery Disconnect Switch “ON”. Switch main breaker to “ON”. Pull all E-STOPS out. Put all Start/Stop buttons in the “Stop” position and start generator.

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Start the “Shakers” first, “Cones” second (when enough fluid is present in dirty tank), “Mix” third (when enough fluid is present in clean tank). All three will stay on most of the time. No order for powering off. Start the “Lift Pump/Pit Pump” as needed.

Tools needed:

o Mud test kit, including sand content, scale and PH test strips. o Pry bar and rubber mallet for tightening screens. o Wrench for plugs. o Grease gun. o Operators Manual.

Mixing Bentonite Mix bentonite at the mixing table until desired viscosity is reached. Should be 5 minutes

per bag or as the bentonite manufacturer’s recommendation. When mixing bentonite open the mixing valve and close off the floor jet’s valve. When you have finished mixing the bentonite, open the floor jet’s valve and close the mixing valve.

Do not let centrifugal pumps run dry (empty tank) for any length of time. The fluid keeps the packing glands cool.

The fluid supplying the cones is from the dirty tank. After being processed by the cones, the fluid goes to the clean tank. When the clean tank is full, it will over flow back into the dirty tank to get clean again. The more this process happens the cleaner the fluid is.

NOTE: Do not be concerned with sand being discharged from cones. Water and bentonite have sand in them. If clumps of bentonite are being discharged from cones slow down process of dumping bentonite in hopper. Read the manufacturer’s recommended dumping rate in the back of bentonite’s bag. Usually it is 5 minutes per bag. NOTE: Do not overflow tank. It is best to keep the tanks 90% full.

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Send fluid to rig:

Attach the drill’s 2” hose to the “Mix & Rig” pump, then open the valve. Always use a rigid hose instead of fire or pump discharge hose, very important on rigs requiring high flow. There may be air in the hose. You can bleed it out at the drill or it will eventually work its way out.

Once the hose to the rig is attached and valve is open, there is no need to shut off the “Mix & Rig” pump valve, as long as the floor jets and/or the hopper valves are open. It will help keep the clean tank agitated.

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Fluid level:

Do not overfill the dirty tank! Fluid should overflow from the clean tank to the dirty tank, if the dirty tank overflows to the clean tank, the drilling fluid going to the Drill will not be clean.

Send fluid to shaker:

Attach the 3” hose from the Lift Pump/Pit Pump to the 3” Drilling Fluid Valve. Open the Drilling Fluid Valve (You can adjust the amount of fluid going onto the scalper

screens by regulating the Drilling Fluid Valve). Connect the Lift/Pit Pump power cord. Once there is enough fluid in the return pit, turn ON the Lift/Pit Pump to send fluid to the

shaker.

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Never let sand or polymers dry on screens. Wash off screens often. Always wash off at the end of a shift.

Cleaning:

The bottom screens, scalpers, do the first pass of cleaning. Use the screens to take out as much of the solids and sand as possible. The best case scenario is if the fluid almost runs off the shaker but doesn’t.

o You need to have just enough fluid coming back to keep up with drilling process. If you have to shut off pit pump and wait for the fluid level to go down in tank, you can probably use finer screens. If your sand content is below 1%, you don’t need to change anything.

o Adjust the angle of the shaker using the front air bag to keep fluid on longer or speed up the flow across the screens.

o Change screens to a finer screen if all the fluid is falling thru the first screen or change to coarser screen if fluid is running off shaker.

o The finer the scalper screens, the less work the cones have to do.

The cones do the fine cleaning, down to 15 microns, but only take out about 90% of the sand per pass. The dirtier the fluid in the dirty tank, the more passes are required. Allow the cones to clean and re-clean as often as possible. The cone pump draws from the dirty tank and sends it into the clean tank. As the clean tank gets full, it will overflow back into the dirty tank allowing the cones to clean again. This is why it is important to keep the clean tank agitated and everything suspended. The more passes the cones clean, the cleaner the drilling fluid will be going back to the drill.

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If there is a hole or tear in the screens the cones have to work harder (more passes). It is very important to monitor the screens. This may lead to premature wear of the mud pump on the drill.

If you get a tear in a screen it will show up when testing for sand content. Best to test for sand every hour and record.

Keep screens clean. Do not allow mud or polymer to dry on the screens. Wash screens often with fresh water or with the provided garden hose and sprayer if no fresh water is available.

Screens: Standard Screens (In API Designation): Due to variances in soil conditions there is no screen set that will work on every soil type in every region and on every hole. Experience and a good assortment of screens will help you fine tune your reclaimer for every job.

Scalper (Bottom Screens) – 60 “Back” (Close to spoils chute), 45 “Front” (Under the Mud

Dump Box)

Cones (Top Screen) – 120 (Underneath the Cones)

Rule of thumb: Blinding screens- Select finer screens.

Cones fluid overflow- Select one step coarser screen.

Cones overload- Select finer scalper screens.

Scalper fluid overflow- Select one step coarser Back screen and/or one step coarser Front

screen.

The goal is to use as fine a screen as possible without fluid running off the shaker. Adjusting the angle using the front air bag will help.

If all the fluid falls thru first screen and never makes it to next screen then the screen is too coarse and should be finer. The angle of the shaker can be adjusted down (more air in front airbag) to move fluid faster and may alleviate the problem.

Never leave anything on screens to dry, including polymers, it will plug the screens. Wash off screens often and at end of shift.

The wedges for the screens will float. Still it is best to not drop them when changing screens.

You can use 100% silicone in a caulking gun to repair a tear in screens while waiting for another screen or waiting for down time to replace screens.

It is best to keep a good selection of screens at hand.

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Lift/Pit Pump:

The Lift pump/Pit Pump works best when hung or spaced off the bottom of the return pit.

Try to keep the big pieces away from bowl. Always use the basket/ guard that is provided with Lift Pump/Pit Pump.

Caution: Do not submerge electric motor under water:

If something gets lodged in Lift Pump/Pit Pump it may throw a breaker. If breaker is adjusted correctly it will trip. Consult your local dealer if the Lift Pump/Pit Pump continues to trip the breaker. Remove Lift Pump/Pit Pump and remove obstacle and then restart and test. Now place back into return pit, avoiding the obstacles.

Caution: Always Lock Out/Tag Out the Battery Disconnect Switch before working in the Main Electrical Box:

The cord to the Lift Pump/Pit Pump has a ground included in it, but does no good if Thunderstorm is not grounded. Ground Lift Pump/Pit Pump if Thunderstorm is not grounded.

If no fluid is being transferred to shaker for an extended time, turn off the Lift Pump/Pit Pump.

Inspect impeller, bearings, shaft and coupling in Lift Pump/Pit Pump, replace if worn. The entire impeller assembly (Part #920) includes bearings, shaft and coupler.

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Cones:

The Cones can last up to 2 years, but they can wear earlier depending on how much they have been cleaning throughout the year. A good sign of wear is the excessive fluid discharge from the nozzle and decrease cleaning performance.

Cone inspection: 1- Remove the cone from the manifold by removing the 2” Victaulic clamp (1) and the 4

flange bolts. 2- Remove the Nozzle Nut (6) and Nozzle (5) from the cone body (4). 3- Remove the cone’s T-Bolt clamp (3) to separate the cap (2) from the body (4). 4- Look inside the cap for signs of wear and/or grooves near the inlet’s bore. 5- Look inside the body for signs of wear and/or grooves near the nozzle output.

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Generator Service:

Part Numbers: 1. Oil Filter- #109 2. Inline Fuel Filter- #108 3. Perkins Main Fuel Filter- #107 4. Air Filter- #113

The Thunderstorm 1 comes standard with a Tier 4i engine powering the Gen Set. All Tier 4 engines require clean fuel.

Replace 5/16” Inline Fuel Filter every 250 hours. Part #108 Service engine including all filters after the first 100 hours. Service engine at 500 hours interval, 1000 hours, 1500 hours… for the life of the unit. Check Air Filter every100 hours. Contact your Perkins Dealer for information on Emission control service.

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Main Electrical Box:

Caution: Always Lock Out/Tag Out the Battery Disconnect Switch before working in Main Electrical Box.

Every 6 months, open the Main Electrical Box and make sure all electrical connections and items are tight and secure, including overload breakers, motor starters and transformer.

All the electric motor overload breakers and starters are located inside Main Electrical Box. The wiring code and colors are the same. L1 or T1 is black, L2 or T2 is red, L3 or T3 is blue

and ground is green. There is no neutral on 480VAC 3phase.

Daily Maintenance

If centrifugal pumps have a grease fitting in the packing gland, grease every 6 hrs. If it has a plug in the packing gland then you do not have to grease it, since it is a mechanical seal.

Clean area around packing glands. Grease Lift pump every 6 hrs.

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Weekly Maintenance:

First sign of generator RPM fluctuation change all fuel filters. Inspect bolts connecting air bags. Tighten if necessary. Inspect Lift Pump/Pit Pump power cord. Fix or replace as needed. Inspect shaker screens for tears and holes. Replace as needed. Tighten or replace packing in centrifugal pumps as needed. Do not over tighten! Over

tightening will cause premature wear. Inspect and tighten shaker motor bolts to 380 ft/lbs. Inspect impeller shaft, bearings and coupler on Lift pump/Pit Pump, replace as necessary.

Using information from testing fluid:

Test the PH of the water. It is best to keep the PH between 8 and 9. Add soda ash if above 9. Check daily or when you change water source.

Mix bentonite in water to get desired viscosity and chart it. As soil conditions change, you will know how to respond.

You may have to mix a second tank of drilling fluid to fill tank and return pit. Before you start cleaning the returns, get a weight of new and clean drilling fluid. Chart it. For best results your return weight should not go up higher than 30% than the original

clean drilling fluid weight. Test mud weight at the return pit and compare to original weight of new and clean fluid. Drilling speed and flow rates will control the percentage of solids in the return pit. More than 30% of the cuttings in return pit will close up your hole.

Test cleaned drilling fluid daily. Compare with the original clean drilling fluid. If it is 10.5lbs or heavier, you have too much silt and need to do some deep cleaning or replace some or all the fluid in the tank.

Deep cleaning is running full drilling fluid circulation without drilling for half an hour or until the mud weight gets close to the original weight.

Test for sand content every hour, this only takes a few minutes, and can save a mud motor or the mud pump on the drill.

Keep track of amount of water that is added during a crossing and where. This will tell you a lot about formations and if an additive is needed. If you are gaining water, you need to be aware of where and when as well. Free water will thin your bentonite ’s viscosity and may cause other problems like fluctuating the PH of your drilling fluid.

Always chart every reading. If testing is all new to you, your bentonite supplier will be happy to put on a school for you.

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Winterizing:

Lift Pump/Pit Pump- Remove the Lift Pump/Pit Pump from the pit and disconnect the 3” hose. Lay the pump on its side or upside down if possible, to drain as much fluid from the bowl as possible. Then stand it up and pour antifreeze into the bowl.

Drilling fluid and fresh water supply lines- Disconnect the hoses going into the 2” and 3” valves. Once disconnected, fully open both valves to drain the leftover fluid in the pipe. Leave them open afterwards.

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Cone Pump- Close the pump’s suction valve. Drain the pump by removing the drain plug at the bottom of the impeller housing.

Mix and Rig Pump-The Mix & Rig pump supply drilling fluid to the floor jets, mud hopper and the mud pump in the drill. It contains a valve for each function. To winterize the pump you have to close the suction valve, the floor jets valve and the To Rig valve.

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Disconnect the garden and To Rig hoses. Drain the pump by removing the drain plug at the bottom of the impeller housing. Once drained, leave the garden hose and the To Rig valves partially open.

Hoses- Make sure all hoses (Lift Pump/Pit Pump, garden hose and To Rig hose) are fully drained of fluids. Failure to do so may cause pump failure or screen damage due to ice buildup within the hoses.

End of crossing:

Clean tanks, hook up the spoils chute, deflate air bags, insert the shaker lock pins and store Lift Pump/Pit Pump and hoses.

Clean screens, make note of replacements needed. Never travel with air in air bags.

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Thunderstorm Recommended HDD Rig Sizing Chart: Stormy- 20,000lbf/9.07tf and lower. Thunderstorm I- 50,000lbf/22.5tf and lower. Thunderstorm II- 100,000lbf/45tf and lower. Thunderstorm III- 250,000lbf/112.5tf and lower. * Pit pumps are designed for the specific size of Thunderstorm.