2.

REVISION INFORMATION
REVISION NUMBER DATE REVIEWER(S)
00 AUGUST 27, 2012

DISCLAIMER

Flo Draulic West has made every effort to ensure that this document contains accurate and current
information. This document is intended to be used in conjunction with a complete training program and
on-site supervision. Flo Draulic West does not warrant or guarantee that the information contained
herein is either complete or accurate in every respect. The reader hereby protects, indemnifies, and
holds harmless Flo Draulic West together with its officers, employees, and agents from and against all
liability for personal injury, death, or property damage to any person arising directly or indirectly from
this documents use by the reader of the information contained herein.

*Specifications are subject to engineering and/or improvement changes.

CONTACT INFORMATION

1008 – 16TH Ave

Nisku, Alberta T9E 0A9
CANADA

Phone: (780) 979-0333

Fax: (780) 979-0336

E-mail us at [email protected]
Visit us at www.flodraulic.com

COPYRIGHT INFORMATION

All information contained within this technical manual is © copyright of Flo Draulic West, all rights
reserved. It is a breach of copyright if this technical manual is copied or reproduced, in whole or part,
using any means whatsoever, without the prior written approval of Flo Draulic West.
3. TABLE OF CONTENTS
4. ABOUT THIS DOCUMENT
The Flo Draulic Group is committed to exceed our customer’s expectations by providing quality
products, delivered on time, and followed-up with exceptional after-sales service.

The use of components different from those specified by Flo Draulic West may result in decreased
system performance or failure. If trouble is encountered with the system, refer to the designated
section of the manual for instructions on cleaning/repair or replacement of compromised components.

The scope of material included in this manual may not apply to your Power Unit, Components and
Actuators, and information on more custom units may require obtaining service and application
information from other sources. It is imperative that personnel involved in the installation, service and
operation of the Power Unit, Components and Actuators be accustomed the operation of the
equipment; the system capabilities and limitations.

This document is a user manual for Hyduke Energy Services Inc. for the Hydraulic Power Unit systems,
actuators, controls, and other equipment supplied by Flo Draulic West.
5. SAFETY
All personnel must be aware of the dangers related to the operation and maintenance of well-site
equipment, as well as to site-specific hazards. The following are critical to well site safety:

• the wearing of personal protective equipment (PPE)

• regular safety orientations
• correct use and handling of lifting equipment

Hydraulics

Pressurized hydraulic systems store energy capable of exerting extreme force. Serious injuries or even
death can occur as a result of improper use or mishandling of such equipment.

To minimize the dangers of equipment operation and maintenance:

• perform all required pre-start checks and inspections

• ensure that all lines and hoses are connected correctly to prevent any unintended operation of
the equipment
• shut down the equipment and release pressure from the system before performing any kind of
maintenance or disconnecting any hydraulic lines
• never use your hands to try and detect a pinhole leak. Always use a piece of wood or cardboard,
and wear safety glasses, a face shield, or both

Electrical

• Ensure that equipment and tools are properly grounded prior to start-up and operations.
• Never touch a tool and test equipment simultaneously.
• Stand on a dry wooden platform, a rubber mat, or a similar type of insulation when working on
tools.
• Use grounding jumpers that are separate from the AC input lines.

The following safety notices have been added to this manual, however these notices do not replace
proper training on equipment or well site safety procedures.
5. PREPARATION FOR USE
Unpacking and Checking
Preform visual inspection for transport damage and contamination. All open ports on the Power Unit,
Components and Actuators were plugged to prevent the entry of contamination. These plugs must not
be removed until just before piping connections are to be made to the unit.

Report all damages and contamination immediately to carrier and send a copy to Flo Draulic West.

Storage - Short Term

Power Unit, Components and Actuators should be stored indoors, covered with plastic sheet, and all
ports plugged.

Storage - Long Term (Greater than 6 Months)

Fill the reservoir on Power Unit to max capacity with clean hydraulic fluid to prevent the entry of
moisture.

5.1 INSTALLATION
Locating Power Units, Components and Actuators
Power Units should be installed indoors and in a dry environment with an ambient temperature of 15 C
to 38 C. Power Units, Components and Actuators can be installed outdoors if provisions were made for
extreme temperature conditions.

Supply and Return Connections

Connect all piping and hose between the Power Unit, Components and Actuators. Line sizes should be
determined based on oil flow, operating pressure and allowable pressure drop between the Power Unit,
Components and Actuators. With installations, the longer lines are to be flushed through.

Reservoir Filling
Inspect the reservoir for debris and if necessary, clean before opening and filling. Also check that the
available hydraulic fluid has not been contaminated with water. The reservoir must be filled with the
appropriate hydraulic fluid, and above all, that its viscosity is correct. Wherever possible, always use a
filling device which incorporates a special filter. The type of fluid must be compatible with the seals used
on the Power Unit, Components and Actuators, and must comply with the recommendations of the
manufactures of the component parts. Dirt and Heat are a Hydraulic System’s worst enemy.

Coupling Alignment
The pump/motor shaft alignment should be checked before start-up using the coupling installation
instructions provided in appendices of this manual. If re-alignment is required, the motor mounting
bolts should be loosened, and shims inserted. If the pump/motor assembly has been mounted with a
bell-housing, the only check required is to verify that the coupling halves have adequate clearance, and
that the coupling set-screws are tight. A slot is provided in the bell housing for this purpose.

Electrical
Electrical installation for the drive and controls is only to be carried out after the connection
specifications have been confirmed (available voltage, wattage, etc.). Verify that the all electrical
components (refer to component nametag or other service information in this manual for operating
voltage and ratings) match the facility power source available. If necessary, connect the coolant supply.
Check the correct direction of rotation of the pumps before switching on.

5.2 START UP PROCEDURE

1. Open any ball or gate valve (if applicable) located in the pump suction line.

2. Fill the pump housing by pouring the oil into the pump case drain port (in the case of piston-
type pumps)

3. Adjust the system relief valve and/or pump pressure compensator so that pressure will be near
zero during the initial start. Set the directional control valves to their at-rest position.

4. Charge the accumulators to their specified pre-charge pressures.

5. Bump the pump motor once, to verify correct pump rotation. If the direction is incorrect,
reverse the rotation and re-bump to verify correct pump rotation.

6. Run the pump motor for 10-15 seconds (3) to (6) times to prime the pump and allow the pump
to run several minutes at zero pressure. Check the piping for any leaks and correct immediately.

7. Bleed the system at the load lines, as far as possible at the highest points. Operate the
directional control valves and allow the loads to move in and out a number of times. Adjust the
load slowly. Increase the setting of the pressure control valves and/or pressure compensators.
Bleeding has been completed correctly when no more foam appears in the reservoir, when all
load movements are smooth and free from jerks, and when no abnormal noises are present.

8. Continue increasing pressure until normal operating pressure is obtained, and recheck system
for leaks. Lock adjustment screws in place. If the system has a pressure compensated pump and
a relief valve, adjust the relief valve approximately 10% higher than the compensator so that
excessive heat is not generated by the relief valve.

9. During the start-up sequence, all filters should be monitored closely. Replace any filter elements
immediately, as soon as they begin to go into by-pass as indicated on visual indicator.

10. After the entire system has been wetted with fluid, check the hydraulic fluid level and top it off
after bleeding has been completed.
 11. Observe the operating temperature of the machine and verify that the cooling equipment (if
applicable) is operating correctly. After it has been running at full load for a number of hours,
the final operating temperature should not have risen above 70° C. If it has, ascertain the cause,
check the cooling equipment.

12. Check and repair fitting leaks after the installation has been running for a number of hours.

13. Clean the filters (or replacing filter elements) within the first few hours of operation.

5.3 GENERAL MAINTENANCE

Typical maintenance must include several different types of operations that may be performed in any
number of sequences depending on well conditions, operating environment, or a variety of other
contributing factors. These are only guidelines, however, and all items may not apply to every Hydraulic
Power Unit, Components and Actuators. Procedures outline typical maintenance events that can be
modified as required to meet the operator’s preferences, the objectives of the operators, as well as the
specific industrial conditions.

Operating
First Time

6 Months
Monthly
Weekly.

Yearly
Component
Daily

Maintenance Procedure

Hydraulic Reservoir
Check fluid level √
Monitor fluid temperature √
Check for leaks √
Take fluid sample √
Change fluid 50 √
Hoses, Piping & Fittings

Check for leaks √

System Filters
Monitor contamination indicators √
Replace Element 50 √
Suction Strainers

Clean Strainer 10 √
Pump/Motor Couplings

Check alignment (noise) √

Pressure and Flow Valves

Check settings 10 √
Signal Elements
Check settings of pressure switches and
the positions of the limit switches
10 √
Cylinder(s)

Check the piston rod, scraper rings √

Clean and grease the suspension points √

Operating
First Time

6 Months
Monthly
Weekly.

Yearly
Component

Daily
Maintenance Procedure

Mounting Hardware

Inspect and tighten (as needed) 100

Accumulator

Check charge pressure 10 √

COMPONENTS
See component literature in appendices.

RECOMMENDED SPARE PARTS

Spare filter elements should be purchased with the Power Unit, Components and Actuators, and be
available during the start-up operation. Other spare parts may be required, and are a function of the
duty cycle of the hydraulic system, operation environment, and acceptable downtime of the equipment.

It is recommended that spare parts for the system be in stock (on hand) to reduce downtime in the case
of component failure.

5.4 PREVENTATIVE MAINTENANCE

• Check/adjust settings, remove, repair or replace valves, pumps or other components that are
running hot. Follow your equipment owner's manual in appendices.

• Break in new components gradually. New components typically have tight tolerances that
expand at different rates, and may be prone to seize with excessive thermal expansion.

• Start a cold pump or motor on hot oil by running long enough to draw the hot oil into
component. Allow a few minutes to equalize the temperature in all the components parts.
Repeat until the temperature on the outside of the component equals that on the piping.
 • Remove dirt and dust from equipment. Dirt will prevent the hydraulic system from getting rid of
the heat.

• Check and change the oil more frequently in hot climates.

Periodically siphoning an oil sample from the reservoir, and comparing it with a sample of clean, new oil.
Oil that has been running too hot will look darker and feel thinner than new oil. It will also smell burned.
Chances are, it will contain more contaminants, because hot oil leads to accelerated wear of component
parts.

5.5 TROUBLESHOOTING
• Fluid contaminated with incompatible
Dirty oil
foreign matter.
• Components not properly cleaned after
servicing. • Suction leak to pump aerating oil.

• Inadequate screening in fill pipe. • Lack of antifoaming additives.

• Air breather left off. (No air breather Moisture in oils

provided... inadequate unit provided... • Cooling coils not below fluid level.
insufficient protection of air breather.)
• Cold water lines fastened directly
• Tank not properly gasketed. against hot tank causing condensation
within tanks.
• Pipe lines not properly covered while
servicing machine. • Soluble oil solution splashing into
poorly gasketed tanks causing
• Improper tank baffles not providing
condensation within tank.
settling basin for heavy materials.
• Moisture in cans used to replace fluid in
• Filter dirty or ruptured.
tanks.
Foaming oil
• Extreme temperature differential in
• Return of tank line not below fluid level.
certain geographical locations.
Broken pipe, line left out between a
bulkhead coupling and the bottom of • Drain not provided at lowest point in
the tank. tank to remove water collected over
possibly long operating periods.
• Inadequate baffles in reservoir.
Possible Causes of System Overheating
Pump Fluid

• Variable pump control is defective • Viscosity (too low) causing excessive

leakages
• Excessive rotational speed
• Viscosity (too high) causing excessive
• Efficiency reduction due to wear
flow resistance
Hose/Piping
• Foaming fluid
• Pressure filter blocked
Actuators (Motors/Cylinders)
• Line ID undersized causing frictional
• Efficiency losses due to wear
resistance
• Internal friction
Pressure Valves
• Internal leakage
• Flow too high
Cooler
• Valve undersized
• Water shut off or heat exchanger
• Pressure setting too high
clogged.
• Response time too long
Reservoir
Flow Control Valves
• Reservoir assembled without baffling or
• Flow set too low sufficient baffling
• Faulty valve • Sized too small
Directional Control Valves Other
• High leakage • Ambient temperature is too high
• Spool sticking • Thermostat set too high
Possible Causes of Excessive Noise
Suction Line • Foaming fluid

• Suction filter clogged or sized too small Actuators

• Line blocked, leaking, ID too small or • Wear of running surfaces

too many bends • Check compatibility of fluid being
Pump pumped against manufactures
recommendations.
• Rotating too fast
• Aeration of fluid in reservoir (return
• Max. pressure exceeded
lines above fluid level.)
• Seal leakage
• Worn or sticking vanes (vane type
• Control system oscillating pump).
Hose/Piping

• ID too small

• Return filter blocked

Pressure Valves

• Valve worn or not closing properly

(chatter)

• Incorrect design

Flow Control Valves

• Valve oscillates and may cause other

control valves to oscillate

Directional Control Valves

• Defective solenoid or voltage too low

causing valve to chatter

• Contamination or excessive wear

• Excessive flow through valve

Fluid

• Cavitation Problems - Fluid level too low

or viscosity too high

• Contamination causing damage or

blockages
6. OVERALL SYSTEM DESCRIPTION
The equipment supplied by Flo Draulic West, and as such the scope of this manual, consists of the
components contained in the following Hydraulic Schematics;

FW-S-11095 – Top Drive and Rig Systems Hydraulic Power Unit

FW-S-11085 – Rig Moving System

FW-S-12048 – Rig Mast and Related Systems

FW-S-12042 – Hydraulic Catwalk

These schematics are referenced in the appropriate section of the operations manual and are contained
in Appendix 1.
7. RIG HPU – FW-S-11095
OVERALL DESCRIPTION

The HPU consists of a 400 HP AC motor driving a 24.6 cu.in./rev Denison P24 Gold Cup pump and a 50
HP AC motor driving a 90cc Sauer Danfoss piston pump and a 1.61 cu.in./rev Permco vane pump. The
pumps circulate hydraulic fluid from a common reservoir and while the rig hydraulics can be operated
with the top drive pump offline, the top drive most be operated with both electric motors driving the
pumps on the HPU.

The Denison top drive pump supplies fluid to the closed loop Warrior 250H14 top drive motor and is
controlled by the Top Drive Operator’s Console. The Sauer Danfoss pump supplies fluid to the open
loop, closed center system feeding the control valves located in the rig system. The Permco vane pump
circulates hydraulic fluid from the reservoir to a heat exchanger and filters to provide cooling and
filtration independent of what functions are being used.

1. KIDNEY LOOP AND RIG PUMP SYSTEM

a. PRE-OPERATIONS CHECKLIST
i. Ensure hydraulic reservoir is filled to operational level with correct fluid
ii. Ensure that the suction ball valves for the piston and vane pump are open
iii. Ensure that all hydraulic connections are completely engaged, paying close
attention to hydraulic quick couplers
b. OPERATIONS
i. Engage the 50 HP AC motor via the motor control switch. The vane pump
pressure can be monitored at the gauge mounted on the pump output. The
piston pump will energize the closed center system with a constant 3000PSI
pressure which can fluctuate depending on which functions are being used.
ii. The temperature switch located on the vane pump output will control the
AC motor for the heat exchanger in response to elevated hydraulic fluid
temperatures.
c. MAINTENANCE
i. Replace hydraulic fluid, when it no longer meets the manufacture specs.
(Needs to be sampled monthly)
ii. Replace hydraulic filters at 1500 operational hours or when a restriction
indicator detects high differential pressure.
iii. See OEM information for component specific maintenance requirements.
2. TOP DRIVE PUMP SYSTEM
a. PRE-OPERATIONS CHECKLIST
i. Ensure hydraulic reservoir is filled to operational level with correct fluid
ii. Ensure that the suction ball valves for the piston pump are open
iii. Ensure that all hydraulic connections are completely engaged, paying close
attention to hydraulic quick couplers
 iv. Ensure all settings for the Warrior 250H14 Top Drive are adjusted as per the
Warrior OEM operations manual.
b. OPERATIONS
i. Once the Denison P24 pump is engaged, the pressure and flow demands for
the top drive will dictate how the pump operates. The safety systems
controlled by the Warrior Controls will destroke the pump if the OEM
programming detects a fault, however the user can monitor pressures and
filter restrictions on the live gauges on the HPU.
ii. Operations of the Warrior top drive and its control and safety systems are
contained in the Warrior OEM literature.
c. MAINTENANCE
i. Replace hydraulic fluid when it no longer meets manufacture specs. (Needs
to be sampled monthly)
ii. Replace hydraulic filters at 1500 operational hours or when a restriction
indicator detects high differential pressure.
iii. See OEM information for component specific maintenance requirements.

HYDRAULIC SYSTEM SPECIFICATIONS

Top Drive Supply Pressure 5000 PSI

Rig Systems Supply Pressure 2700 PSI

Rig Systems Relief Setting 3000 PSI

Kidney Loop Supply Pressure 100 PSI

Kidney Loop Relief Setting 200 PSI

Reservoir Capacity 1622 Litres

Oil Hyduke Supplied

Maximum Temperature 85 C

Minimum Starting Temperature 20 C

ELECTRICAL SYSTEM SPECIFICATIONS

Top Drive Electric Motor 400 HP, 600 VAC, 1750 RPM, TEFC

Rig Systems Electric Motor 50 HP, 600 VAC, 1750 RPM, TEFC

Cooler Motor 5 HP, 1750 RPM, 3 PHASE, 600 VAC

EQUIPMENT LIST – TOP DRIVE HPU

MAKE PART # DESCRIPTION QUANTITY

DENISON P24S-2R1E-9A2-B00-2B0 GOLD CUP PUMP 1
PERMCO T6CM-B28-3R00-C1 VANE PUMP (ON P24S) 1
MAGNALOY S4441402F PUMP/MOTOR MOUNT 1
MAGNALOY M80031228 COUPLING 1
MAGNALOY M80020016 COUPLING 1
MAGNALOY M870H INSERT 1
C400P2GC 400 HP ELECTRIC MOTOR 1
STAUFF SF070G10B-TU/B/V/2 PRESSURE FILTER 2
STAUFF SE070G10B REPLACEMENT ELELMENT 10 MICRON -
ANCHOR CS#12-1-7 CHECK VALVE 1
- PRESSURE SWITCH 200 PSI 1
STAUFF STA-S-010-B-P3-U-LTB ACCUMULATOR 1 GALLON 2
HEDLAND R2084-ASCI8 C/W F6557-15 FLOW METER 85 GPM, 4-20MA, #16 2
ORB
HYDRAFORCE SF20-23-20T-N-24DG SOLENOID VALVE 1
FLO DRAULIC FW-M-6082 CUSTOM HOT OIL SHUTTLE 1
WEST
SUN HYDRAULICS DSIH-XHN SHUTTLE VALVE 1
SUN HYDRAULICS RPIC-LNN RELIEF VALVE 1
STAUFF SPG-63-0300S PRESSURE GAUGE 3
STAUFF SPG-63-6000S PRESSURE GAUGE 2
STAUFF SPG-63-3000S PRESSURE GAUGE 1
Y913057-39 PRESSURE TRANSDUCER 0-9000 PSI 4-20 2
MA
Y913057-H30 PRESSURE TRANSDUCER 0-1000 PSI 4-20 2
MA
Y913057-H34 PRESSURE TRANSDUCER 0-3000 PSI 4-20 1
MA
STAUFF SMK20-7/16 UNF VE TEST POINT 12
HAWE PMV 41-43/G24 PROPORTIONAL PRESSURE RELIEF 24 1
VDC
SUN HYDRAULICS DTDA-MHN-GAH/S-224 SOLENOID VALVE 24 VDC 2
0.040” DIA ORIFICE FITTING 2
HAWE AC40-1/4 ACCUMULATOR 40CC 1
SUN HYDRAULICS RDDA-LAN-FAI/S RELIEF VALVE 1

STAUFF SF300G10B-TG/R/E/2 PRESSURE FILTER 4

STAUFF SE300G10B REPLACEMENT ELEMENT 10 MICRON
MAKE PART # DESCRIPTION QUANTITY
INSERTA ICFT-A-6224-N15 CHECK VALVE 15 PSI 2
FLODRAULIC WEST FW-M-6083 CUSTOM TEE MANIFOLD 6
FLODRAULIC WEST FW-M-6084 CUSTOM 1.5”CD62 ADAPTER PLATES 12
INSERTA IBF-B-6232-N15 BALL VALVE 1
INSERTA ICFT-A-6232-N15 INSERTA CHECK VALVE 15 PSI 2
STAUFF SF300G10B-TG/M/E/2 PRESSURE FILTER 2
STAUFF SE300G10B REPLACEMENT ELEMENT 10 MICRON 2
RT7-2AL-TXNU-4-A-S-3-LT-4-14 TEMPERATURE TRANSDUCER 4-20 MA 1
SUN HYDRAULICS FDEA-LAN-ICM PRESSURE COMPENSATED FLOW 1
CONTROL
SUN HYDRAULICS PVFB-LAN-BCL PRESSURE REDUCING/RELIEVING VALVE 1
SUN HYDRAULICS DAAA-MCN-WFO-224 SOLENOID VALVE (VENT FOR PVFB-LAN 1
VALVE)
STAUFF STA-S-050-B-PS-U-LTB ACCUMULATOR 5 GALLON 1
ANCHOR CS#12-1-7 CHECK VALVE 1
SUN HYDRAULICS RPGC-LWN-CEM RELIEF VALVE 1
ANCHOR CS#16-1-7 CHECK VALVE 1
PEC326TC-50-1805 ELECTRIC MOTOR 50 HP 600 VAC 1
MAGNALOY COUPLING 1
SAUER FRR090CLS2520NNNBKB2A1NNNNN PISTON PUMP 90CC 1
PERMCO PT6CM-B08-3R00-C1 VANE PUMP 1
ANCHOR CS#8-1-7 CHECK VALVE 1
SUN HYDRAULICS RPEC-LAN-FEJ RELIEF VALVE 1
STAUFF SPG-63-0300S PRESSURE GAUGE 1
NASON HT-1C-120R/HR TEMPERATURE SWITCH 120 F 1
THERMAL BOL-1600-2-6 COOLER 600V 1
TRANSFER
ANCHOR CS#24-1-65 CHECK VALVE 65 PSI (COOLER BYPASS) 1
STAUFF RF130G10B/U/M/G RETURN FILTER 1
STAUFF RE130G10B REPLACEMENT ELEMENT 10 MICRON 1
STAUFF RF070G10B/U/M/G RETURN FILTER 2
STAUFF RE070G10B REPLACEMENT ELEMENT 2
SUCTION BALL VALVE 1
SUCTION BALL VALVE 1
SUCTION BALL VALVE 1
STAUFF SGB-90-03 & DBA-075 DESSICANT BREATHER 2
STAUFF SNA254BST12 SIGHT LEVEL GAUGE 2
WIKA 33060A006G4 & 31-90400 TEMPERATURE GAUGE & THERMOWELL 1
DRAIN BALL VALVE 1
MURPHY L1111 LOW LEVEL SWITCH 1
8. MOVING SYSTEM – FW-S-11085
OVERALL DESCRIPTION

The rig moving system consists of an HPU, control valves, a Hetronic radio system, and hydraulic
cylinders. The HPU consists of a 30 HP AC motor driving a multi-outlet HAWE pump. Two custom Flo
Draulic West manifolds control fluid flow, pressure, and the cylinder soft-advance feature. The six HAWE
directional control valves feature electric and manual operation – the Hetronic radio controls the valves
under normal operating conditions while the manual operation can be used in emergencies.

1. HPU
a. PRE-OPERATIONS CHECKLIST
i. Ensure hydraulic reservoir is filled to operational level with correct fluid
ii. Ensure that the suction ball valves for the piston pump are open
iii. Ensure that all hydraulic connections are completely engaged, paying close
attention to hydraulic quick couplers.
iv. Ensure that the rig is ready to be moved and that all personnel and equipment
are in safe locations.
b. OPERATIONS
i. Once the electric motor is running and the pump is supplying oil to the system,
the Hetronic radio is used to control the lift, side shift, and travel cylinders. To
move the rig, the lift cylinders are extended to lift the rig from the matting.
Once up, the travel cylinders are retracted to move the rig the distance of their
stroke – 72”. To change the direction of the rig travel, use the side shift cylinders
to adjust the position of the walking pads when the pads are off the rig matting
and the rig is resting on the matting.
c. MAINTENANCE
i. Replace hydraulic fluid when it no longer meets manufacture specs. (Oil needs
to be sampled monthly)
ii. Replace hydraulic filters at 1500 operational hours or when a restriction
indicator detects high differential pressure.
iii. See OEM information for component specific maintenance requirements.
2. CYLINDERS
a. PRE-OPERATIONS CHECKLIST
i. Ensure that all hydraulic connections and quick couplers are engaged.
ii. Ensure that all pins and support components are fixed and in good operating
condition
iii. Ensure that if the hydraulic supply lines to any cylinder were opened for repair,
or if any cylinder was removed and repairs, that the cylinder and lines are
properly purged of all air.
b. OPERATIONS
 i. Ensure that there are no noises or apparent mechanical binding or failures
during routine operations
c. MAINTENANCE
i. Routinely inspect cylinders for damage and noticeable differences in
performance between other cylinders. Repair as needed.
3. CONTROL VALVES
a. PRE-OPERATIONS CHECKLIST
i. Ensure all electrical connections to solenoids are connected and wiring is not
damaged.
ii. Ensure that all manual control handles are installed and can be accessed.
b. OPERATIONS
i. The directional control valves will function in sequence according to the
Hetronic Radio System.
ii. In case of a radio system failure, the individual valves can be manually actuated
to allow the rig to be moved. In this case extreme caution must be exercise and
your Flo Draulic West representative must be notified to provide support.
c. MAINTENANCE
i. See OEM information for component specific maintenance requirements.
4. HETRONIC RADIO SYSYTEM
a. PRE-OPERATIONS CHECKLIST
i. Ensure that the radio system is fully charged and communicating with the
receiver.
b. OPERATIONS
i. While inspecting the cylinders in question, go through all functions before
attempting to move rig. Extend and retract cylinders through a range of travel
before any force is exerted that would move the rig – ensure that the radio
signals are being communicated to the cylinders.
c. MAINTENANCE
i. Fully charge battery packs when not in use.
ii. See OEM information for component specific maintenance requirements.

HYDRAULIC SYSTEM SPECIFICATIONS

Supply Pressure (HAWE Relief) 3000 PSI

Pressure Relief Setting (SUN Relief) 3400PSI

Reservoir Capacity 300 Litres

Oil Hyduke Supplied

Max Temperature 85 C
Minimum Starting 20 C

ELECTRICAL SYSTEM SPECIFICATIONS

Electric Motor 30 HP, 600 VAC, 1750 RPM, TEFC

EQUIPMENT LIST – MOVING SYSTEM

MAKE PART # DESCRIPTION QUANTITY
HE286T-30-1805 30HP ELECTRIC MOTOR 1
MAGNALOY M28486100M PUMP/MOTOR MOUNT 1
MAGNALOY M40012816 COUPLING 1
MAGNALOY M400M3008 COUPLING 1
MAGNALOY M470U INSERT 1
HAWE R11,8-11,8-11,8-11,8-11,8-11,8 RADIAL PISTON PUMP 1
FLO DRAULIC WEST FW-M-8058 CUSTOM MANIFOLD 1
SUN HYDRAULICS DWDA-LAN/770-224 DIRECTIONAL VALVE 12 V 2
SUN HYDRAULICS XEOA-XXN CAVITY PLUG 2
SUN HYDRAULICS RDBA-LCN RELIEF VALVE 6
HAWE FW-2-8097 DIRECTIONAL VALVE 2
HAWE FW-2-8099 DIRECTIONAL VALVE 1
HAWE FW-2-8100 DIRECTIONAL VALVE 1
HAWE FW-2-8098 DIRECTIONAL VALVE 2
FLO DRAULIC WEST FW-M-8057 CUSTOM MANIFOLD 1
SUN HYDRAULICS CXDA-XCN CHECK VALVE 6
SUN HYDRAULICS DWDA-LAN/770-224 SOLENOID VALVE 1
SUN HYDRAULICS RBAE-LAN RELIEF VALVE 2
SUN HYDRAULICS CBCA-LHN-YEJ DUAL COUNTERBALANCE VALVE 14
PC60405 CYLINDER 6” BORE X 8” STROKE X 3.5” ROD 6
PC10.0728 CYLINDER 10” BORE X 6” STROKE X 6” ROD 6
PC60351 CYLINDER 6” BORE X 72” STROKE X 4” ROD 2
STAUFF SDF2215-25-1-0 RETURN FILTER HEAD 1
STAUFF SF6731-MG RETURN FILTER ELEMENT 2
STAUFF CI-20 RETURN FILTER INDICATOR 1
STAUFF SGB-90-03 & TBA-075 TANK BREATHER 1
STAUFF SNA254-B-S-T-12 TANK SIGHT GAUGE
STAUFF 2BVL2024B SUCTION BALL VALVE
HYDRA- CONTROL SVM056004 SELECTOR 1
HETRONIC S08F4496 TRANSMITTER/RECEIVER 1
CQP38-SAE-1/2M QUICK COUPLER
FIRG12-SAE-1/2F QUICK COUPLER
HDC38-M QUICK COUPLER CAP
HDC38-F QUICK COUPLER PLUG
9. HYDRAULIC RIG SYSTEM – FW-S-12048
OVERALL DESCRIPTION

The Rig System is powered by the Rig HPU which supplies the open loop closed center system via hose
and quick couplers. All of the following control valves and actuators receive the pressurized hydraulic
fluid and return it back to the HPU tank via a series of hose and piping.

A seven-bank HAWE proportional directional control valve controls 6 Rotzler tugger winches and also
directs flow to the wireline winch. A FDWest wireline winch is controlled by a single-bank Hydrocontrol
valve.

Two single-bank HAWE valves control the Mast Raise and Mat Scope cylinders, while a 2-bank
Hydrocontrol valve controls the two BOP handler cylinders. Finally, a single bank HAWE valve controls
the customer supplied Alco pipe slips.

1. MAST RAISE CYLINDERS

a. PRE-OPERATIONS CHECKLIST
i. Ensure that all quick couplers have been coupled correctly.
ii. Ensure that the HPU is operating as per Section 7.
iii. Ensure that the mast raise cylinder air bleed procedure has been followed and
that the hydraulic system feeding the cylinders has not been opened. Please
contact Flo Draulic West directly is there is a question concerning air in the mast
raise cylinders.
iv. Ensure that all mechanical checks and considerations for the Mast are followed
as per the Rig Manufacturer’s manual
b. OPERATIONS
i. Select the 7-Bank HAWE valve #7 to the Cylinder position.
ii. Operate the single-bank HAWE valve smoothly, ensuring that starts and stops
are done slowly to minimize swaying of the mast.
c. MAINTENANCE
i. Maintain HAWE valve bank as per manufacturer’s specifications
ii. Inspect the barrels of the mast raise cylinders for scoring, pitting, rusting, and
for evidence of lost hard surfacing. Repair as needed.
iii. Inspect the gland seals for evidence of leakage. Repair as needed.
iv. Ensure that the mast raise cylinders are operating in a linear fashion only. Side
loading and bending forces will result in damage to the cylinder. Correct
mechanical structure as needed.
2. WIRELINE
a. PRE-OPERATIONS CHECKLIST
i. Ensure that all quick couplers have been coupled correctly.
 ii. Ensure that the HPU is operating as per Section 7.
iii. Ensure that the measuring line is prepared for use as intended.
b. OPERATIONS
i. Select the 7-Bank HAWE valve #7 to the Wireline position.
ii. Operate the Hydro Control valve bank to spool in or spool out line.
c. MAINTENANCE
i. Maintain the Hydro Control valve bank as per manufacturer’s specifications.
ii. Maintain the Char-Lynn motor as per manufacturer’s specifications.
3. MAST SCOPE CYLINDERS
a. PRE-OPERATIONS CHECKLIST
i. Ensure that all quick couplers have been coupled correctly.
ii. Ensure that the HPU is operating as per Section 7.
iii. Ensure that all mechanical checks and considerations for the Mast Pin Cylinders
are followed as per the Rig Manufacturer’s manual.
b. OPERATIONS
i. Select the 7-Bank HAWE valve #7 to the Cylinder position.
ii. Operate the single-bank HAWE valve smoothly, ensuring that starts and stops
are done slowly to minimize swaying of the mast.
c. MAINTENANCE
i. Maintain HAWE valve bank as per manufacturer’s specifications
4. BOP HANDLER CYLINDERS
a. PRE-OPERATIONS CHECKLIST
i. Ensure that all quick couplers have been coupled correctly.
ii. Ensure that the HPU is operating as per its Operations Manual
iii. Ensure that all mechanical checks and considerations for the Mast Pin Cylinders
are followed as per the Rig Manufacturer’s manual
b. OPERATIONS
i. Select the 7-Bank HAWE valve #7 to the Cylinder position.
ii. Operate the 2-bank Hydrocontrol valve smoothly, ensuring that starts and stops
are done slowly to minimize swaying of the BOP.
c. MAINTENANCE
i. Maintain Hydrocontrol valve bank as per manufacturer’s specifications
5. ALCO PIPE SLIPS
a. PRE-OPERATIONS CHECKLIST
i. Ensure that all quick couplers have been coupled correctly.
ii. Ensure that the HPU is operating as per Section 7.
iii. Ensure that all mechanical checks and considerations for the Mast Pin Cylinders
are followed as per the Rig Manufacturer’s manual
b. OPERATIONS
i. Operate the proportional HAWE valve bank smoothly, following the pipe slips
manufacturer’s recommendations.
c. MAINTENANCE
 i. Maintain HAWE valve bank as per manufacturer’s specifications
6. TUGGER WINCHES
a. PRE-OPERATIONS CHECKLIST
i. Ensure that all quick couplers have been coupled correctly.
ii. Ensure that the HPU is operating as per Section 7.
iii. Ensure that all mechanical checks and considerations for the Tugger Winches
are followed as per the Rig Manufacturer’s manual
b. OPERATIONS
i. The proportional HAWE directional control valve allow fine control over the
Rotzler winches.
ii. Operate winches as per the Rig Manufacturer’s manual.
c. MAINTENANCE
i. Maintain HAWE valve bank as per manufacturer’s specifications.
ii. Maintain Rotzler winches as per manufacturer’s specifications.

HYDRAULIC SYSTEM SPECIFICATIONS

Supply Pressure (HAWE Relief) 2700 PSI

Pressure Relief Setting (SUN Relief) 3400PSI

Oil Hyduke Supplied

Max Temperature 85 C

Minimum Starting 20 C

ELECTRICAL SYSTEM SPECIFICATIONS

Electric Motor 50 HP

EQUIPMENT LIST – RIG SYSTEM

MAKE PART # DESCRIPTION QUANTITY
10. CATWALK – FW-S-12042
OVERALL DESCRIPTION

The hydraulically operated catwalk consists of an HPU, directional control valves, a skate motor, and a
series of hydraulic cylinders. A 50 HP AC motor drives a 75cc Linde pump that provides the fluid power
to the two directional control valves. One 8-Bank Hydrocontrol valve controls the 8 levelling cylinders
for the catwalk. The 7-Bank HAWE valve controls the skate motor and the 6 index and kicker cylinders.
The HPU also has a 1.54 cu.in./rev gear pump for a kidney loop cooling and filtration circuit.

1. HPU
a. PRE-OPERATIONS CHECKLIST
i. Ensure hydraulic reservoir is filled to operational level with correct fluid
ii. Ensure that the suction ball valves for the piston pump and gear pump are open
iii. Ensure that all hydraulic connections are completely engaged, paying close
attention to hydraulic quick couplers
b. OPERATIONS
i. Once the HPU is running, the actuator demand will determine fluid flow.
ii. Ensure that the pressure and return filter restriction indicators are not showing
a clogged filter. If so, shut down the system and replace the filter in question.
c. MAINTENANCE
i. Replace hydraulic fluid when it no longer meets manufacture specs. (Oil must be
sampled monthly)
ii. Replace hydraulic filters at 1500 operational hours or when a restriction
indicator detects high differential pressure.
iii. See OEM information for component specific maintenance requirements.
2. JACKING DIRECTIONAL CONTROL VALVES
a. PRE-OPERATIONS CHECKLIST
i. Ensure that all manual control handles are installed and can be accessed
b. OPERATIONS
i. Extend or retract cylinders to level the catwalk as per manufacturer’s
specifications.
c. MAINTENANCE
i. See OEM information for component specific maintenance requirements.
3. CATWALK FUNCTION DIRECTIONAL CONTROL VALVES
a. PRE-OPERATIONS CHECKLIST
i. Ensure all electrical connections to solenoids are connected and wiring is not
damaged.
ii. Ensure that all manual control handles are installed and can be accessed
b. OPERATIONS
i. Extend or retract the ODS and DS kicker and index cylinders to handle pipe as
per the catwalk manufacturer’s specifications.
 ii. Actuate the skate motor to handle pipe as per the catwalk manufacturer’s
specifications.
c. MAINTENANCE
i. See OEM information for component specific maintenance requirements.

HYDRAULIC SYSTEM SPECIFICATIONS

System Supply Pressure 5000 PSI

System Pressure Relief Setting 2700 PSI

Kidney Loop Supply Pressure 100 PSI

Kidney Loop Pressure Relief Setting 200 PSI

Reservoir Capacity 1622 Litres

Oil Hyduke Supplied

Temperature 85 C

Minimum Starting 20 C

ELECTRICAL SYSTEM SPECIFICATIONS

Electric Motor 50 HP, 460 VAC, 1750 RPM, TEFC

Cooler Motor XX HP, 1750 RPM, 3 PHASE, 460 VAC

EQUIPMENT LIST – MOVING SYSTEM

MAKE PART # DESCRIPTION QUANTITY
PEC-326TC-50-1804 50HP ELECTRIC MOTOR 1
MAGNALOY M324872C PUMP/MOTOR MOUNT 1
MAGNALOY M50020416 COUPLER 1
MAGNALOY M500A1412C COUPLER 1
MAGNALOY M570N INSERT 1
LINDE 630AW00077A 75CC PISTON PUMP 1
26010-RZE 1.54 CU.IN. PUMP 1
STAUFF SDF-2215-25-1-0 DUAL ELEMENT RETURN FILTER HEAD 1
STAUFF SF6731-MG FILTER ELEMENT 2
STAUFF CI-20 RESTRICTION INDICATOR 1
THERMAL BOL-30-2-3 OIL COOLER 1
TRANSFER
SUN HYDRAULICS RPGC-LAN-CAL RELIEF VALVE 1
STAUFF RV-20-7-S CHECK VALVE 1
STAUFF SF070GI0B-TU/B/V/2 PRESSURE FILTER 1
STAUFF NDV-12N NEEDLE VALVE 1
SUN HYDRAULICS RPGC-LAN-CEM RELIEF VALVE 1
STAUFF SPG-63-3000P 3000PSI GAUGE 1
STAUFF CS#16-1-65 CHECK VALVE 1
STAUFF SPG-63-1000S 1000PSI GAUGE 1
SUN HYDRAULICS CBGG-LJN-YJM COUNTERBALANCE VALVE 1
FD WEST FW-D-6020 (114-1034- SKATE ASSEMBLY 1
006/25CF2-66-1-T75/20G6-1)
HAWE FW-53-10133 DIRECTIONAL VALVE ASSEMBLY 1
SUN HYDRAULICS CBCA-LHN-YEJ COUNTERBALANCE VALVE 8
HYDRO CONTROL HC-D4/8-IR001(175)-AU04- DIRECTIONAL VALVE 1
W002A-H001(D4A0108)
STAUFF SGB-90-03 BREATHER 1
NASON HT-1C-120R/HR TEMPERATURE SWITCH 1
NASON HT-1C-180R/HR TEMPERATURE SWITCH 1
MURPHY L111 LOW LEVEL SWITCH 1
STAUFF SNK254VC012 LEVEL SWITCH 1
STAUFF 2BVL2032B 2” BALL VALVE 1
STAUFF 2BVL2016B 1” BALL VALVE 1
11. APPENDIX 1
FD WEST SCHEMATICS
12. APPENDIX 2
OEM INFORMATION AND LITERATURE