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CRTi™
Maintenance Procedure
Revision G
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Page 2 of 43
TABLE OF CONTENTS
1. Scope ................................................................................................................................................................. 4
2. Related Documentation .................................................................................................................................... 4
3. Definitions ......................................................................................................................................................... 4
4. Responsibilities .................................................................................................................................................. 5
5. Overview ........................................................................................................................................................... 5
6. Procedure - Inspection ...................................................................................................................................... 6
7. CRTi Storage ................................................................................................................................................... 33
8. OEM Refurbishment Program ........................................................................................................................ 35
Appendix A: Combined Wear Procedure ............................................................................................................. 36
Appendix B: Mandrel Neck Area Reduction Calculation ...................................................................................... 39
Appendix C: Maximum Casing Inside Diameter ................................................................................................... 42
Appendix D: Cam Latch Torque Release Check .................................................................................................... 43
TABLE OF FIGURES & TABLES
Figure 1: CRTi shown in CRTi Assembly Stand .........................................................................................................7
Figure 2: Removing Jaw/Integral Slip from CRTi ......................................................................................................8
Figure 3: Mandrel lubrication evaluation ................................................................................................................8
Figure 4: Jaw/Integral Slip lubrication evaluation....................................................................................................9
Figure 5: Casing Seal Removal ...............................................................................................................................10
Figure 6: Removing all Jaws/Integral slips from CRTi.............................................................................................11
Figure 7: CRTi 1,2-4.5, CRTi 1,2-5.5 or CRTi 2,3-7.0 Lower Half rotation ..............................................................11
Figure 8: CRTi 1,2-4.5, CRTi 1,2-5.5 or CRTi 2,3-7.0 Lower Half removal ..............................................................12
Figure 9: CRTi 4-7 or CRTi 1,2-8.63 Bumper removal .............................................................................................12
Figure 10: CRTi 4-7 or CRTi 1,2-8.63 Cap Housing removal ...................................................................................13
Figure 11: CRTi 4-7 or CRTi 1,2-8.63 Lower Half removal ......................................................................................13
Figure 12: CRTi Lower Half Cam Inspection ...........................................................................................................14
Figure 13: CRTi Lower Cam Housing Inspection .....................................................................................................14
Figure 14: CRTi Mandrel Seal Surface Inspection ..................................................................................................15
Figure 15: CRTi Intermediate and Upper Cam Inspection .....................................................................................15
Figure 16: CRTi Mandrel Cone Inspection ..............................................................................................................16
Figure 17: CRTi 1,2-4.5, CRTi 1,2-5.5 or CRTi 2,3-7.0 Bumper removal.................................................................17
Figure 18: CRTi 4-7 or CRTi 1,2-8.63 Upper Housing Lock Ring removal ...............................................................17
Figure 19: CRTi 4-7 or CRTi 1,2-8.63 Upper Cam Housing removal .......................................................................18
Figure 20: CRTi Intermediate Cam Removal ..........................................................................................................18
Figure 21: CRTi Upper Cam Removal .....................................................................................................................18
Figure 22: CRTi Lock Sleeve Removal .....................................................................................................................19
Figure 23: CRTi Bumper Removal...........................................................................................................................19
Figure 24: CRTi Lower Cam Housing Removal .......................................................................................................19
Figure 25: CRTi Cage Removal................................................................................................................................20
Figure 26: CRTi Cam Latch Removal .......................................................................................................................20
Figure 27: CRTi Cam Latch Spring, End Ring and Latch Key Removal ....................................................................21
Figure 28: CRTi Lower Cam Belleville Spring Removal ...........................................................................................21
Figure 29: Thickness Measurements .....................................................................................................................23
Figure 30: Measuring axial backlash in make-up threads. .....................................................................................24
Figure 31: ODm Measurements ..............................................................................................................................26
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Page 3 of 43
Figure 32: Die tooth tip measurement ..................................................................................................................28
Figure 33: Jaw Wear Locations ..............................................................................................................................29
Figure 34: Mandrel Wear Allowance .....................................................................................................................29
Figure 35: Jaw and Die Wear Allowances ..............................................................................................................30
Figure 36: CRTi shipment .......................................................................................................................................33
Figure 37: Wear allowance measurement .............................................................................................................36
Figure 38: ODm And t Measurements ....................................................................................................................39
Table 1: Inspection Frequency .................................................................................................................................5
Table 2: CRTi Geometry Measurement Limits .......................................................................................................26
Table 3: Die test ring ID and measurement ...........................................................................................................38
Table 4: Original Tool Dimensions .........................................................................................................................40
Table 5: Casing Maximum Inside Diameter ...........................................................................................................42
Table 6: Cam Latch Release Torque .......................................................................................................................43
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Page 4 of 43
1. Scope
1.1.
This standard maintenance procedure applies to all Volant internal casing
running tools (CRTi™).
2. Related Documentation
2.1.
Assembly and Operations Manual document numbers 40022 (CRTi2-7.0),
40023 (CRTi1-4.5), 40024 (CRTi1-5.5), 40025 (CRTi1-8.63), 40028 (CRTi2-5.5),
40029 (CRTi2-4.5), 40030 (CRTi3-7.0), 40034 (CRTi2-8.63) and 40039 (CRTi47.0)
2.2.
Category 3 Inspection Form number 101014 and Category 4 Inspection Form
number 101015
2.3.
CRTi Running Procedure, document number 100027
2.4.
CRTi tool databook
3. Definitions
3.1.
Thread Lubricant: Jet-Lube Kopr-Kote, Premium thread lubricant and seal, or
equivalent approved lubricant.
3.2.
Grease: Omnigaurd #2 High Temperature EP Grease or equivalent lubricant
3.3.
CRTi: Volant Casing Running Tool (internal)
3.4.
Lower half: Cage, Lower Cam Housing, Lower Cam Assembly, Bumper, Cam
Latch and Latch components.
3.5.
Alignment Marks: Lines marked on the Bumper and Upper Cam Housing of the
tool that align when the tool is locked out or latched.
3.6.
Latched: Position in which the cam latches inside the Housing of the CRT are
engaged and the dies are retracted.
3.7.
Meterage limit: The number of meters ran between inspections. This limit is
initially set at 4,000 m for category 2B, and 50,000m for category 2C.
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Page 5 of 43
Backlash: The gap in the axial direction between stab flanks of a mating thread
pair when the thread pair is engaged on their load flanks.
4. Responsibilities
4.1.
The operations coordinator is responsible for training staff and ensuring
compliance with this procedure.
Contact Volant Product Support at support@volantproducts.ca to assess any
CRTi components found to be damaged or non-conforming.
4.2.
All operations staff is responsible for the proper execution of this procedure.
Refer to Volant’s Assembly Manual to verify part numbers, fasteners, seals, Orings and proper Re-assembly installation instructions.
5. Overview
The inspection schedule in this document is governed by API recommended practice
8B. Because the CRT™ does not fit perfectly into any of the equipment designation
categories, Volant has developed and recommends the minimum inspection
frequencies listed in Table 1.
Inspection
Type
Minimum Frequency
of Inspection
Action in Case
of Fault
Maintenance
Required
Category 1
Daily
Category 2A
Inspection
Level 1 Maintenance
Category 2A
Weekly / Job
Category 2B
Inspection
Level 2A Maintenance
Category 2B
Weekly or every 4,000m
ran
Category 2C
Inspection
Level 2B Maintenance
Category 2C
Quarterly or every
50,000m run
Category 3
Inspection
Level 2C Maintenance
Category 3
Annually
Category 4
Inspection
Level 3 Maintenance
Category 4
Revision G
5-year
N/A
Table 1: Inspection Frequency
Level 3 Maintenance
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The specific requirements of each inspection category are described in Section 6 of this
document. When an inspection indicates a fault condition, the action identified in Table
1 is generally required unless otherwise specified, in addition each inspection level has
an associated maintenance requirement. While Volant recommends documenting all
maintenance and inspections, only categories 3 and 4 must be documented to conform
with API Spec 8B.
Maintenance documentation should indicate the maintenance date, personnel
responsible for the inspection and include full part serial numbers, pictures and
description of any defects, repairs, replacements, and NDT results. Contact Volant
Product Support at support@volantproducts.ca for any CRTi maintenance inquiries.
6. Procedure - Inspection
6.1. Category 1 Inspection
6.1.1.
Observe equipment during operation for indications of inadequate
performance.
6.1.2.
Observe operations for indication of overload of hoisting or torque
capacity.
6.2. Category 2A Inspection (perform category 1 inspection plus the
following)
While working on the tool ensure that the tool is properly placed in the
CRTi Assembly Stump, as shown in Figure 1.
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Figure 1: CRTi shown in CRTi Assembly Stand
6.2.1.
Check air pressure.
6.2.1.1. Compare measured pressure to value recorded at tool assembly.
Pressure losses that can’t be attributed to temperature change
triggers a Level 2 maintenance procedure. Loss of air pressure may
indicate a problem with a seal or seal surface.
6.2.2.
Revision G
Evaluate lubricant condition.
6.2.2.1.
Bleed off all air pressure and remove Schrader valve from Upper
Cam Housing.
6.2.2.2.
Unlatch the CRTi by rotating the Bumper to the right. Remove the
keeper and one jaw/integral slip from the tool in order to properly
evaluate the lubricant condition between this part and the
Mandrel.
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Figure 2: Removing Jaw/Integral Slip from CRTi
6.2.2.3.
Lubricant should be free of foreign matter; including drilling fluid,
water, sand, and dirt.
Figure 3: Mandrel lubrication evaluation
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Figure 4: Jaw/Integral Slip lubrication evaluation
6.2.2.4.
There should be adequate lubricant in place at all times to ensure
proper tool function and minimize wear on the sliding surfaces of
the Mandrel and jaws/integral slips. Improper lubricant conditions
can result in tool malfunction as well as component damage.
6.2.2.5.
Record meterage, and check meterage since previous Category 2B
inspection against meterage limit.
6.2.3.
Check all exposed fasteners for signs of damage.
6.2.4.
Clean tool joint thread and conduct visual inspection to ensure that
condition is acceptable. (see section 13.3.2. of API Specification 7G).
6.2.5. Check the condition of the casing seal (packer cup) and evaluate whether it
will need to be replaced. Check that the outside diameter of the casing
seal is greater than or equal to the maximum inside diameter of the pipe
that is being run.
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Maximum casing inside diameter can be calculated based on
information provided in API Specification 5CT and is provided in
Appendix C.
6.3. Category 2B Inspection
6.3.1.
Bleed off all air pressure inside the CRT and then remove Schrader valve
from Upper Cam Housing.
6.3.2.
Remove casing seal assembly (Packer Cup, Stabbing guide and retaining
components)
Figure 5: Casing Seal Removal
Revision G
6.3.3.
Visually inspect Casing Seal Carrier bore and threads, as well as Mandrel
threads for signs of erosion/corrosion.
6.3.4.
Remove all jaws/integral slips from the cage and visually inspect die
tooth wear on outside of slips/dies.
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Figure 6: Removing all Jaws/Integral slips from CRTi
6.3.5.
For CRTi 1,2-4.5, CRTi 1,2-5.5 or CRTi 2,3-7.0
6.3.5.1. Manually actuate tool by turning cage clockwise.
Figure 7: CRTi 1,2-4.5, CRTi 1,2-5.5 or CRTi 2,3-7.0 Lower Half rotation
6.3.5.2. Slowly remove the Lower Half of the tool, wiping the Lower
Cam Housing during removal to ensure that contaminants do
not fall into the Upper Cam Housing.
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Figure 8: CRTi 1,2-4.5, CRTi 1,2-5.5 or CRTi 2,3-7.0 Lower Half removal
6.3.6.
For CRTi 4-7 or CRTi 1,2-8.63
6.3.6.1.
Remove the Bumper and inspect for wear.
Figure 9: CRTi 4-7 or CRTi 1,2-8.63 Bumper removal
6.3.6.2.
Remove the Cap Housing by rotating the part relative to the
Upper Cam Housing until the splines disengage. Inspect the Cap
Housing for damage and wear.
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Figure 10: CRTi 4-7 or CRTi 1,2-8.63 Cap Housing removal
6.3.6.3.
Manually actuate the tool by turning cage clockwise
and remove the Lower Half of the tool, wiping the Lower
Cam Housing during removal to ensure that contaminants
do not fall into the Upper Cam Housing.
Figure 11: CRTi 4-7 or CRTi 1,2-8.63 Lower Half removal
6.3.7.
For all CRTi Base Tools
Clean lubricant from Lower Cam and conduct a visual inspection of the
cams; noting any signs of scarring, gouges in cam surface or any other
signs of uneven wear. Cams should remain smooth to the touch on all
surfaces. Visually inspect the Cam Latch Spring, Latch Pins, O-rings or
Quad Rings and sealing surfaces, ensuring they are smooth and free of
any damage.
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Figure 12: CRTi Lower Half Cam Inspection
6.3.8.
Examine the sealing surface on the exterior of Lower Cam Housing for
scratches, gouges and signs of wear. Always rest Lower Cam Housing on
a rubber or wood surface to prevent component damage.
Figure 13: CRTi Lower Cam Housing Inspection
6.3.9.
Revision G
Examine the sealing surface on the Mandrel below the Upper Cam for
scratches, gouges and signs of wear.
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Figure 14: CRTi Mandrel Seal Surface Inspection
6.3.10.
Rotate the Intermediate Cam relative to the Upper Cam. Rotation
should be smooth and free of any indications of roughness or uneven
wear. Inspect the Intermediate Cam ramps and the J-hooks on the Upper
Cam, ensuring cams are smooth to the touch.
Figure 15: CRTi Intermediate and Upper Cam Inspection
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Clean lubricant from, and conduct a visual inspection of, the Mandrel
and jaw/slip cones. With usage, the contact points between the Mandrel
and the jaws/slips will become evenly polished, this is to be expected
and does not compromise the condition of the tool. Mandrel and
jaw/slip cone surfaces should remain smooth to the touch. Any surface
roughness, uneven wear, corrosion, pitting, or scarring should be noted.
Figure 16: CRTi Mandrel Cone Inspection
Revision G
Page 16 of 43
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6.4. Category 2C Inspection
6.4.1.
Perform a complete tool teardown to inspect for any component
damage and allow for re-lubrication of all CRTi components
For CRTi 2-4.5, 2-5.5 or 3-7.0
6.4.1.1. Remove and inspect the Upper Cam Housing.
Figure 17: CRTi 1,2-4.5, CRTi 1,2-5.5 or CRTi 2,3-7.0 Bumper removal
For CRTi 4-7, 2-8.63
6.4.1.2. Remove the Upper Housing Lock Ring.
Figure 18: CRTi 4-7 or CRTi 1,2-8.63 Upper Housing Lock Ring removal
6.4.1.3. Rotate the Upper Cam Housing relative to the Upper Cam until the
splines misalign. Remove and inspect the Upper Cam Housing.
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Figure 19: CRTi 4-7 or CRTi 1,2-8.63 Upper Cam Housing removal
6.4.2.
For all CRTi Base Tools
Unthread and remove the Intermediate Cam from the Upper Cam. Check
the threads and ramps for any signs of damage.
Figure 20: CRTi Intermediate Cam Removal
6.4.3.
Unthread and remove the Upper Cam from the Mandrel. Check the
threads, ramps and J-hooks for any signs of damage. Note and record the
lug adjustment (number of lugs the Upper Cam is rotated back from the
shouldered position) when disassembling the tool and always follow the
cam adjustment procedure in the assembly manual when reassembling the
tool.
Figure 21: CRTi Upper Cam Removal
6.4.4.
Revision G
Remove and inspect the Lock Sleeve and the Mandrel.
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Figure 22: CRTi Lock Sleeve Removal
6.4.5.
Remove the Bumper from the Lower Cam.
Figure 23: CRTi Bumper Removal
6.4.6.
Remove the Lower Cam Housing.
Figure 24: CRTi Lower Cam Housing Removal
6.4.7.
Revision G
Separate the Cage from the Upper Cam.
Page 19 of 43
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Figure 25: CRTi Cage Removal
6.4.8.
Separate the Cam Latch from the Lower Cam by removing the Lug
Latches, Pin Latches, and the alignment bolts
Figure 26: CRTi Cam Latch Removal
6.4.9.
Carefully remove the Latch Keys, Spring-Latch and End Ring from the
Cam Latch.
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Figure 27: CRTi Cam Latch Spring, End Ring and Latch Key Removal
6.4.10. Remove the Spiral retaining ring using the Belleville installation tool
and remove the Belleville springs.
Figure 28: CRTi Lower Cam Belleville Spring Removal
6.4.11. After the complete tool teardown ensure all the parts are free of any
contaminants and lubrication before inspection and reassembly. If any CRTi
components are found to be damaged or non-conforming, contact Volant
Product Support by email at support@volantproducts.ca for further part
evaluation.
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6.5. Category 3 Inspection (perform Category 2A, 2B and 2C inspection )
Although Volant recommends documenting all maintenance and inspections,
categories 3 and 4 must be documented to conform to API RP 8B.
Documentation should include a record of all significant defects found, repairs
made, rework conducted, NDT results and personnel involved in the
maintenance and inspection.
Ensure all parts, after a complete tool teardown, are free of contaminants
and lubrication before beginning the Category 3 inspection.
NDT Inspection
6.5.1.
NDT Inspection
NDT methods should be applied to further inspect critical areas in the CRT™
to assess specific components and to identify any damage or wear that
exceeds Volant’s allowable tolerances. Methods to inspect the tool include
Magnetic Particle Inspection (MPI), Liquid Penetrant Inspection (LPI) and
Ultrasonic (UT) Inspection.
6.5.1.1.
Primary Load Carrying Component Inspection
Conduct magnetic particle inspection per section 8.4.7 of API
Specification 8C, of all primary load carrying components. PLC
components include the Mandrel, jaws, spokes, and dies.
All relevant indications should be documented and verified with
LPI. Relevant indications at any critical section must be removed
prior to use. Critical sections include the following: the neck
portions between Mandrel cones, spline roots, thread roots,
thread relief and other grooves (including the retractor ring notch)
on both the internal and external surface of the Mandrel. Removal
of indications may be attempted provided the component
function is not affected. All relevant indications should be
reported to Volant Product Support (support@volantproducts.ca)
for further assessment and review prior to removal, unless explicit
instructions have already been provided.
6.5.1.2.
Mandrel Bore Erosion / Neck Thickness Check
Conduct an ultrasonic inspection (or other suitable nondestructive examination) at 5 or more equally spaced locations to
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check the average thickness of the Mandrels top neck. Use the
thickness data to calculate the cross sectional area as explained in
Appendix B. Area reduction must not exceed 5%. Ensure that the
UT gauge is properly calibrated for the Mandrels specific material.
The end of the Mandrel can be used as a gauge block and verified
using a calibrated Vernier caliper. Refer to Appendix B for sample
calculations.
Thickness
Figure 29: Thickness Measurements
6.5.2.
Cams Inspection
6.5.2.1.
After removing the Upper Cam Housing, clean and visually inspect
the cam surfaces and all thread flanks to ensure they are smooth
and show no signs of galling or deformation.
6.5.2.2.
Inspect all the cams for any pitting, raised or lowered edges along
the surface and the threads.
6.5.2.3.
Conduct an MPI inspection on all primary cam assembly
components, including: Upper Cam, Intermediate Cam, Lower
Cam and Latch Cam.
All relevant indications should be documented. Indications at any
critical section must be removed prior to continued use. Critical
sections include the following: the hooks, breakout ramp reliefs
and latch key pockets. All relevant indications should be reported
to Volant Product Support (support@volantproducts.ca) for
further assessment and review prior to removal, unless explicit
instructions have already been provided.
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Page 24 of 43
Check backlash in make-up threads by engaging the threads and
measuring relative axial movement between the Upper and
Intermediate Cams.
Thread the Intermediate Cam onto the Upper Cam and rotate until
the cam dogs clash as shown in the first image in Figure 30. Backoff the Intermediate Cam until the clearance is seen between the
Intermediate and Upper Cam ramps as shown in the second image
in Figure 30. Mark across both cams to rotationally link the two
cam sets as shown in the third image in Figure 30. Flip the cams
upside down and rest the Upper Cam on blocks, allowing the
Intermediate Cam to ‘hang’ on the Upper Cam as shown in the last
image in Figure 30. Use three feeler gauges between the cam
ramps to measure the axial backlash in the Upper and
Intermediate Cam threads. Axial backlash should not exceed
0.035”.
Cam dogs contacting
Mark rotation between cams
Rotate until there is cam ramp clearance
Measure clearance between cam ramps
(Upper Cam support blocks not shown)
Figure 30: Measuring axial backlash in make-up threads.
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Page 25 of 43
Verify that the Belleville spring condition is acceptable and that the
Belleville stack is applying load to the spiral retaining ring.
Mandrel Inspection
Note: These metrics have been developed to ensure the following
are maintained:
Revision G
•
Bearing area sufficient to support the loads produced in
operation.
•
Surface uniformity to prevent inconsistent friction
between the Mandrel and jaws.
•
Integrity in the critical neck region.
6.5.3.1.
After completing the NDT inspection of the Mandrel, conduct
visual inspection of the tool joint thread to ensure that condition
is acceptable and conduct an API Rotary connection inspection per
API RP 7G
6.5.3.2.
Area loss due to wear/corrosion/pitting on Mandrel/jaw cones
should not exceed 25% of any 1 square inch area. Scarring parallel
to the tool axis (of a length greater than 0.075”) should not exceed
0.015” in width. Circumferential scarring of any length should not
exceed 0.050” in width. Individual instances of pitting should not
exceed 0.075” diameter.
6.5.3.3.
Draw a straight edge across the face of each cone to check for
uniform surface condition. Any raised sections that impede
smooth transition should be abraded away using emery cloth.
6.5.3.4.
Install one die on an un-lubricated Mandrel and rotate the die
around the Mandrel’s circumference. Feel for any interruptions as
the die slides across the cones. Complete this at various axial
positions to ensure consistent friction across the entire range of
the tool. Any inconsistencies may become exaggerated under load
and cause component damage.
6.5.3.5.
Inspect all Mandrel threads including the tool joint threads, Carrier
threads and Cam threads to ensure that they are smooth and show
no signs corrosion or galling. .
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Page 26 of 43
6.5.3.6.
Inspect the rest of the Mandrel surface for any pitting, galling, rust,
raised or lowered edges.
6.5.3.7.
Inspect the splines for any damage, pitting or corrosion.
6.5.3.8.
Measure Mandrel top neck outer diameter. Mandrel top neck
diameter should not be less than the specified minimum in Table
2.
Diameter
Figure 31: ODm Measurements
Base Tool
CRTi1-4.5
CRTi2-4.5
CRTi1-5.5
CRTi2-5.5
CRTi1-7.0
CRTi2-7.0
CRTi3-7.0
CRTi4-7.0
CRTi1-8.63
CRTi2-8.63
Mandrel Spline
Min. Width (in)
Mandrel Top Neck
Min. diameter (in)
0.835
2.655
1.235
3.280
1.235
3.280
1.230
3.975
1.235
3.975
1.235
3.975
0.985
4.125
1.185
5.235
1.185
5.235
0.835
2.655
Table 2: CRTi Geometry Measurement Limits
6.5.3.9.
The Mandrel Neck Area Reduction limit is 5%. Running the CRT
Mandrel at or beyond the 5% limit does not comply with API 8C
ratings requirements and needs to be replaced.
When the Mandrel neck area reduction is between 3.5% - 5%
consider increasing the frequency of Category 3 inspections.
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The Mandrel Neck Area Reduction wear limit is only an indicator
and this area is purposefully chosen as one of the most critical
sections of the Mandrel; however this measurement does not
constitute a thorough assessment of the Mandrel’s capacity and
should not be taken as such.
Refer to Appendix B for Mandrel Neck Area Calculations.
6.5.3.10. Conduct a visual inspection of the Mandrel’s bore.
If significant bore erosion or corrosion is observed, inspect with a
borescope to help evaluate the cause of the damage and contact
Volant Product Support by email at support@volantproducts.ca to
discuss steps that can be taken to minimize further damage.
6.5.4.
Die Tooth Inspection
Grip Surface Considerations: Volant’s CRT is designed to maintain
effective casing penetration while still accommodating for some die
wear. Several issues arise as the teeth wear down and must be
considered when assessing a dies suitability for service:
6.5.4.1.
•
Reduced radial range can cause the tool to stroke out. This is
most likely to happen when running the lightest weight casing for
a given die set.
•
Reduced debris tolerance. Material collects in the valleys
between teeth faster than new dies, which may prevent proper
die penetration. It is important to make sure that die teeth are
thoroughly cleaned up during operations and maintenance.
•
Uneven wear creates biased loading on components. This can
increase operating stresses and generally results in increased
wear and tear on component leading to further component
damage.
Die Teeth Width
The dies must be sufficiently sharp to be able to penetrate
the surface of the casing in order to grip in either hoist or
torque. On an evenly spaced grid, measure the average flat
width of 10 intact teeth on each die using an optical
micrometer (if one is not available, a caliper may be used).
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Measure the average width across the parallel sides of the
tooth tip as shown in Figure 32. For each die, discard the 3
largest measurements and calculate the mean of the
remaining values. The maximum average flat width across
the tooth tip should not exceed 0.040”.
Note: If the average flat width exceeds 0.025”, radial range
will be reduced and the tool may fail the combined diametric
wear measurement in Appendix A. It is recommended that
radial range be checked prior to every job if die wear past this
limit is suspected.
a
b
a, b= tooth tip flat
average (a,b) < 0.025 in
Figure 32: Die tooth tip measurement
6.5.4.2.
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Inspect the Die surfaces for broken teeth (teeth that are noticeably
shorter than adjacent teeth and unlikely to contact the casing ID).
Up to 25% of the teeth can be broken in any 1.5”x1.5” square.
Broken teeth concentrated into one area may cause uneven
loading and premature wear on the Mandrel and Jaw faces. The
top and bottom 1” of the die face is exempt from this requirement
(see Figure 33).
Exempt From Inspection
Figure 33: Jaw Wear Locations
1”
6.5.5.
1”
Combined Diametric Wear
Measure the combined diametric wear on Mandrel and grip
assembly using the procedure outlined in Appendix A. If the
measurement falls outside acceptable range further investigation
is required to determine which components are out of
specifications. Repeat the procedure with substitute components
if available. This procedure will identify if the combined wear loss
is greater than the allowable component losses identified in Figure
34 & Figure 35.
Splines
Mandrel top neck
Note 1.
16 places on spline sides
Note 1.
Note:
1. Wear allowance .005” on surfaces indicated
Figure 34: Mandrel Wear Allowance
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Note 1
Wear allowance .005” on surfaces indicated
Note 1
Note:
1.
Wear allowance 0.010” on surfaces indicated
Figure 35: Jaw and Die Wear Allowances
6.5.6.
Cage Inspection
Remove the Cage seals and thoroughly clean the Cage. Inspect for
any visual wear or deformation. It is recommended to subject the
cage through an MPI. This will give us any indications of potential
cage failure.
Look for any Cage twists, or bending along the window grooves as
well as any signs of surface irregularities.
6.5.7.
Inspection of other CRTi parts
6.5.7.1.
Bumper
Inspect Bumper surfaces and thread condition for wear, pitting or
signs of deformation. Check for debris buildup in the Bumper holes
where bolts are installed to rotationally lock the Bumper to the
Lower Cam.
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Latch Key, Pin and Lug
Inspect the Latch Key for any signs of wear or damage and check
Latch Lug and Pin for signs of any irregularities. Check the Latch
Pins for straightness.
6.5.7.3.
Latch Spring & End Ring Spring
Visually inspect the Latch Spring and End Ring for any cracks,
dents, nicks that could cause further scarring to the Mandrel and
Cam Latch.
6.5.7.4.
Lock Sleeve & Upper Cam Housing
Inspect the splines of the Lock Sleeve and Upper Cam Housing for
corrosion and wear. Clean up the rust affected areas with an
abrasive cleaning pad (e.g. Scotch-Brite 3M pad).
6.5.7.5.
Additional Base Tool Parts
For other parts such as an Upper Housing Lock Ring and Cap
Housing, inspect for any wear, damage or irregularities that could
potentially cause problems. Check any threads for wear and
damage. Look for any signs of rust indications and clean the
affected areas.
6.5.7.6.
Casing Seal Assembly
Inspect all the parts of the Casing Seal Assembly for any signs of
wear and pitting.
Inspect the Carriers flow bore for any signs of damage or erosion
as well as the Carrier threads for signs of washout and damage.
Ensure that all sealing surfaces and seal grooves are smooth and
free of corrosion or pitting.
6.5.7.7.
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Inspect all Step Up components for any signs of wear, damage, and
corrosion. Critically, the slots in the faces for the spool plate and
cover plates should be smooth and free of corrosion and surface
damage.
6.6. Category IV Inspection (Perform Category III inspection plus the following)
6.6.1.
Proof Load Test
In order to re-certify the Mandrel, Volant recommends conducting a
tensile proof-load test. This is contrary to the recommendations in API RP
8B but serves the purpose of evaluating the capacity of the Mandrel in
the context of exposure related damage including erosion, corrosion, and
surface wear.
Please contact Volant to review options for Mandrel proof-load testing to
ensure the Mandrel is mounted in an appropriate test fixture. The test
fixture should contact the Mandrel in the same manner that Dies or
Integral Slips do when the tool is in its fully assembled state.
Make sure that the Mandrel box threads and all the cones are lubricated
as per normal use.
Recommended proof test load is 1.5 times the rated load of the tool as
per section 8.6.2 of API Specification 8C. The proof load should be held
for a minimum of 5 minutes.
Proof load testing can be done at Volant’s facility. Contact Volant Product
Support at support@volantproducts.ca for more information.
Revision G
6.6.2.
Conduct a non-destructive MPI examination in accordance with API
Specification 8C to confirm that Mandrels are free of cracks and damage.
6.6.3.
Conduct a cam latch hook torque release check as defined in Appendix
D.
6.6.4.
Document the following information including: component serial
numbers, test equipment serial numbers, test date and names of the
personal involved in the inspection, maintenance, repair and assembly.
Also document the load profile that includes the load and duration
information for the complete cycle and inspection results.
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Also document any other testing activities and results or component
defects and repairs.
7. CRTi Storage
If the CRTi is stored for a short period between jobs follow the maintenance
procedure as outlined in Table 1.
For long term storage special considerations should be taken. Consider the
environmental conditions that could vary over time such as temperature and
humidity, where the tool is being stored.
If applying any protective compound for the application of long term storage,
verify that the surfaces being applied are free of any moisture and contaminants
prior to the application of any compound. Seal the tool using a vapor barrier such
as shrink-wrap shown below and place a desiccant within the vapor barrier.
Follow the manufacturer’s instructions to determine the amount of desiccant
that should be used.
Figure 36: CRTi shipment
Before reassembly any protective compound or corrosion inhibiters applied
should be removed prior to reassembly of the tool.
If the tool is assembled and stored for more than three months always perform
a 2C inspection. If any problems or issues are found, follow the maintenance
procedure for corrective action.
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Page 35 of 43
8. OEM Refurbishment Program
Depending upon the age of the tool, Volant can assist in CRTi inspections,
including:
•
Category III Inspection and Level III Maintenance
OEM technicians will perform a complete tool tear down and Level 3
inspection of the CRTi based on API 8B recommended practices which
includes MPI, UT inspections and complete component assessment.
•
Category IV Inspection and Level IV Maintenance
This inspection will include the Category III inspection and the PLC Proof Load
testing.
•
CRTi Refurbishment
If at any point during an inspection it is found that the CRTi requires repair
or service, Volant can recommend a refurbishment plan that will return your
tool to a functional condition.
•
General Tool & Component Assessment
Volant’s Product Support group is available to any customer 24/7 to help
assess any equipment by phone/email. Parts/tools may also we sent directly
to Volant for a thorough assessment.
The OEM Refurbishment program will provide any associated reports and
certificates upon the completion of the inspection. For more information
contact Volant Product Support by calling 1.877.7VOLANT (1.877.786.5268)
or email support@volantproducts.ca.
If you require a quote or additional equipment needs, please feel free to
contact our Sales team at 1.866.8VOLANT (1.866.886.5268) or email
sales@volantproducts.ca.
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Page 36 of 43
Appendix A: Combined Wear Procedure
Check the combined wear allowance by engaging the CRTi in a test ring, slowly
applying 50 psi of air pressure to the Housing and measuring the “A” dimension as
shown in Figure 37 with a Vernier caliper. Compare the measured dimension to the
allowable range given in Table 3.
.5” Ring
Thickness
1.0”
Ring face to top of jaw
A = distance from
bottom face of cage to
end of mandrel
Ring
Width approx. = diameter/2
Figure 37: Wear allowance measurement
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Page 37 of 43
Casing
Weight (ppf)
13.5
18.0
23.0
17.0
CRTi1,2-4.5
Jaw/Die
Ring ID
Part #
+/- 0.003(in)
80957
4.084
82000
4.442
81182
4.841
80980
5.063
Allow. Range For "A"
(in)
Max 0.410 / Min 0.310
Max 0.410 / Min 0.310
Max 0.410 / Min 0.310
Max 0.410 / Min 0.310
Casing
OD (in)
5.50
5.50
7.00
7.00
Casing
Weight (ppf)
23.0
17.0
32.0
23.0
CRTi1,2-5.5
Jaw/Die
Ring ID
Part #
+/- 0.003(in)
81129
4.772
80913
4.944
81284
6.210
80981
6.483
Allow. Range For "A"
(in)
Max 0.719 / Min 0.619
Max 0.719 / Min 0.619
Max 0.719 / Min 0.619
Max 0.719 / Min 0.619
Casing
OD (in)
7.00
7.00
7.63
8.63
8.63
9.63
9.63
10.75
10.75
10.75
11.75
13.38
13.38
15.00
16.00
18.63
18.63
18.63
20.00
20.00
Casing
Weight (ppf)
35.0
26.0
33.7
36.0
32.0
53.5
43.5
60.7
51.0
40.5
54.0
72.0
61.0
92.5
65.0
111.0
97.7
87.5
111.0
94.0
CRTi1,2,3-7.0
Jaw/Die
Ring ID
Part #
+/- 0.003(in)
81062
6.157
80928
6.400
80986
6.925
80824
7.986
80987
8.082
80988
8.672
80825
8.842
81085
9.796
81323
9.982
82021
10.156
80833
11.010
81064
12.478
80828
12.646
81504
13.942
80826
15.348
81293
17.624
81292
17.752
80832
17.854
81799
19.040
81991
19.210
Allow. Range For "A"
(in)
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Max 0.852 / Min 0.752
Casing
OD (in)
4.50
5.00
5.50
5.50
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OD (in)
7.00
7.00
8.63
9.63
9.63
10.75
10.75
10.75
11.75
12.75
13.38
13.38
13.38
16.00
18.63
18.63
20.00
20.00
Casing
Weight (ppf)
35.0
26.0
36.0
53.5
43.5
79.2
73.2
65.7
60.0
54.8
72.0
61.0
54.5
65.0
97.7
87.5
133.0
106.5
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CRTi4-7.0
Jaw/Die
Ring ID
Part #
+/- 0.003(in)
81508
6.155
81277
6.420
81421
7.970
81420
8.620
81793
8.837
81138
9.345
81494
9.514
81255
9.670
81495
10.880
82039
11.972
81150
12.460
81897
12.624
81306
12.682
81431
15.317
81566
17.741
81434
17.789
81483
18.815
81759
19.258
Page 38 of 43
Allow. Range For "A"
(in)
Max 0.708 / Min 0.608
Max 0.708 / Min 0.608
Max 0.708 / Min 0.608
Max 0.708 / Min 0.608
Max 0.708 / Min 0.608
Max 0.708 / Min 0.608
Max 0.708 / Min 0.608
Max 0.708 / Min 0.608
Max 0.708 / Min 0.608
Max 0.708 / Min 0.608
Max 0.708 / Min 0.608
Max 0.708 / Min 0.608
Max 0.708 / Min 0.608
Max 0.708 / Min 0.608
Max 0.708 / Min 0.608
Max 0.708 / Min 0.608
Max 0.708 / Min 0.608
Max 0.708 / Min 0.608
CRTi1,2-8.63
Casing
OD (in)
8.63
9.63
9.63
10.75
10.75
10.75
11.75
12.75
13.38
13.38
13.38
16.00
18.63
18.63
20.00
20.00
22.00
26.00
1
Casing
Weight (ppf)
Jaw/Die
Part #
Ring ID
+/- 0.003(in)
Allow. Range For "A"
(in)
36.0
81024
8.040
Max 1.074 / Min 0.974
53.5
81154
8.710
Max 1.074 / Min 0.974
43.5
81756
8.910
Max 1.074 / Min 0.974
79.2
81138
9.402
Max 1.074 / Min 0.974
73.2
81494
9.572
Max 1.074 / Min 0.974
60.7
81255
9.728
Max 1.074 / Min 0.974
60.0
81495
10.938
Max 1.074 / Min 0.974
54.8
82039
12.030
Max 1.074 / Min 0.974
72.0
81150
12.518
Max 1.074 / Min 0.974
61.0
81897
12.680
Max 1.074 / Min 0.974
54.5
81306
12.740
Max 1.074 / Min 0.974
65.0
81431
15.374
Max 1.074 / Min 0.974
97.7
81566
17.798
Max 1.074 / Min 0.974
87.5
81434
17.846
Max 1.074 / Min 0.974
133.0
81483
18.873
Max 1.074 / Min 0.974
106.5
81759
19.316
Max 1.074 / Min 0.974
224.0
81750
20.100
Max 1.074 / Min 0.974
275.0
81462
24.083
Max 1.074 / Min 0.974 1
Table 3: Die test ring ID and measurement
For test rings that differ from the specified ring ID please contact support@volantproducts.ca
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Page 39 of 43
Appendix B: Mandrel Neck Area Reduction Calculation
Mandrel neck area calculation. Measure Mandrel top neck OD and Mandrel top neck
wall thickness
AR = Area Reduction (%)
tavg = Average Mandrel thickness 2
ODi = Original Mandrel outside diameter
ODm = Measured Mandrel outside diameter
IDi = Original Mandrel inside diameter
Ai = Original Mandrel area
NA = Mandrel Neck Area
π = 3.14159
NA = π × [t avg (ODm − t avg )]
  NA  
  *100
AR = 1 − 

A
  i 
ODm t
Figure 38: ODm And t Measurements
2
Thickness measurement should be taken with ultrasonics.
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Tool
ODi
IDi
Ai
CRTi1-4.5
2.672 +/- 0.005
1.000 +/- 0.03
4.82 +/- 0.07
CRTi2-4.5
2.672 +/- 0.005
1.000 +/- 0.03
4.82 +/- 0.07
CRTi1-5.5
3.286 +/- 0.005
1.250 +/- 0.01
7.25 +/- 0.05
CRTi2-5.5
3.286 +/- 0.005
1.250 +/- 0.01
7.25 +/- 0.05
CRTi1-7.0
3.991 +/- 0.005
1.500 +/- 0.03
10.74 +/- 0.10
CRTi2-7.0
3.991 +/- 0.005
1.500 +/- 0.03
10.74 +/- 0.10
CRTi3-7.0
3.991 +/- 0.005
1.500 +/- 0.03
10.74 +/- 0.10
CRTi4-7.0
4.141 +/- 0.002
1.500 +/- 0.01
11.70 +/- 0.04
CRTi1-8.63
5.250 +/- 0.002
2.000 +/- 0.03
18.51 +/- 0.11
CRTi2-8.63
5.250 +/- 0.002
2.000 +/- 0.03
18.51 +/- 0.11
Table 4: Original Tool Dimensions
Calculation Example:
A CRTi 2-5.5 tool is undergoing a CAT 3 inspection. ODm was measured at 3.28 in. The ultra
sonic thickness gauge provides us with 5 Mandrel thickness measurements. t1 = 1.007 in, t2
= 1.009 in, t3 = 1.008 in, t4 = 1.007 in and t5 = 1.006 in.
tavg = 1.007 + 1.009 + 1.008 + 1.007 + 1.006 = 1.0074 in
5
Ai = 7.25in (fromTable 4)
π = 3.14159
Neck Area can be found using the formula
NA = π × [t avg × (ODm − t avg )]
NA = 3.14159 × [1.0074 × (3.28 − 1.0074 )]
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NA = 3.14159 × [1.0074 × (2.2726)]
NA = 7.1924 in2
Area Reduction can be found using the formula
  NA  
  *100
AR = 1 − 

A
i



  7.1924  
AR = 1 − 
  * 100
  7.25  
AR = (1 − (0.9879 )) * 100
AR = 0.79%
The Area Reduction is within the Category 3 limit as it is less than 5%.
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Appendix C: Maximum Casing Inside Diameter
Outside
Diameter
(in)
4.50
4.50
4.50
4.50
4.50
5.00
5.00
5.00
5.00
5.00
5.00
5.00
5.50
5.50
5.50
5.50
5.50
5.50
5.50
5.50
5.50
5.50
5.50
5.50
6.63
6.63
6.63
6.63
7.00
7.00
7.00
7.00
7.00
7.00
7.00
7.00
7.00
7.00
7.00
7.00
7.00
7.63
7.63
7.63
7.63
7.63
7.63
7.63
7.63
7.63
Weight
(ppf)
9.5
10.5
11.6
13.5
15.1
11.5
13.0
15.0
18.0
21.4
23.2
24.1
14.0
15.5
17.0
20.0
23.0
26.8
29.7
32.6
35.3
38.0
40.5
43.1
20.0
24.0
28.0
32.0
17.0
20.0
23.0
26.0
29.0
32.0
35.0
38.0
42.7
46.4
50.1
53.6
57.1
24.0
26.4
29.7
33.7
39.0
42.8
45.3
47.1
51.2
Max. ID
Wt lim.
(in)
4.154
4.118
4.069
3.993
3.904
4.631
4.568
4.486
4.361
4.220
4.142
4.101
5.090
5.031
4.976
4.868
4.766
4.605
4.488
4.370
4.254
4.136
4.020
3.903
6.143
6.021
5.898
5.788
6.629
6.551
6.466
6.380
6.293
6.208
6.123
6.043
5.883
5.765
5.647
5.531
5.413
7.129
7.076
6.987
6.882
6.750
6.632
6.570
6.513
6.396
Max. ID
WlThk
(in)
4.186
4.153
4.108
4.038
3.955
4.665
4.607
4.532
4.417
4.285
4.214
4.175
5.128
5.074
5.023
4.923
4.829
4.680
4.572
4.461
4.353
4.243
4.134
4.024
6.188
6.076
5.962
5.861
6.666
6.594
6.515
6.437
6.356
6.277
6.199
6.125
5.976
5.867
5.758
5.649
5.539
7.176
7.127
7.045
6.949
6.826
6.718
6.660
6.608
6.499
Outside
Diameter
(in)
7.63
7.75
8.63
8.63
8.63
8.63
8.63
8.63
8.63
9.63
9.63
9.63
9.63
9.63
9.63
9.63
9.63
9.63
9.63
9.63
10.75
10.75
10.75
10.75
10.75
10.75
10.75
10.75
10.75
10.75
11.75
11.75
11.75
11.75
11.75
11.75
13.38
13.38
13.38
13.38
13.38
16.00
16.00
16.00
16.00
18.63
20.00
20.00
20.00
26.00
Weight
(ppf)
55.3
46.1
24.0
28.0
32.0
36.0
40.0
44.0
49.0
32.3
36.0
40.0
43.5
47.0
53.5
58.4
59.4
64.9
70.3
75.6
32.8
40.5
45.5
51.0
55.5
60.7
65.7
73.2
79.2
85.3
42.0
47.0
54.0
60.0
65.0
71.0
48.0
54.5
61.0
68.0
72.0
65.0
75.0
84.0
109.0
87.5
94.0
106.5
133.0
*
Max. ID
Wt lim.
(in)
6.277
6.696
8.208
8.132
8.041
7.949
7.854
7.759
7.651
9.126
9.050
8.968
8.892
8.822
8.683
8.589
8.562
8.443
8.325
8.206
10.325
10.190
10.095
10.000
9.914
9.819
9.724
9.578
9.461
9.342
11.232
11.152
11.038
10.935
10.850
10.759
12.879
12.784
12.689
12.593
12.529
15.444
15.324
15.216
14.909
17.981
19.364
19.246
18.989
*
Table 5: Casing Maximum Inside Diameter
Revision G
Max. ID
WlThk
(in)
6.389
6.786
8.250
8.180
8.096
8.012
7.924
7.837
7.737
9.175
9.105
9.030
8.960
8.895
8.768
8.680
8.656
8.545
8.437
8.327
10.369
10.245
10.158
10.070
9.991
9.904
9.816
9.682
9.573
9.463
11.285
11.211
11.106
11.012
10.933
10.849
12.931
12.844
12.756
12.669
12.609
15.504
15.394
15.294
15.012
18.050
19.434
19.325
19.089
24.250
Page 42 of 43
4110 56 Ave NW
Edmonton AB T6B 3R8
Canada
Phone:
Fax:
780.490.5185
780.437.2187
CRTi™ Maintenance Procedure
Doc. No. 40021 Rev.G
Page 43 of 43
Appendix D: Cam Latch Torque Release Check
With the tool completely assembled, latched and mounted in a chain vice or stump
clamp, apply 40 psi air pressure to the air spring. Place a test ring over the slip
assembly. Apply torque to the Bumper to release the tool and engage the test ring.
Verify that the observed torque not less than the indicated typical minimum as
outlined below in Table 6.
Tool Designation
Air Pressure (psi)
Typ. Min. Release Torque (ft-lbs)
CRTi1-4.5,CRTi2-4.5
40
100
CRTi1-5.5, CRTi2-5.5
40
150
CRTi1-7.0, CRTi2-7.0, CRTi3-7.0
40
150
CRTi4-7.0
40
170
CRTi1-8.63, CRTi2-8.63
40
240
Table 6: Cam Latch Release Torque
Revision G