Instruction Manual Kelly Bars

AA000610.wmf

Keep this manual also for future use!

BAUER Doc.-No.

KEL031EN_00 BAUER Maschinen GmbH P.O. Box 12 60 D-86522 Schrobenhausen Germany Phone: +49 8252 97-0 Fax: +49 8252 97-1359

(valid for all types of kelly bars) Users are also advised to read the operating instructions for kelly bars as given in the separate BAUER "Operating Manual for Drill Rigs, Tools and Accessories".

TABLE OF CONTENS
1 2 2.1 2.2 2.3 2.3.1 2.3.2 2.3.3 INSTRUCTIONS............................................................................................... 2 MAINTENANCE ............................................................................................... 5 Maintenance Intervals ...................................................................................... 5 Prescribed Services.......................................................................................... 6 Repair Welding............................................................................................... 11 Grind Faces to be Joined, Remove Burrs and Clean Weld Zone Free of Grease............................................................................................................ 11 Determine what Material the Parts are Made from ......................................... 12 Observe the Following when Several Parts are to be Welded Together: ....... 12 a) Butt Welding............................................................................................. 12 b) To Weld Gibs onto the Kelly .................................................................... 13 c) To Replace the Kelly Square-Shaped Tool Joint ..................................... 15 Welding Rod Specifications............................................................................ 17 TRANSPORT AND STORAGE ...................................................................... 19 Transportation of Kelly bars............................................................................ 19 OVERSEAS SHIPPING OF KELLY BARS..................................................... 20 STORAGE OF KELLY BARS ......................................................................... 21 Drilling Rod Dolly ............................................................................................ 21

2.3.4 3 3.1 3.2 3.3 3.3.1

KBM / 2007

Kelly bars are designed for the purpose of transferring torques and pressures onto a drilling tool. The kelly used must therefore be treated with as much care as the drilling rig and the tool and bits themselves in order that consistent drilling performance be ensured.

INSTRUCTIONS
The following work instructions specific to kelly bars are a supplement to the supplied work instructions for drilling rigs, tools and accessories. These supplementary instructions serve to help avoiding unnecessary wear.

CAUTION

Not all types of kellys are designed for the full torque of the rotary drive of the drilling rig: Know the max. permissible torque for the kelly and do not exceed it with the rotary drive. Kellys and drilling tools are allowed to be used only for drilling applications; earthmoving, conveying or levelling jobs are not permissible. Kellys may not be used for bringing borehole casings or drilling tools into alignment. Kellys may be operated with free-fall facility only as long as the total load on the kelly rope does not exceed half of the max. pulling capacity of the corresponding winch. Example: Pulling capacity of main winch is 20 tonnes Weight of kelly: (type 4/44) + Weight of auger bit: ( 1500 mm) 7.6 tonnes + 1.6 tonnes 9.2 tonnes (see chapter "Tech. Data") (see imprint on tool)

Calculation: Summation:

20 tonnes : 2 = 10 tonnes > Total: Kelly may still be used with free-fall.

With a kelly inserted in a borehole, it is no longer allowed to make any readjustments with the base machine or at the mast of the drilling rig. Exception: If the mast is displaced from is initial working angle, due to the working forces, it must be readjusted.

Kelly and mast must be parallel at all times of operation. CAUTION

KBM / 2007

Drilling operation with a kelly may be started only when the kelly has been inserted completely so that the drilling tool stands on the bottom of the borehole. For drilling with a kelly in hard formations, the kelly must be of interlockable type; operating with sections not properly locked together would result in excessive wear or damage of the kelly. When drilling for foundation of a pile on hard ground, the inner kelly should not be completely extended. This prevents excessive wear. If a longer type of kelly is used, the inner kelly does not have to be extended to its full length. Bored piles produced in the cased method provide better guidance of the drilling tool and the kelly. This does in general reduce the wear on the drilling tool and the kelly. In extremely tough conditions (such as one-sided drilling in hard material), it is important that no additional forces are put on the kelly, or it could kink and start tumbling: If one-sided stress on the drilling tool, adapt the crowd force correspondingly. In conditions where the borehole is extremely deep or the drilling diameter extremely large, special attention must be paid that teeth and chisels are in good working order: Replace with new drilling bits in good time, do by no means attempt to make up for worn out bits by increasing the crowd force on the kelly. When extending a kelly, readjust torque and pressure (decrease as necessary) to adapt to the conditions. When putting the kelly down on the borehole bottom, especially so with the last section (the inner kelly bar), the kelly must be lowered slowly by the main winch. To avoid damage, prevent the inner kelly hitting the intermediate kelly.

KBM / 2007

When withdrawing a kelly from a borehole, keep an eye on the outermost section: If the outermost section lifts from its rest on the rotary drive, one of the inner sections is not properly unlocked to retract. - STOP lifting by main winch to avoid that the locking mechanism will open now, or the section would slip through and get damaged. - REINSERT kelly to bottom of borehole and then rotate counterclockwise with the rotary drive and pull by the main winch to completely unlock and properly retract all sections. If the drilling rig is equipped with a winch load sensoring device, keep also an eye on the drilling monitor unit and compare there the indicated values of "Tool depth" and "Winch load" to see if sections are unlocking properly. After having retracted one section, the indicated value of "Winch load" should increase only by the weight of the respective section. In this way it is also possible to determine where among the sections an unlocking does not function properly. The method of comparing "Tool depth" with "Winch load" is useful also while extending a kelly (whereby the weight decreases correspondingly with each extended section).

KBM / 2007

MAINTENANCE

Correct maintenance prevents the kelly from wearing down prematurely. By carrying out necessary repair in time, costly repair can be avoided. The kelly must be free of contamination such as sand, concrete and foreign substances. Thoroughly clean the kelly before carrying out maintenance work.

2.1

MAINTENANCE INTERVALS

For kellys used under normal soil conditions (non-cohesive and cohesive soils up to grade 6) Prescribed intervals for: 1st inspection after: subsequent inspections every: double and triple kellys 100 - 150 hrs 400 - 500 hrs quadruple and quindruple kellys 50 - 100 hrs 250 - 300 hrs

For kellys used under tougher conditions (with soil grades exceeding 6 or rock), the intervals should be shortened by half the time given. In case of a failure such as - sections are slipping through - kelly top cover is deformed - sections will not retract or extend smoothly

the kelly must be removed at once and be inspected. Disassembly and repair will require a free space as long as double the length of the kelly when it is retracted.

KBM / 2007

2.2

PRESCRIBED SERVICES

When inspecting, pay special attention to wear on the following components (see also tables on pages 6 through 9): Kelly with 6 gibs
Kelly head

Kelly with 2 or 3 gibs

Kelly head 1 Rubber bumpers 11 Locking recesses Drive gibs in transition zone

12

Tube

Shock absorbers

"A"
Locking 3 recesses

5 6 9 7 8

Pilot bit

"A" Close-up view:

Drive gibs in transition zone Impact ring

Impact ring

4 Drive shell

Compression spring

10 Drive shell 4
Wear ring Drive gib

Square-shaped tool joint

AA000533.wmf

KBM / 2007

Component 1 Kelly head -

Damage Deformation at kelly head Cracks in bore Deformation at cover -

Note - Repair Replace the head; see welding instructions Replace the cover

2 Shock absorbers (on rotary drive

Worn out or smashed

In case the damage was caused by accidental dropping of kelly sections, the kelly will in general be damaged as well so that it must be disassembled and repaired Rebuild by welding max. permissible wear is 10 mm:
max. 10

3 Locking recesses on kelly with 2 or 3 gibs:

Cracks or edges worn down

New on kelly with 6 gibs:

AA000501.wmf

Worn

AA000502.wmf

max. permissible wear is 10 mm:

max. 10

New on kelly with 2 or 3 gibs:

AA000503.wmf

AA000504.wmf Worn max. permissible wear is 30 %:

max.30%

New on kelly with 6 gibs:

AA000505.wmf

Worn

AA000506.wmf

max.30%

New

AA000507.wmf

Worn

AA000508.wmf

KBM / 2007

Component 4 Drive shells Worn out

Damage

Note - Repair Max. permissible wear is 10 mm

View "B"

View "B":

Impact ring Deformation Drive shell Drive gib Wear ring Drive shell

AA000534.wmf

View "A" Drive shell "X"

View "A" "X"

X:

Tube

X: max. 10

New 5 Pilot bit Worn down surface Cracks or deformation in lower part -

Worn

AA000535.wmf

See welding instructions Replace with new tubing

"C":

"C"
Kellyanfnger (Risse) Pilot bit (Cracks)

AA000511.wmf

KBM / 2007

ma x.

10

"A":

"A":

Component 6 Drive gibs

Damage Cracks in transition zone, or burrs and slits on edges, or worn down edges

Note - Repair Max. permissible wear is 10 mm; grind the burr; max wear in transition zone is 30 % a) Max. wear 10 mm b) Max. burr 1 - 2 mm
X:

(a)

"X"

X: "X"

X:

(b)
max. 1-2

New 7 Compression spring 8 Square-shaped tool joint 9 Impact ring

AA000512.wmf

Worn Replace with new

AA000513.wmf

Jolted or broken Cracks in upper part Worn down surface; cracked, burred

Replace with new tool joint Max. permissible wear is 50 mm; grind the burr

AA000514.wmf

AA000515.wmf

KBM / 2007

max. 50
9

max. 10

Component 10 Wear ring 11 Rubber bumpers 12 Tubing material

Damage Cracks or worn down Worn down Deformed, out of shape

Note - Repair Replace with new Replace with new Cut off deformed tubing and replace with new
Deformierung am Rohr Deformation on tube

AA000516.wmf

Also to be inspected are

- all welds for cracks - all bolts that they are properly in place and firm.

It is assumed that the work be carried out by trained and qualified welding personnel ! CAUTION Please, observe the information given in sect. "Repair Welding" ! Twisted, kinked or worn out kellys must be taken out of service ! Never lubricate a kelly bar ! To prove kelly sections have not deformed or got stuck from the welding work, all the sections must be completely extended from one another before the kelly is put into use again !

CAUTION

10

KBM / 2007

2.3

REPAIR WELDING
Due to the consistent technological progress and improvement of materials, no detailed specifications are given on the materials used in the kelly. The materials from which a specific kelly is constructed can be asked for at the After Sales Service Department of BAUER Maschinen GmbH, if so required for a repair. Please, be aware that BAUER Maschinen GmbH will not assume any liability for welding work carried out other than by trained and authorized BAUER personnel ! It is assumed that the work be carried out by trained and qualified welding personnel ! Accident prevention and fire protection safety standards and provisions prevalent in the construction industry must be observed, especially those applicable to "Welding and cutting".

NOTE

CAUTION

Steps for Repairing:

2.3.1

Grind Faces to be Joined, Remove Burrs and Clean Weld Zone Free of Grease
Bruch Break

If the break is ragged, it may be necessary to replace the broken section with new tubing, whereby the "A" dimension must be kept.

"A"

Fgestelle Joint
AA000517.wmf

KBM / 2007

11

2.3.2

Determine what Material the Parts are Made from

The square-shaped tool joint and the kelly head with suspension eye are from alloy steel and require preheating. Also to be heated prior to welding are the areas in the vicinity of the square-shaped tool joint and the kelly head with eye, and thick materials. Preheat the weld zone (approx. 200 mm outwards on both sides of welded joint) to approx. 150 C 180 C. Postheat finished weld to approx. 180 C. Use a sheltered location free of draught (workshop).

2.3.3

Observe the Following when Several Parts are to be Welded Together:

Keep the "A" dimension of the kelly inner bar and the length of the tubes. Keep linear alignment and straightness. Compare tube diameters (tolerance deviation) Observe quality group in accordance with EN 25817 / ISO 5817

"A"
AA000518.wmf

a)

Butt Welding Use a fit-up fixture to hold parts.

25

Fgestelle Joint

AA000519.wmf

Tack-weld spotwise (25 mm) 3 blank steel rods onto the tubing for fixture

12

KBM / 2007

To weld: Detail of B-B and "A":

ca. 100 2

B
60

B
"A" ...Fhrungsleisten / Gibs
AA000520.wmf

Weld gibs onto tube in an offset manner (by step-back welding).

b)

To Weld Gibs onto the Kelly

Maximum permissible wear When Uniform When One-side on material

St 52 max. 10 max. 10 max.30% 25CrMo4v

StE690 max. 10 max. 10 max.30% St 52 25CrMo4v

AA000521.wmf

Uniform wear on gibs, drive shells and locking recesses must not exceed 10 mm.

One-side wear on material requires repair, to prevent a functional failure.

KBM / 2007

13

Kelly Fit-up gibs and tack-weld Weld on gibs in several layers Avoid pitting surfaces Produce flush welds
X: "X" 45

AA000522.wmf

Avoid irregular distribution of heat over the bar - differences in temperature must be kept at a minimum to prevent distortion. Therefore, it is recommended to proceed in a step-back manner.

A kelly with 3 gibs

AA000523.wmf

Do not weld at recesses in zones between arrows marked "- - -" (avoid cross welds).

A kelly with 2 x 3 gibs

AA000524.wmf

14

KBM / 2007

c)

To Replace the Kelly Square-Shaped Tool Joint All parts must be preheated before welding.

NOTE 1. 1 2 3 4 Tool Joint Larger than Kelly Inner Bar Kelly tool joint Kelly inner bar Guiding ring Gibs
2 4 3 1

"Z"

AA000525.wmf

Fit gibs (4) linear with the shape of the tool joint (1). Weld together the inner bar tubing (2) and the tool joint (1), see detail "Z".
10

16

16

10

CAUTION

6 6
AA000526.wmf

Weld gibs (4) onto tool joint (1) and tubing (2). Produce the weld (see arrow) all the way through in one go. NOTE Weld on guiding ring (3).
50

Schweinaht Weld

AA000527.wmf

KBM / 2007

20

Be careful to keep linear alignment and the "A" dimension.

15

2.

Tool Joint Smaller than Kelly Inner Bar

X B C

Section B-B:

D B 2 4 C 3

1
AA000528.wmf AA000529.wmf

1 Kelly tool joint 2 Kelly inner bar

3 Guiding ring 4 Gibs

Section C-C:

Weld together tool joint (1) and inner bar tubing (2), see section D-D and detail "Z".

CAUTION

Be careful to keep linear alignment and the "A" dimension.

Weld gibs (4) onto tubing (2) and tool joint (1) as far as to "*" in section D-D. See also section C-C (empty space at arrow). Avoid pitting at the end. Section D-D: Join guiding ring (3) with gibs (4): Weld together along provided chamfers as far as to "X" in figure above.
20

AA000530.wmf

100

"Z"

3
AA000531.wmf

R6 3
AA000532.wmf

Detail "Z"

The lengths of the individual welds can be understood by comparing sections B-B and C-C (arrows) in figures above.

16

KBM / 2007

2.3.4

Welding Rod Specifications Principally, the manufacturer's specifications must be observed in the application of rod electrodes !

CAUTION

As for the application of basic covered electrodes, it is important that the electrodes be dried in compliance with the manufacturer's indications !

Rod electrode AC Arc welding (111) EN 499 DIN 1913 AWS A 5.1 B.S. 639 NFA 81-309 E 42 2 RB12 E 51 32 B(R) 10 E 7016 E 51 32 B 23 (H) E 513 / 2 B 21H Rod electrode in mm 2.5 3.2 4.0

BAUER-Genuine-Parts-No. / Name 52000 / Phoenix KB Special 49293 / Phoenix KB Special 52001 / Phoenix KB Special

Rod electrode AC Arc welding (111) EN 499 DIN 1913 AWS A 5.1 E 38 2 RB12 E 43 33 RR(B) 7 E 6013 Rod electrode in mm 3.2

BAUER-Genuine-Parts-No. / Name 234306 / Phoenix yellow

Rod electrode AC Arc welding (111) EN 499 E 42 5 B 32 H5 AWS A 5.1 E 7018-1

KBM / 2007

17

Wire electrode MAG-Welding (135) EN 440 DIN 8559 AWS A 5.18 G4 Si 1 SG 3 ER 70S-6

NOTE

Only use protective gas complying with EN 439 directives.

BAUER-Genuine-Parts-No. 700997 217237 700265

Rod electrode in mm 0:8 1:0 1:2

NOTE

Further welding fillers, e.g. for welding on kelly bars with higher quality welding metals, can be inquired from the After Sales Service Department of BAUER Maschinen GmbH.

18

KBM / 2007

3
3.1

TRANSPORT AND STORAGE

TRANSPORTATION OF KELLY BARS
DANGER! Lifting equipment and slings used for loading and unloading must be safe and of sufficient capacity. Avoid abrupt and quick movements when lifting, to prevent the load shifting and sliding away ! Accident prevention regulations and safety standards for operation of lifting equipment must be observed !

Preparation of kelly bars for transport: A 15500 mm 2 x underpinned with timbers, preferably 1/4A + 1/2A + 1/4A apart A > 15500 mm 3 x underpinned with timbers, preferably 1/6A + 2/6A + 2/6A + 1/6A apart

1/6

2/6

2/6

1/6
AA000618.wmf

CAUTION

Risk of damaging the kelly ! The kelly bar may be tied-down only in the direct vicinity of the timbers used for the underpinning. Otherwise, the kelly can get deformed (twisted) from torsion stress and vibrations! If there is an evidence of deformation of the kelly following the transport, the BAUER Maschinen GmbH should be consulted in prevention of potential damage resulting.
2

1 2 3 4 5

Tie-down strap Shims Underpinning Kelly Holding lugs (on transporting vehicle e.g.)

4 1 5 3

AA000621.wmf

KBM / 2007

19

3.2

OVERSEAS SHIPPING OF KELLY BARS

A

1/6

2/6

2/6

1/6

AA000619.wmf

CAUTION

Risk of damaging the kelly ! The kelly bar may be tied-down only in the direct vicinity of the timbers used for the underpinning. Otherwise, the kelly can get deformed (twisted) from torsion stress and vibrations! If there is an evidence of deformation of the kelly following the shipping, the BAUER Maschinen GmbH should be consulted in prevention of potential damage resulting.

1 Tie-down strap 2 Holding lugs (in shipping container e.g.) 3 Bearing support 4 Kelly

3 4 1 2

AA000620.wmf

20

KBM / 2007

3.3

STORAGE OF KELLY BARS

Kelly bars must be underpinned as follows when put into storage: A 15500 mm 2 x underpinned with timbers, preferably 1/4A + 1/2A + 1/4A apart A > 15500 mm 3 x underpinned with timbers, preferably 1/6A + 2/6A + 2/6A + 1/6A apart
A

1/4

1/2

1/4
AA000626.wmf

1/6

2/6

2/6

1/6
AA000618.wmf

NOTE

For optimal storage stability, the surface on which the bars are stored should be firm and level and uniformly supporting. A direct contact with the ground must be avoided. At extremely high ambient storage temperatures, > +40 C (> 104F), as from exposure to direct sunshine e.g., the BAUER Maschinen GmbH recommends to use the double amount of timbers (evenly distributed) in the underpinning. Risk of damaging components ! Before putting a kelly into use again after a longer period of storage, the kelly should be visually inspected for straightness. If there is an evidence of deformation, the BAUER Maschinen GmbH should be consulted in prevention of potential damage resulting.

CAUTION

3.3.1

Drilling Rod Dolly

The dolly supplied with the equipment is only for the transport of kelly bars within a construction site (trail it slowly) and must not be used as an appliance for storing. Remove the kelly bar immediately from the dolly when the transport is finished, and lay it down in compliance with the instructions given in "Storage of Kelly Bars".

KBM / 2007

21