Instruction Manual Kelly Bars

BAUER Maschinen GmbH P.O. Box 12 60 � D-86522 Schrobenhausen � Germany

Phone: +49 8252 97-0 � Fax: +49 8252 97-1359

AA000610.wmf

Keep this manual also for future use!

BAUER Doc.-No. KEL031EN_00

KBM / 2007 1

(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 INSTRUCTIONS............................................................................................... 2

2 MAINTENANCE ............................................................................................... 5 2.1 Maintenance Intervals ...................................................................................... 5 2.2 Prescribed Services.......................................................................................... 6 2.3 Repair Welding............................................................................................... 11 2.3.1 Grind Faces to be Joined, Remove Burrs and Clean Weld Zone Free of Grease............................................................................................................ 11 2.3.2 Determine what Material the Parts are Made from......................................... 12 2.3.3 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

2.3.4 Welding Rod Specifications............................................................................ 17

3 TRANSPORT AND STORAGE ...................................................................... 19 3.1 Transportation of Kelly bars............................................................................ 19 3.2 OVERSEAS SHIPPING OF KELLY BARS..................................................... 20 3.3 STORAGE OF KELLY BARS ......................................................................... 21 3.3.1 Drilling Rod Dolly ............................................................................................ 21

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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 en-sured.

1 INSTRUCTIONS

CAUTION

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.

� 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; earth-moving, 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 Weight of kelly: 7.6 tonnes (see chapter winch is 20 tonnes (type 4/44) "Tech. Data") + + Weight of auger bit: 1.6 tonnes (see imprint (� 1500 mm) on tool)

Calculation: 20 tonnes : 2 = 10 tonnes > Total: 9.2 tonnes

Summation: Kelly may still be used with free-fall.

� With a kelly inserted in a borehole, it is no longer allowed to make any readjust-ments 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.

CAUTION

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

KBM / 2007 3

� 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 im-portant that no additional forces are put on the kelly, or it could kink and start tum-bling: 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 or-der: 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 sec-tion (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.

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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 sec-tions 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 in-crease 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 extend-ing a kelly (whereby the weight decreases correspondingly with each extended sec-tion).

KBM / 2007 5

2 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: double and triple kellys quadruple and

quindruple kellys

1st inspection after: 100 - 150 hrs 50 - 100 hrs

subsequent inspections every: 400 - 500 hrs 250 - 300 hrs For kellys used under tougher conditions (with soil grades exceeding 6 or rock), the in-tervals 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.

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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 with 2 or 3 gibs

1Kelly head

"A"

9Impact ringDriveshell4

"A" Close-up view:

Kelly head

Rubber bumpers

Locking recesses

Drive gibs in transition zone

3

6

11

1

Shockabsorbers 2

10

6

Compressionspring

8 Square-shapedtool joint

Lockingrecesses

9

7

3

6

5

Drive gibsin transition

zone

Impact ring

Pilot bit

12 Tube

Wear ring

Drive shell

Drive gib

4

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KBM / 2007 7

Component Damage Note - Repair

1 Kelly head - Deformation at kelly head - Cracks in bore - Deformation at cover

- 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 re-paired

3 Locking recesses

Cracks or edges worn down Rebuild by welding

on kelly with 2 or 3 gibs:

New AA000501.wmf

max. permissible wear is 10 mm:

max. 10

Worn AA000502.wmf

on kelly with 6 gibs:

New AA000503.wmf

max. permissible wear is 10 mm:

max. 10

Worn AA000504.wmf

on kelly with 2 or 3 gibs:

New AA000505.wmf

max. permissible wear is 30 %:

max.30%

Worn AA000506.wmf

on kelly with 6 gibs:

New AA000507.wmf

max.30%

Worn AA000508.wmf

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KBM / 2007

Component Damage Note - Repair

4 Drive shells Worn out Max. permissible wear is 10 mm

Impact ring

Deformation

Drive shell

View "B"View "B":

Wear ringDrive shell

Drive gib

AA000534.wmf

Drive shell

Tube

"X"

X:

View "A"

"A":

"X"

X:

max. 10

"A":

View "A" max

. 10

New Worn AA000535.wmf

5 Pilot bit - Worn down surface - Cracks or deformation in

lower part

- See welding instructions - Replace with new tubing

"C":

"C"

Pilot bitKellyanfänger

(Cracks)(Risse)

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KBM / 2007 9

Component Damage Note - Repair

6 Drive gibs Cracks in transition zone, or burrs and slits on edges, or worn down edges

Max. permissible wear is 10 mm; grind the burr; max wear in transition zone is 30 %

"X"

X:

New AA000512.wmf

a) Max. wear 10 mm b) Max. burr 1 - 2 mm

X:

max

. 10

"X"

X:

max.1-2

(b)

(a)

Worn AA000513.wmf

7 Compression spring

Jolted or broken Replace with new

8 Square-shaped tool joint

Cracks in upper part Replace with new tool joint

9 Impact ring Worn down surface; cracked, burred

Max. permissible wear is 50 mm; grind the burr

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max

. 50

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KBM / 2007

Component Damage Note - Repair

10 Wear ring Cracks or worn down Replace with new

11 Rubber bumpers Worn down Replace with new

12 Tubing material Deformed, out of shape Cut off deformed tubing and replace with new

Deformierung amRohrDeformation ontube

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Also to be inspected are - all welds for cracks - all bolts that they are properly in place and firm.

CAUTION

It is assumed that the work be carried out by trained and qualified welding personnel ! Please, observe the information given in sect. "Repair Welding" !

CAUTION

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 weld-ing work, all the sections must be completely extended from one an-other before the kelly is put into use again !

KBM / 2007 11

2.3 REPAIR WELDING

NOTE

Due to the consistent technological progress and improvement of ma-terials, 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 MaschinenGmbH, if so required for a repair. Please, be aware that BAUER Maschinen GmbH will not assume anyliability for welding work carried out other than by trained and author-ized BAUER personnel !

CAUTION

It is assumed that the work be carried out by trained and qualified weld-ing personnel ! Accident prevention and fire protection safety standards and provi-sions prevalent in the construction industry must be observed, espe-cially those applicable to "Welding and cutting".

Steps for Repairing: 2.3.1 Grind Faces to be Joined, Remove Burrs and Clean Weld Zone Free of Grease

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"

Fügestelle

Break

Joint

Bruch

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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 vi-cinity 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"

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

25FügestelleJoint

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

KBM / 2007 13

To weld:

Detail of B-B and "A":

"A"

B

ca. 100

60°

2

...Führungsleisten

B

/ 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

max.30%

St 52

max.30%25CrMo4v

25CrMo4v

StE690

St 52max. 10

max. 10

max

. 10

max

. 10

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Uniform wear on gibs, drive shells and locking recesses must not ex-ceed 10 mm.

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

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KBM / 2007

Kelly – Fit-up gibs and tack-weld – Weld on gibs in several layers – Avoid pitting surfaces – Produce flush welds

"X"

X:

45°

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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

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Do not weld at recesses in zones between arrows marked "- � - � -" (avoid cross welds). A kelly with 2 x 3 gibs

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KBM / 2007 15

c) To Replace the Kelly Square-Shaped Tool Joint

NOTE

All parts must be preheated before welding.

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

2 4

"Z"

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� 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".

CAUTION

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

66

16 16

10° 10°

20

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� Weld gibs (4) onto tool joint (1) and tubing (2).

NOTE

Produce the weld (see arrow) all the waythrough in one go.

� Weld on guiding ring (3). 50

SchweißnahtWeld

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KBM / 2007

2. Tool Joint Smaller than Kelly Inner Bar

2 3 1

B

BD

X

C

C

D

4 AA000528.wmf

1 Kelly tool joint 3 Guiding ring 2 Kelly inner bar 4 Gibs � 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.

� Join guiding ring (3) with gibs (4): Weld together

along provided chamfers as far as to "X" in figure above.

2

3

R6

20°

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Detail "Z"

Section B-B:

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Section C-C:

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Section D-D:

2 3

"Z"

4 100 1*

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

KBM / 2007 17

2.3.4 Welding Rod Specifications

CAUTION

Principally, the manufacturer's specifications must be observed in the application of rod electrodes ! As for the application of basic covered electrodes, it is important thatthe electrodes be dried in compliance with the manufacturer's indica-tions !

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

BAUER-Genuine-Parts-No. / Name Rod electrode Ø in mm 52000 / Phoenix KB Special 2.5 49293 / Phoenix KB Special 3.2 52001 / Phoenix KB Special 4.0

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

BAUER-Genuine-Parts-No. / Name Rod electrode Ø in mm 234306 / Phoenix yellow 3.2

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

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KBM / 2007

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

NOTE

Only use protective gas complying with EN 439 directives.

BAUER-Genuine-Parts-No. Rod electrode Ø in mm

700997 0:8 217237 1:0 700265 1:2

NOTE

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

KBM / 2007 19

3 TRANSPORT AND STORAGE

3.1 TRANSPORTATION OF KELLY BARS

DANGER!

Lifting equipment and slings used for loading and unloading must besafe and of sufficient capacity. Avoid abrupt and quick movementswhen 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

A

1/6 2/6 1/62/6

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 de-formed (twisted) from torsion stress and vibrations! If there is an evidence of deformation of the kelly following the trans-port, the BAUER Maschinen GmbH should be consulted in preven-tion of potential damage resulting.

1 Tie-down strap 2 Shims 3 Underpinning 4 Kelly 5 Holding lugs (on transporting vehicle e.g.) 3

4

1

5

2

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KBM / 2007

3.2 OVERSEAS SHIPPING OF KELLY BARS

A

1/6 2/6 1/62/6

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 de-formed (twisted) from torsion stress and vibrations! If there is an evidence of deformation of the kelly following the ship-ping, 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

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KBM / 2007 21

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 1/41/2 AA000626.wmf

A

1/6 2/6 1/62/6 AA000618.wmf

NOTE

For optimal storage stability, the surface on which the bars are storedshould be firm and level and uniformly supporting. A direct contact with the ground must be avoided. At extremely high ambient storage temperatures, > +40° C (> 104°F),as from exposure to direct sunshine e.g., the BAUER Maschinen GmbH recommends to use the double amount of timbers (evenly dis-tributed) in the underpinning.

CAUTION

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 beconsulted in prevention of potential damage resulting.

3.3.1 Drilling Rod Dolly

The dolly supplied with the equipment is only for the transport of kelly bars within a con-struction 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".