Introduction

Five years of extensive development by Gearhart United has resulted in the Redback Roller Reamer, which
according to the Company is the most economical and cost effective Roller Reamer available.
The last two years has seen the sealed bearing Roller Reamer accepted by some of the major Oil Companies
in:
Southeast Asia, Australia, the Middle East and the North Sea.
Gearhart United set out to design and manufacture a Roller Reamer that can be adjusted utilising tapered
rather than parallel sided blocks and with load-bearing surface between cutter and ~p'm that is totally sealed
and pressure equalised, providing longer down-hole life and full utilisation of the Tungsten Carbide Inserts.
The tool has been designed to be redressed on site within an hour, rather than a day, using small tools rather
than sledge hammers.
Unlike the standard Roller Reamers on the market, the Redback Roller Reamer is infinitely adjustable
through the exposed height of the Tungsten Carbide Insert. As the carbide wears and tool becomes under
gauge, the cutter assembly can be removed using hexagon key and wrench, then place shims in the bottom
of the pocket. The wedges and roller assembly are then returned to the pocket, bringing the worn Reamer
back to gauge.

Inspection
When the Reamer is removed from the hole the following inspection procedures should be followed:

STEP 1: Pockets should be cleaned so that compacted drilling solids or other debris do not interfere with
rotation. Check for free movement in the cutter assembly with the use of a screwdriver. This is
achieved by placing the screwdriver in the pocket area in-between the cutter and the pocket. Using
the screwdriver as a leaver, check for movement either up and down or sideways (this does not
mean rotational movement). If free movement is detected then change the worn cutter for a new
re-dress kit. If no movement is detected the cutters are good and can be used again.
STEP 2: Measure your ring gauge accurately to determine the actual ID size. The minimum ring gauge size
should be the hole size in operation at that time. Pick the top row of buttons on each cutter. Turn
the cutter so that the carbide button on each cutter is pointing straight out from the Reamer. Pass
gauge ring over this row of buttons. As shown drawing G2089.
STEP 3: The Redback Roller Reamer may be dressed with either one of two types of cutters - the Hard
Formation or Soft Formation.

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Maintenance
STEP 1: As soon as the Reamer is removed from the hole it should be laid down and washed off with fresh
water.
STEP 2: Lubricate the threads with a good drill collar compound and put on thread protectors.
STEP 3: Determine whether the Reamer is still suitable for use. Look at Inspection chapter to show how to
perform this action. If the Reamer is useable store in a protected area . If not, remove sets of
Cutters, see Undressing chapter, dress with new set and place in a protected area until time for use.
STEP 4: New or re-useable Cutter Assemblies should be stored in a clean dry place out of the weather.

Undressing of Reamer

First, read all the Inspection Steps described in the Inspection Section of this Manual. Be sure the tool needs Redressing before
starting the following procedure.

TOOLS REQUIIRED FOR UNDRESSING

Ratchet Wrench. Large Screw Driver. In-hex Socket (with new kit). Lifting Strap (with new kit).

1. Clean out holes above Capscrews so you can fully engage the In-hex
Socket Adaptor (complete with kit).

2. Use Ratchet Wrench to remove two Capscrews in each cartridge, one in

each wedge.

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3. Move the cartridge into the middle of the pocket with Large Screw Driver
4. Slide one end of the plastic strip (complete with kit) under the cutter
section of the cartridge. Pull strap until equal length on both sides.

5. Lift out of packet with strap. Use bar through strap on larger sizes.
6. Repeat for all pockets.
7. Clean out all pockets well before Redressing.

8. Be sure all Shims are out of all pockets.

9. At this stage check the recoil inserts, two in each pocket. See thread insert
information chapter
10. If Reamer is to be left undressed, grease pocket fully before storage.

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Dressing of Reamer

TOOLS REQUIRED FOR DRESSING

1. Torque Wrench (see chart for setting)
2. In-hex Socket (complete with kit)
3. Drill Collar compound
4. Gauge Ring

PARTS REQUIRED FOR DRESSING

1. Cartridge Cutters 3 per set.
2. Wedges 6 per set.
3. Socket Head Cap Screws (6).
4. Shims if applicable (see chapter on Shimming)

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1. Clean all parts before starting to dress Reamer.

2. Check for body metals pressed over into the pocket area, if found remove metal
unit flush.

3. Coat the inside of pocket with

*Drill Collar Compound.

4. Lower cutting Cartridge into pocket, push down to bottom of pocket.

5. Move Cartridge to side of pocket until it reaches face opposite drilled holes in
bottom of pocket.

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6. Obtain one wedge and coat slotted area with *Drill Collar Compound. Place
Capscrew into slot, regrease screw and face of wedge.

7. Obtain In-hex Socket (complete with kit) and push into top of capscrew.

8. Lower Wedge, Capscrew and In-hex Socket into area adjacent to block. Screw
down to bottom by hand.
9. Repeat steps 6 to 8 for second Wedge of Cutter Cartridge.

10. From Torque Setting Chart G2090, set Torque Wrench to correct foot/pounds
for size of cartridge.
11. Pull down both Wedges until Wrench trips out.
12. Repeat steps 3 to 11 for other pockets.
13. Use Gauge Ring to check size of Reamer before running in hole.

* Note: for use in lubrication of Redback Roller Reamer pockets. Gearhart states
that it is important to use a thread compound that meets or exceeds the
performance objectives as set out in API RP 7A1 "Thread compounds for rotary
shouldered connections."

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Shimming
This method is used when the Reamer has worn carbide, meaning the Cutter will be under gauge (see Inspection section for details on
checking bearings).
Shimming is a way of bringing as worn set of Cutters back up to gauge size.

1. After gauging, determine amount of shim required.

2. Remove Cutters as explained in chapter (undressing).
3. Clean out pockets and coat with high temperature grease.

4. Obtain shim and enter into pocket at an angle of 45degrees to the

bottom (not straight up and down)
5. When edge of shim has located corner of pocket, let the other side
fall down to the bottom.
6. Grease top of shim before continuing to redress with cartridge

7. Be sure to place equal amounts of shim under each block.

8. It is not recommended to have more than 3/16" of shim under block
at one time.
9. After all three cutters have been shimmed check with gauge ring.
(As described in Chapter 2 of the Inspection section)

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Thread Insert Information
The Redback Roller Reamer is equipped with replaceable threaded inserts located in the pocket area. The threaded inserts provide a
way to simply and easily change damaged threads without having to alter the Reamer body by re-threading.
These inserts are expected to have an effective service life which would exceed the life of the body. If, however, difficulties should
arise, use the instructions shown here for installing new inserts.

REMOVAL OF INSERTS

1. Insert the spear like removal tool into the damaged insert and lightly tap with hammer.
This makes two small indentations into the top of the insert.

2. Apply pressure downward with the removal tool located in the two indentations, and
turn counter clockwise until the thread is out of the body.

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Thread Insert Information
REPLACEMENT OF INSERTS

1. When replacing the insert, first push the new one onto the insertion tool so the the
tang locates in the slot of the tool.

2. With light hand pressure introduce the insert and tool into the pocket.

3. Screw in a clockwise direction until the insert becomes a to turn below the
surface of the pocket.

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4. With the insert down, lift tool up above the tang and turn 90 degrees.

5. Place back down on top of the tang and tap down sharply with a hammer. Do not
try to twist off the tang.

6. Blow out, broken off tang with air line. Look down hole to see if the tang has been
removed.

7. Check insert installation by screwing a capscrew into the hole by hand, this shold
go all the way to the bottom of the hole.

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Job Specific Safety Analysis

REDRESSING OF REDBACK ROLLER REAMER AND STABILISERS

In conjunction with instructions in Maintenance Manual

Work Phase Potential Hazard Required Action

Layout of Reamer Injury due to lifting Personnel trained in rigging considering the use of load
and equipment prior equipment rated lifting equipment
to redress
No safety pins and Tools rolling off supports Install safety pins and stops on support rack
stops installed on
support rack
Cleaning the Eye injury from air borne Wear eye protection
Reamer after use. particles
Removal of Personnel trained in use of recommended hand tools. Refer
Strain Injury
Capscrews Chapter 4
Capscrew not Bodily Injury Clean out Capscrew. Be sure Allen wrench seated all the
cleaned out way as per manual. Refer Chapter 4
Removal and Strain Injury and injury due to Personnel trained, and to Rigging instructed in manual
inserting Roller cartridge falling. handling techniques and use of hoists with objects above
Reamer cartridge the weight range of 16-20 kilos.
Reamer unsecured Tool can rotate when torquing Secure reamer body with chain tool or suitable tool.
capscrew causing fall or
injury to personnel
Clean out of Eye injury from air borne Wear eye protection
pockets particles
Torque up of Strain Injury Use only recommended torque settings. Personnel trained
wedges in use of recommended hand tools. Refer chapter 5.

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