Manual Sistema Top Drive TDS-11SA PDF [PDF]

Zitiervorschau

User Manual

TDS-11SA – Top Drive Drilling System

Customer References Customer: Galena Park Rig / Hull: Rig 135 Tag Number: N/A

National Oilwell Varco References: SO Number / Project Number: 134718/TX8912 Document Number: D811002283-MAN-002 Revision: 01 Volume: 1

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Document number Revision Page

D811002283-MAN-002 01 2

REVISION HISTORY

01

09.10.2012

Rev

Date (dd.mm.yyyy)

For Information

CHANGE DESCRIPTION Revision 01

Change Description For Initial Release

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Reason for issue

I. Vargas Prepared

L. Krajenbrink Checked

H. Lim Approved

Bill of Material Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Part Number

Description

SM00856 SM01053 50000870 D811002283-DOS-001 M614003010-SPL-001 10620488-SPL 127425 D392001271-MKT-001 D25TDS11-MAN-001 VDR00029 VDR00030 ASP00020 3ASP00073 ASP00019 DS00008 D811000719-PRO-001 SM00081 D811001337-DAS-001

Service Manual, TDS-11SA Service Manual, Washpipe Assembly Links User Manual Technical Drawing Package Mechanical Spares List Control Spares List Electrical Trouble Shooting Guide TDS-11SA, Pocket Guide TDS-11SA VFD Operation Manual Reliance Installation, Operating Manual (180-449) Reliance Installation, Operating Manual (L210-400) Motor Housing Assembly Procedure (TDS-9SA/TDS-11SA) Installation Procedure for TDS Motor Hub & Pinion Gear Safety Wiring Procedure Design Torque Standard Recommended Lubricants and Fluids Hydraulic Fluid Cleanliness Service Center Directory

NEXT ASSY

PRODUCT

M611005667-GEN-001

TDS-11SA

This document contains proprietary and confidential information which is the property of National Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use of this design or distribution of this information to others is not permitted without the express written consent of NOV. This document is to be returned to NOV upon request or upon completion of the use for which it was loaned. This document and the information contained and represented herein is the copyrighted property of NOV. © National Oilwell Varco

CURRENT DRAWN

INITIAL T. Harmon

CHECKED

H. Lim

APPVD

H. Lim

DATE

User Manual

NOV Galena Park, AC Ideal Rig 135 TDS-11SA

01/13/2012

SCALE:

WT LBS:

SIZE:

SHT:

AV DWG NO.:

D811002283-MAN-001

1 OF 1 REV:

01 D811000457-GEN-001/04

FINAL DOCUMENTATION TDS-11SA - Top Drive Drilling System

Chapter 1.0 Service Manual, TDS-11SA

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Service Manual TDS-11SA Top Drive

Reference

Reference Description

This document contains proprietary and confidential information which is the property of National Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use of this design or distribution of this information to others is not permitted without the express written consent of NOV. This document is to be returned to NOV upon request or upon completion of the use for which it was loaned. This document and the information contained and represented herein is the copyrighted property of NOV. © National Oilwell Varco

www.nov.com Form D811001123-GEN-001/06

National Oilwell Varco RIG SOLUTIONS 11000 Corporate Centre Drive Houston, TX 77041

Document Number

Rev.

SM00856

D

SM00856 Revision D

Revision History D

15.08.2012

Engineering Update

J. Roman

H. Lim

M. Clark

C

11.11.2011

Engineering Update

T. Drake

H. Lim

M. Clark

B

2006

Teamcenter migration version.

–

–

–

A

2003

Teamcenter migration version.

–

–

–

–

2000

First Issue: Original Instructions

–

–

–

Rev

Date (dd.mm.yyyy)

Reason for issue

Prepared

Checked

Approved

Change Description Revision

Change Description

–

First Issue: Original Instructions. No relevant issue history.

A

Revision migrated in Teamcenter. No relevant revision history.

B

Revision migrated in Teamcenter. No relevant revision history.

C

• • • • • • • • • • • • • • • • • • • • • • •

D

• Corrected Guide Beam Joint illustration (page 5-6). • Corrected Plan View dimensions; added 30.0” setback illustration (page 2-7 and page 2-8).

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Updated cover illustration, applied latest FrameMaker template, and reorganized material. Removed outdated VFD references and added ABB ASC800 reference and specs (page 2-3). Added Noise Data (page 2-5). Updated upper main body seals lubrication interval and procedure (page 5-59 and page 5-60). Added optional NOV Mechanical Washpipe information (various locations throughout manual). Added new control house illustration, dimensions and weight (various pages, starting with page 3-6). Added new guide beam warning information (page 3-9, page 3-12, page 3-16, page 3-23). Changed procedure so it was not specific to option 2 (page 3-26). Added auxiliary cable jacket installation procedure (page 3-29). Added secondary retention to counterbalance illustration (page 3-34). Added bail lock components to decommissioning illustration (page 3-42). Added additional long-term storage and return-to-service instructions (CE fix) (page 3-43). Added new console illustrations and operation information (starting on page 3-30 and page 4-1). Moved Making and Breaking Tool Joint Connections to Operation (page 4-19). Added Well Control Procedure (page 4-28) Added Joint Pin and Bushing wear limits to Guide Beam Joint Inspection (page 5-6). Removed Blower Motor Inspection illustration from red lined instructions. Updated Non-Destructive Examination section (page 5-56). Replaced Link Tilt in illustrations where maintenance procedure are affected (various pages). Added driller’s control console maintenance information (page 5-97) Moved hydraulic setup to Maintenance and troubleshooting to the new troubleshooting chapter. Moved hydraulic symbol description to Appendix A. Moved PH-50 Pipe Handler service manual information to Appendix B.

SM00856 Revision D Page i of viii

Table of Contents Chapter 1: General Information Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Advisories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hot Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrostatic Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Documentation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1 1-1 1-1 1-1 1-1 1-2 1-2 1-2 1-2 1-3 1-3 1-4 1-4 1-4 1-5 1-5 1-5 1-5 1-5

Chapter 2: Description Introduction to the TDS-11SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Performance Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Noise Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Top Drive Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Top Drive Plan View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 30.0" Setback Top View Dimensions (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 39.5" Setback Top View Dimensions (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Identification Labels and Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Lifting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Typical Equipment Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Chapter 3: Installation Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Illustrated Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Crown Padeye and Hang-Off Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Intermediate Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Main Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Locating the Control House . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1 3-2 3-3 3-3 3-4 3-5 3-6

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SM00856 Revision D Page ii of viii

Table of Contents Installing Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Grounding the Control House (Land Rigs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Identifying Guide Beam Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Raising the Top Guide Beam Section to the Drill Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Attaching the Carriage Sling to the Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Moving Guide Beam Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Hooking the First Guide Beam Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Hoisting the First Guide Beam Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Stabbing and Pinning the First Guide Beam Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Completing Guide Beam Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Hoisting and Attaching the Guide Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Removing the Hoist Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Moving the Top Drive to the Rig Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Attaching the Top Drive to the Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Lifting the Top Drive into the Rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Connecting the Top Drive to the Guide Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Bottom Intermediate Section Warning Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Attaching the Torque Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Pinning the Top Drive to the Guide Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Releasing the Top Drive from the Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Installing Derrick Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Installing Service Loops at the Derrick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Installing Service Loop Jackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Installing the Driller’s Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Installing the Console Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Motor Rotation Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Installing the Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Installing the Counterbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Initial Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Hydraulic System Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Electrical System Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Mechanical Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Adjusting the Link Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 Securing the Top Drive for Rig-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 Removing and Storing Cables and Service Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Setting the Latches and Locking the Bail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 Long Term Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 Storage Location and Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 Pre-Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

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Table of Contents Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 Returning the Top Drive to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Chapter 4: Operation Stateless Driller’s Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 IBOP and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Pipe Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 E-Stop, BX Elevator, Counterbalance, and Dolly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Meters and Limit Adjustment Knobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Amphion™ Touchscreen Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Basic Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Drilling Ahead with Singles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Drilling Ahead with Triples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Back Reaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Making and Breaking Tool Joint Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Breaking out the Saver Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Making up the Saver Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Breaking out the Lower IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Making up the Lower IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Breaking out the Upper IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Making up the Upper IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Well Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Component Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Chapter 5: Maintenance Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre-Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Documentation You Will Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regulatory Standards You Will Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare Parts You May Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare Parts and Fluids Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Wire (Lockwire) Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Secondary Retention Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1 5-1 5-1 5-1 5-1 5-1 5-2 5-2 5-3 5-3 5-3 5-3 5-4

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Table of Contents Inspecting Rig Interface Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Inspecting the Guide Beam and Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Crown Padeye and Hang-Off Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Guide Beam Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Main Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Intermediate Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Inspecting the Motor Housing and Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Illustrated Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Internal Lubrication Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Belt-Driven Encoder Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Gearbox Lube Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Bail and Main Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 S-Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Upper Main Shaft Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Standard Washpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Upper Bonnet Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Main Shaft and Load Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Main Shaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Motor Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Drilling Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Inspecting the PH-75 Pipe Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 Illustrated Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 Stopping and Starting the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Link Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44 IBOP Actuator Cylinder and Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45 Tool Joint Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47 IBOP Valves and Saver Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49 Shot Pin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50 Rotating Link Adapter and Load Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52 Nondestructive Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56 Making Visual Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56 Magnetic Particle Inspection (MPI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56 Ultrasonic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57 IBOP Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57 Recommended Lubricants and Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58 Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59

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Table of Contents Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every Three Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every Six Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yearly and As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearbox Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Location of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Fluid Level and Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Reservoir Bladder (Yearly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Hydraulic System Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precharging the Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IBOP Timing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IBOP and Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adding Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Up Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pumps and Unloading Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterbalance Circuit and Stand-Jump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Motor Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shot Pin Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Link Tilt Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotating Link Adapter Hydraulic Motor Relief Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Console Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-60 5-60 5-60 5-61 5-62 5-62 5-65 5-66 5-67 5-67 5-67 5-68 5-69 5-70 5-73 5-73 5-74 5-75 5-76 5-77 5-78 5-79 5-80 5-81 5-82 5-83 5-83 5-88 5-92 5-93 5-95 5-96 5-97

Chapter 6: Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Personnel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Determining the Nature of Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identifying Troubleshooting Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical System and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication and Cooling System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre-Troubleshooting Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1 6-2 6-2 6-3 6-3 6-3 6-3 6-3 6-4 6-4 6-5

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Table of Contents Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 HPU and Reservoir Bladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Counterbalance and Stand Jump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Counterbalance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Stand Jump Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Motor Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Shot Pin Cylinder and Clamp Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Link Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Gearbox Lubrication Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Tool Rotation and Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Rotating Link Adapter Motor Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 IBOP Actuator Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

Appendix A: Hydraulic Symbols Appendix B: PH-50 Pipe Handler Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 Equipment Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4 Safety Wire (Lockwire) Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4 Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5 Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6 Link Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7 Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8 Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9 Clamp Cylinder Body Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9 Removing the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10 Disassembling the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11

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Table of Contents Inspecting the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12 Inspecting the Stabilizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-13 Disassembling the IBOP Actuator Cylinder and Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-15 Inspecting the IBOP Actuator Cylinder and Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-16 IBOP Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-17 Tool Joint Locks Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-17 Inspecting the Tool Joint Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-18 Inspecting IBOP Valves and Saver Subs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-19 Shot Pin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-20 Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-20 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-21 Rotating Link Adapter/Load Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-22 Removing the Rotating Link Adapter (while the top drive is in the mast) . . . . . . . . . . . . . . . . . B-22 Disassembling the Link Tilt Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-22 Inspecting the Rotating Link Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-23 Assembling the Link Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-24 Installing the Rotating Link Adapter (while the top drive is in the mast) . . . . . . . . . . . . . . . . . . B-25 Wireline Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-26 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-26 Nondestructive Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-27 Making Visual Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-27 Magnetic Particle Inspection (MPI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-27 Ultrasonic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-28 IBOP Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-28 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-28

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Table of Contents

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List of Figures Figure 2-1. Figure 2-2. Figure 2-3. Figure 2-4. Figure 2-5. Figure 2-6. Figure 2-7. Figure 2-8. Figure 3-1. Figure 3-2. Figure 3-3. Figure 3-4. Figure 3-5. Figure 3-6. Figure 3-7. Figure 3-8. Figure 3-9. Figure 3-10. Figure 3-11. Figure 3-12. Figure 3-13. Figure 3-14. Figure 3-15. Figure 3-16. Figure 3-17. Figure 3-18. Figure 3-19. Figure 3-20. Figure 3-21. Figure 3-22. Figure 3-23. Figure 3-24. Figure 3-25. Figure 3-26. Figure 3-27. Figure 3-28. Figure 3-29. Figure 3-30. Figure 3-31. Figure 3-32. Figure 3-33. Figure 3-34. Figure 3-35. Figure 3-36. Figure 3-37. Figure 3-38. Figure 3-39.

TDS-11SA Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Performance Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Top Drive Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Top Drive Plan View (30.0" Setback). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Top Drive Plan View (39.5" Setback). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Identification Labels and Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Lifting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Typical Installed Equipment Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Illustrated Installation Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Installing the Crown Padeye and Hang-Off Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Installing the Intermediate Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Installing the Main Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Locating the Control House . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Installing Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Grounding the Control House (Land Rigs). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Raising the Top Guide Beam Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Attaching the Carriage Sling to the Hook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Moving Guide Beam Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Hooking the First Guide Beam Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Hoisting the First Guide Beam Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Stabbing and Pinning the First Guide Beam Section. . . . . . . . . . . . . . . . . . . . . . . . 3-15 Completing Guide Beam Section Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Hoisting and Attaching the Guide Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Removing the Hoist Carriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Moving the Top Drive to the Rig Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Attaching the Top Drive to the Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Lifting the Top Drive into the Rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Connecting the Top Drive to the Guide Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Bottom Intermediate Guide Beam Section Warning Label . . . . . . . . . . . . . . . . . . . 3-23 Attaching the Torque Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Pinning the Top Drive to the Guide Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Releasing the Top Drive from the Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Installing Derrick Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Installing Derrick Service Loops at the Derrick . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Installing the Driller’s Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Installing the Console Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Motor Rotation Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Installing the Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Installing the Counterbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Initial Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Hydraulic System Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Electrical System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Mechanical Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Adjusting the Link Tilt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 Securing the Top Drive for Rig-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 Removing and Storing Cables and Service Loops . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Setting the Latches and Locking the Bail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

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List of Figures Figure 4-1. Figure 4-2. Figure 4-3. Figure 4-4. Figure 4-5. Figure 4-6. Figure 4-7. Figure 4-8. Figure 4-9. Figure 4-10. Figure 4-11. Figure 4-12. Figure 4-13. Figure 4-14. Figure 4-15. Figure 4-16. Figure 5-1. Figure 5-2. Figure 5-3. Figure 5-4. Figure 5-5. Figure 5-6. Figure 5-7. Figure 5-8. Figure 5-9. Figure 5-10. Figure 5-11. Figure 5-12. Figure 5-13. Figure 5-14. Figure 5-15. Figure 5-16. Figure 5-17. Figure 5-18. Figure 5-19. Figure 5-20. Figure 5-21. Figure 5-22. Figure 5-23. Figure 5-24. Figure 5-25. Figure 5-26. Figure 5-27. Figure 5-28. Figure 5-29. Figure 5-30. Figure 5-31.

NOV Stateless Driller’s Control Console (Front Panel Closed) . . . . . . . . . . . . . . . . . 4-2 NOV Stateless Driller’s Control Console (Front Panel Opened) . . . . . . . . . . . . . . . . 4-3 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Top Drive Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 IBOP and Brake Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Pipe Handler Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 E-Stop, BX Elevator, Counterbalance, and Dolly Controls . . . . . . . . . . . . . . . . . . . 4-12 Meters and Limit Adjustment Knobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Default Top Drive Amphion Touchscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Drilling Ahead With Singles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Drilling Ahead With Triples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Back Reaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Breaking Out the Saver Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Breaking out the Lower IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Breaking out the Upper IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Well Control Component Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 Inspecting the Crown Padeye and Hang-Off Link . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Inspecting the Guide Beam Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Inspecting the Main Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Inspecting the Intermediate Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Inspecting the Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Motor Housing and Transmission Illustrated Index . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Inspecting Internal Lubrication Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Adjusting the Belt-Driven Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Inspecting the Gearbox Lube Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Inspecting Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Inspecting the Bail and Main Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Inspecting the S-Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Inspecting the Upper Main Shaft Liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Inspecting the Washpipe (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Inspecting the Washpipe (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Inspecting the Upper Bonnet Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Inspecting the Main Shaft and Load Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Inspecting Main Shaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Inspecting the Motor Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Inspecting the Drilling Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Disassembling/Assembling the Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 PH-75 PIpe Handler Illustrated Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 Stopping and Starting the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Inspecting the Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 Inspecting the Link Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 Removing the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41 Disassembling the Clamp Cylinder Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 Inspecting the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 Inspecting the Stabilizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44 Inspecting the IBOP Actuator Cylinder and Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46 Inspecting the Tool Joint Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

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List of Figures Figure 5-32. Figure 5-33. Figure 5-34. Figure 5-35. Figure 5-36. Figure 5-37. Figure 5-38. Figure 5-39. Figure 5-40. Figure 5-41. Figure 5-42. Figure 5-43. Figure 5-44. Figure 5-45. Figure 5-46. Figure 5-47. Figure 5-48. Figure 5-49. Figure 5-50. Figure 5-51. Figure 5-52. Figure 5-53. Figure 5-54. Figure 5-55. Figure 5-56. Figure 5-57. Figure 5-58. Figure 5-59. Figure 5-60. Figure 6-1. Figure 6-2. Figure 6-3. Figure 6-4. Figure 6-5. Figure 6-6. Figure 6-7. Figure 6-8. Figure A-1. Figure A-2. Figure A-3. Figure B-1. Figure B-2. Figure B-3. Figure B-4. Figure B-5. Figure B-6. Figure B-7.

Inspecting the IBOP Valves and Saver Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49 Inspecting the Shot Pin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51 Inspecting the Rotating Link Adapter and Load Stem . . . . . . . . . . . . . . . . . . . . . . . 5-53 General Lubrication (1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62 General Lubrication (2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63 General Lubrication (3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64 Gearbox Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65 Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66 Hydraulic System Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 Hydraulic System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69 Inspecting the Hydraulic Fluid Level and Indicator . . . . . . . . . . . . . . . . . . . . . . . . . 5-73 Inspecting the Hydraulic Reservoir Bladder (Yearly) . . . . . . . . . . . . . . . . . . . . . . . . 5-74 Inspecting the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75 Using the Hydraulic System Test Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76 Precharging the Accumulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77 Inspecting the IBOP Timing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78 Inspecting the IBOP and Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79 Adding Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81 Draining Hydraulic Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82 Hydraulic Pumps and Unloading Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83 Pressure Cycle Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85 Pump Setup Manifold Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86 Pump Setup Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87 Counterbalance Setup Manifold Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90 Counterbalance Setup Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91 Motor Brake Setup Manifold Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92 Setting up the Shot Pin Circuit (1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93 Setting up the Shot Pin Circuit (2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94 Setting up the Rotating Link Adapter Hydraulic Motor Relief Circuit . . . . . . . . . . . . 5-96 HPU and Reservoir Bladder Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Counterbalance and Stand Jump Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . 6-10 Brake Circuit Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Shot Pin Cylinder and Clamp Cylinder Schematic Diagram . . . . . . . . . . . . . . . . . . 6-15 Link Tilt Cylinders Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Gearbox Lubrication Hydraulic System Schematic Diagram . . . . . . . . . . . . . . . . . . 6-19 Rotating Link Adapter Motor Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 IBOP Actuator Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Hydraulic Symbols (1 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Hydraulic Symbols (2 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Hydraulic Symbols (3 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 PH-50 Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 PH-50: Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 PH-50: Elevator Link Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6 PH-50: Link Tilt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8 PH-50: Removing the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10 PH-50: Disassembling the Clamp Cylinder Body. . . . . . . . . . . . . . . . . . . . . . . . . . . B-11 PH-50: Inspecting the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12

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List of Figures Figure B-8. Figure B-9. Figure B-10. Figure B-11. Figure B-12. Figure B-13. Figure B-14.

PH-50: Inspecting the Stabilizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-14 PH-50: Inspecting the IBOP Actuator Cylinder and Yoke . . . . . . . . . . . . . . . . . . . . B-16 PH-50: Inspecting the Tool Joint Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-18 PH-50: Inspecting IBOP Valves and Saver Subs . . . . . . . . . . . . . . . . . . . . . . . . . . B-19 PH-50: Inspecting the Shot Pin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-21 PH-50: Inspecting the Rotating Link Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-23 PH-50: Inspecting the Wireline Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-26

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General Information

1

Conventions This manual is intended for use by field engineering, installation, operation, and repair personnel. Every reasonable effort has been made to ensure the accuracy of the information contained herein. National Oilwell Varco® (NOV) will not be held liable for errors in this material, or for consequences arising from misuse of this material.

Advisories Graphic symbols and bracketed text indicate advisories for a specific topic. This information provides additional details and may advise the reader to take a specific action to protect personnel from potential injury or lethal conditions. Advisories may also describe actions necessary to prevent equipment damage.

Note

The note symbol indicates that additional information is provided about the current topic.

Caution

! The caution symbol indicates that potential damage to equipment, or injury to personnel exists. Follow instructions explicitly. Extreme care should be taken when performing operations or procedures preceded by this caution symbol.

Warning

The warning symbol indicates a definite risk of equipment damage or danger to personnel. Failure to follow safe work procedures could result in serious or fatal injury to personnel, significant equipment damage, or extended rig down time.

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General Information

Conventions Advisories Hot Surfaces

The hot surface symbol indicates the presence of a hot surface or component. Touching this surface could result in bodily injury. To reduce the risk of injury from a hot component, allow the surface to cool before touching.

Electrostatic Discharge

The Electrostatic Discharge (ESD) symbol indicates the potential for static electrical discharge is present. ESD can damage or destroy sensitive electronic components. ESD can also set off explosions or fires in flammable environments. Always discharge static electricity prior to working on sensitive components or in flammable environments.

Illustrations Illustrations (figures) provide a graphical representation of equipment components or screen snapshots for use in identifying parts, or establishing nomenclature, and may or may not be drawn to scale. For component information specific to your rig configuration, see the technical drawings included with your NOV documentation.

Safety Requirements The NOV equipment is installed and operated in a controlled drilling rig environment involving hazardous situations. Proper maintenance is important for safe and reliable operation. Procedures outlined in the equipment manuals are the recommended methods of performing operations and maintenance.

! To avoid injury to personnel or equipment damage, carefully observe requirements outlined in this section.

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General Information

1

Safety Requirements Proper Use of Equipment NOV equipment is designed for specific functions and applications, and should be used only for its intended purpose.

Safe Lifting When lifting and handling NOV equipment, use approved lifting procedures and safe methods.

Lifting equipment improperly creates a hazardous working environment. To avoid lifting hazards, only lift equipment with material handling equipment rated for the expected load and only from the designated lift points. Failure to follow safe lifting guidelines may result in serious or fatal injury to personnel, significant equipment damage, and extended rig down time.

! Individuals working with rig equipment must never lift anything over 55 lb (25 kg) without assistance. Always get help from additional rig personnel or use lifting equipment.

Always follow all federal, state and local rules, codes, and rig-specific safety guidelines when lifting and handling NOV equipment. Operators and maintenance personnel should be properly trained in safe lifting procedures and the inspection of material handling equipment and lifting components. Safe lifting recommendations provided in this manual do not take precedence over local safety rules and regulations, OSHA regulations, or instructions issued by the manufacturers of rig hoisting equipment and other tools on the rig.

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General Information

Safety Requirements Personnel Training All personnel performing installation, operations, repair, or maintenance procedures on the equipment, or those in the vicinity of the equipment, should be trained in rig safety, tool operation, and maintenance to ensure their safety.

! Personnel should wear protective gear during installation, maintenance, and certain operations.

Contact the NOV training department for more information about equipment operation and maintenance training.

Recommended Tools Service operations may require the use of tools designed specifically for the purpose described. The equipment manufacturer recommends that only those tools specified be used when stated. Ensure that personnel and equipment safety are not jeopardized when following service procedures and that personnel are not using tools that were not specifically recommended by the manufacturer.

General System Safety Practices The equipment discussed in this manual may require or contain one or more utilities such as electrical, hydraulic, pneumatic, or cooling water.

! Read and follow the guidelines below before installing equipment or performing maintenance to avoid endangering exposed persons or damaging equipment.



Isolate energy sources before beginning work.



Avoid performing maintenance or repairs while the equipment is in operation.



Wear proper protective equipment during equipment installation, maintenance, or repair.

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General Information

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Safety Requirements Replacing Components 

Verify that all components (such as cables, hoses, etc.) are tagged and labeled during assembly and disassembly of equipment to ensure correct installation.



Replace failed or damaged components with original equipment manufacturer certified parts. Failure to do so could result in equipment damage or injury to personnel.

Routine Maintenance Equipment must be maintained on a routine basis. See product-specific service manuals for maintenance recommendations.

! Failure to conduct routine maintenance could result in equipment damage or injury to personnel.

Equipment Documentation Location The User Manual provided with the equipment order contains this service manual, the engineering installation and commissioning procedures, the Technical Drawing Package (TDP), along with specifications, parts lists, and other instructions. These documents must be used by the installation and commissioning crew, equipment operators, and maintenance personnel. Make sure an equipment User Manual is available in the location where the equipment is being installed, commissioned, operated, and maintained.

Equipment Disposal The equipment owner is responsible for removing and dismantling the equipment at the end of the equipment’s useful operating life. It is also the equipment owner’s responsibility to conform to all applicable regulatory policies, standards, and recycling guidelines when removing the equipment, dismantling equipment components, disposing of fluids, and disposing of consumable spare parts after scheduled and unscheduled equipment maintenance.

Service Centers For a directory of NOV Service Centers, see NOV document number D811001337-DAS-001, titled “Service Center Directory.” This document is located in the User Manual. The link below provides after-hours contact information for emergencies or other equipment issues requiring an immediate response by NOV service personnel. www.nov.com/ContactUs/24HrEmergencyContacts.aspx

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Description

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Introduction to the TDS-11SA Overview The TDS-11SA Top Drive is an AC-motor top drive developed for use as a portable or permanent unit on a wide variety of land and offshore applications. Its compact size also allows for installation on small workover and portable rigs. The top drive is driven by a Variable Frequency Drive (VFD) control system. The TDS-11SA generates 800 HP with a hoisting capacity of 500 tons and a continuous drilling torque rating of 37,500 foot-pounds (ft-lb) (50,843 [N-m]). The top drive has a maximum speed of 228 rpm and a make-up / break-out torque capacity of 50,000 ft-lb / 60,000 ft-lb (65,791 N-m / 81,349 N-m). Speed can be maintained from 114 rpm to 180 rpm without downgrading the 800 HP rating of the motors. The following are components of the TDS-11SA Top Drive: 

Integrated swivel



Single-speed gear box



Bi-directional link tilt system



Remote and manual internal blowout preventers (IBOPs)



PH-75 Pipe Handler (75,000 ft-lb backup capacity [101,686 N-m])



A dual guide-rail assembly to react torque

Figure 2-1 shows the TDS-11SA Top Drive and the location of major components.

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Description

Introduction to the TDS-11SA Major Components Counterbalance System

Motor Cooling System

Hydraulic Disc Brakes (2)

Gooseneck (S-Pipe)

AC Drilling Motors (2) Transmission/ Motor Housing

Hydraulic System Rotating Link Adapter

Guide Beam and Carriage

Rear

Right Side Pipehandler

Left Side

Front Figure 2-1. TDS-11SA Top Drive

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Description

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Specifications General Specifications Component

Item

Description

Weight

• 35,000 lb (15,876 kg) – Top Drive/Shipping Skid • 31,000 lb (14,061 kg) – Top Drive only

Stack-up height

19 ft (5.8 m)

Power requirements

700 KVA @ 575-600 VAC, 50/60 Hz

Horsepower

800 hp

Output torque (continuous)

37,500 ft-lb (50,843 N-m) (800 hp)

Tool torque (intermittent and stall)

55,000 ft-lb (74,570 N-m)

Maximum speed (at full power)

228 rpm

Hoisting capacity

500 ton (453.6 mt)

Load path

Single

Gooseneck entry

3 in. 1002 female union

S-Pipe mud hose connection

4 in. API line pipe or 4 in. 1002 female union

Drill Pipe

Sizes

3-1/2 in. to 5 in. (4 in. to 6-5/8 in. OD tool joint)

Pipe Handler

Type

PH-75 (75,000 ft-lb [101,686 N-m] backup torque)

Drilling Motor

Type

Reliance AC-575 VAC (2 x 400 hp)

Variable Frequency Drive

Type

ABB ASC800 2 (800 hp, 600/690 VAC input)

Motor Braking

Type

Hydraulic caliper disc brakes

Type

Local intake pressure blower

Power

(2) 5 hp AC motors

Speed

3,600 rpm

Type

Single speed, double reduction helical gear system

Gear ratio

10.5:1 (4.38:1 optional)

Top Drive

Motor Cooling System

Gearcase

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Description

Specifications General Specifications Component

Gearcase Lubrication

Hydraulic System

Electrical and Control House (Drive House)

Item

Description

Type

Pressure feed

Reservoir capacity

15 gallons (56.8 liters)

Full internal flow

10 gpm (37.9 lpm)

Oil type

EP grade (see Recommended Lubricants and Hydraulic Fluids, D81100719-PRO-001)

Oil pressure

10 psi (minimum), 30 psi (maximum)

Power

10 hp, AC motor

Flow

8.0 gpm/3.5 gpm (30.3 lpm/13.2 lpm) (high/low)

Reservoir capacity

25 gallons (95 liters)

Oil type

Mineral-based hydraulic oil (see Recommended Lubricants and Hydraulic Fluids, D81100719-PRO-001)

Size

14’6" L x 7’0" W x 7’8" H

Weight

8,000 lb (3630 kg) (with single A/C unit)

Input requirement

600 VAC (50/60 Hz), or 750 VDC, or 690 VAC (50 Hz)

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Description

2

Specifications Performance Curve 55,000 50,000 45,000

Drill Pipe Torque (ft-lbs)

800 HP 40,000 35,000

Dual AC Motor Top Drive TDS-11SA 2 x 400 = 800 HP, 500 Ton System 10.5:1 Transmission

30,000 25,000 20,000 15,000 10,000 5,000 0 0

25

50

75

100

125 150

175 200

225 250

Drill Pipe RPM

Figure 2-2. Performance Curve

Noise Data The following data was taken one meter (39.4 in) radially outward from the outer diameter of the gearbox and at a height of 1.6 meters (63 in) above the drill floor, with the top drive in its lowest position. Noise data was recorded at eight equal angles around the top drive. The highest noise level is at the rear (91.3 dB(A)). Front

86.2 dB(A)

Front+45°

86.6 dB(A)

Right

90.4 dB(A)

Right+45°

87.7 dB(A)

Rear

91.3 dB(A)

Rear+45°

88.3 dB(A)

Left

89.0 dB(A)

Left+45°

89.9 dB(A)

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SM00856 Revision D Page 2-6 of 12

Description

Specifications Top Drive Height Bail 120 in (304.8 cm)

31.0 in (78.7 cm)

Bail 88 in (223.5 cm)

260.0 in (660.4 cm) 230.0 in (584.2 cm)

To Center of Gravity 160.0 in (406.4 cm)

To Center of Gravity 25.0 in (63.5 cm)

50.0 in (127 cm) 67.0 in (170.2 cm)

= 35,000 lb (15876 kg)

65.0 in (165.1 cm)

To Center of Gravity 41.5 in (105.4 cm)

Figure 2-3. Top Drive Height

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2

Description

Specifications Top Drive Plan View 30.0" Setback Top View Dimensions (Standard)

Rear 35.9 in (91.2 cm)

2.5 in (Shipping Skid Only) (6.35 cm)

Guide

C L Beam

30.0 in Setback (76.2 cm) 34 in (86.4 cm)

56.1 in O.A. (142.5 cm)

C Well L 15.8 in (40.1 cm)

22.1 in (56.1 cm)

21 in (53.3 cm)

31.0 in (78.7 cm)

26.0 in (66.0 cm)

32.6 in (82.8 cm) Service Loop Bracket (Left-Hand Option)

C L Well 65.2 in (165.6 cm)

Front

S-Pipe (Outside Guard) (Left-Hand Option)

Figure 2-4. Top Drive Plan View (30.0" Setback)

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SM00856 Revision D Page 2-8 of 12

Description

Specifications Top Drive Plan View 39.5" Setback Top View Dimensions (Optional) Rear 35.9 in (91.2 cm)

2.5 in (Shipping Skid Only) (6.35 cm)

Guide

C L Beam

39.5 in Setback (76.2 cm) 65.6 in O.A. (166.6 cm)

43.5 in (110.5 cm)

C Well L 15.8 in (40.1 cm)

22.0 in (55.8 cm)

21 in (53.3 cm)

31.0 in (78.7 cm)

26.0 in (66.0 cm)

32.6 in (82.8 cm)

Service Loop Bracket (Left-Hand Option)

C L Well 65.2 in (165.6 cm)

Front

S-Pipe (Outside Guard) (Left-Hand Option)

Figure 2-5. Top Drive Plan View (39.5" Setback)

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Description

2

Identification Labels and Numbers

Trace code identifies the configuration of your equipment.

Encoder Instruction Label Located on the righthand brake cover

AC Motor Identification Label Located on the side of each AC motor

TOP DRIVE DRILLING SYSTEM MODEL: TDS-11SA SERIAL NO: GROSS WT (LBS): PART No & REV: (KG): SALES ORDER: MFG DATE: SAFE WORKING LOAD: 500 TONS MAX RPM: 228 RATED VOLTAGE: 550V/3 PHASE FULL LOAD CURRENT: 732A MAX MUD PRESSURE (PSI):

Top Drive Identification Plate Located on the front of the motor housing

Warning Labels Located on the side of each AC motor

Warning Label Located on the side of the bonnet

If an equipment label is worn, dirty, or otherwise illegible, clean it or order a new label. Failure to adhere to this warning could result in severe injury to rig personnel. Figure 2-6. Identification Labels and Numbers

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SM00856 Revision D Page 2-10 of 12

Description

Lifting Points Lifting Point For lowering/hoisting the Top Drive and Guide Beam/Skid

Tag Line Attachment Points For the Guide Beam/Skid with Top Drive attached

Optional Lifting Point For the Guide Beam/Skid with Top Drive attached

Crane Lifting Points For the Guide Beam/Skid with Top Drive attached

Crane Lifting Points For the Guide Beam/Skid with Top Drive attached (1 each side)

Figure 2-7. Lifting Points

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Description

Typical Equipment Arrangement Existing Traveling Equipment 500-ton Hook/Block Combo-Typ.

Crown Clearance 12.5 ft. (3.8 m)**

Block Top

* Dimensions are subject to verification.

Stroked-Typ. 13.5 ft. (4.1 m)*

TDS-11SA Top Drive

** Standard configuration with two IBOPs and 120 in. elevator links.

Bail Rest TDS Work Height 19.0 ft. (5.8 m)**

Sectional Guide Beam

Tool Joint Derrick Termination at ~73 ft. (24.4 m) Level* Mud Hose 75 ft. (22.9 m)* Connected to Standpipe at 73 ft. (22.3 m) Level

Drill Stand Made-up at 4 ft. (1.2 m) Level 93 ft. (28.3 m)

Service Loop

Two (2) Custom Spanners On A-Frames or Mast Side Panels (by Customer)

Driller’s Control Console

Control Cable with Connectors 150 ft. (45.7 m)

NOV Drive House Local Power Supply Diesel/Alternator Set/AC Buss

AC Cables

7.0 ft. (2.1 m)-Minimum

10.0 ft. (3 m)-Minimum*

Portable Torque Reaction Beam “U”- Bolted to Spanners - (by Customer)

Clear Working Height 142 ft. (43.3 m)

C L Beam Service Loop Tool Joint 4.0 ft. (1.2 m) Drill Floor

AC Power and Control Cables

Figure 2-8. Typical Installed Equipment Arrangement

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Description

SM00856 Revision D Page 2-12 of 12

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Installation

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! The User Manual provided with the equipment order contains this service manual, the engineering installation and commissioning procedures, the Technical Drawing Package (TDP), along with specifications, parts lists, and other instructions. These documents must be used by the installation and commissioning crew. Make sure an equipment User Manual is available in the location where the equipment is being installed and commissioned.

Preparation The top drive interfaces with the rig’s hoisting system and electrical power system. Derrick and electrical system modifications are required when installing the top drive on existing rigs. For derricks that handle triples, the required top drive travel is about 100 ft. (30.5 m) compared to about 75 ft. (23 m) when using a Kelly. It is generally necessary to replace the regular rotary hose (which is normally 60 ft. [18 m] long) with a 75 ft. (23 m) hose, and extend the standpipe height to approximately 73 ft. (22 m). Although many rig floor layouts are possible, installing the guide beam on the drawworks side of the derrick, or mast, and opposite the V-door is an ideal arrangement for handling tubulars from the V-door. The location of the electrical loop and mud hose is an important installation consideration for pipe setback purposes, to ensure proper clearance and to help prevent wear to the service loop and mud hose. Other important installation considerations include the location of the following: 

The casing stabbing board



Floor and derrick accessories



Drawworks fastline



Guide beam hang-off bracket and torque reaction beam



Mud stand pipe extension



Driller’s control console location



Variable frequency drive/electrical house location

To successfully install the TDS-11SA, it is critical to know the precise height and length of the travelling equipment, as well as the location of the tie backs. Refer to the rig GA drawing for these critical dimensions. The GA drawing is located in the Technical Drawing Package (TDP).

3-1 www.nov.com Form D811001123-GEN-001/06

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Installation

Illustrated Index Crown Padeye and Hang-off Link Page 3-3

Counterbalance Page 3-34

Guide Beam Page 3-9

Intermediate Tieback Page 3-4

Rotary Hose

Derrick Termination Page 3-27

Service Loops Page 3-28

Driller’s Control Console Page 3-30 Control Cable with Connectors Page 3-31

Main Tieback Page 3-5

Variable Frequency Drive (VFD) Electrical House (Drive House) Page 3-6 Local Power Supply Diesel/Alternator Set/AC Bus Power Cables Page 3-7 AC Power and Control Cables

Figure 3-1. Illustrated Installation Index

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Installation

Pre-Installation Installing the Crown Padeye and Hang-Off Link Crown Padeye  Weld at 30 inches from well center  Padeye to be suitable for 25 ton load Crown 30 inches

25 Ton Shackle

For land rig applications, when possible, install crown padeye, hang-off link and tieback with mast layed down. Hang-off Link  Adjust length per General Arrangement Drawing

Hang-off Tieback Drill Floor

Typical Cross Girt Below Crown C L Well

Figure 3-2. Installing the Crown Padeye and Hang-Off Link

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Installation

Pre-Installation Installing the Intermediate Tieback

To rotate intermediate tieback loosen locking bolt and rotate out of the way. To secure after rotating tighten locking bolt.

Intermediate Tieback (Shown in Locked Position)

Rotate

Locking Bolt Pivot Point

Drill Floor 30.0 inches

Refer to General Arrangement Drawing for installation height.

C L Well

Figure 3-3. Installing the Intermediate Tieback

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Installation

Pre-Installation Installing the Main Tieback Procedure  Install the main spreader beam at the appropriate distance from well center  Install the tieback plate and tieback link  Torque and lock wire all bolts

Typical (depending on block and hook configuration.

Tieback Link

Tieback Plate

Main Spreader Beam

Apply Anti-seize Compound Typical Auxiliary Spreader Beam Optional Main Tieback and Spreader Beam Adjust after installation of TDS and guide beams

Mast Leg

Drill Floor 30.0 inches

C L Well

Figure 3-4. Installing the Main Tieback

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SM00856 Revision D Page 3-6 of 48

Installation

Pre-Installation Locating the Control House

Drawworks

Recommended Area for VFD House Location

C L Well

V-Door Ramp TDS

Driller’s Control Console

8,000 lb (3630 kg) VFD House w/ single AC unit

C L Well

Typical installation

VFD House

Recommendations  Position the VFD house off-driller’s side or behind the drawworks  Position as close to derrick plate as possible to minimize cable lengths 92 in. (2337 mm)

174 in. (4420 mm)

84 in. (2134 mm)

 Ensure a safe distance from direct sources of heat (i.e. diesel engines, general exhausts)  Location of the VFD house must ensure accessibility from all sides  Do not expose the control house to H2S

Figure 3-5. Locating the Control House

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Installation

Pre-Installation Installing Power Cables

Plug Panel C1 COM

P

P AUX 5 PW

R

P6 VDC

P7 HM I

C2 VDC

Typical installation

C3 HM I

Blanking Plates Spare incoming power connections (3 Places)

P10

-A

P11

-B

VFD Grounding Lug

P12

-C

P10 BLK

Incoming Power Cables 600/690VAC to main circuit breaker (3 Places) Outgoing Power Cables to Top Drive (3 Places)

P11 WH T P12 RED

P10 BLK P11 WH T

P12 RED

Procedure  Clean all connector contacts

Plug Panel

 Connect the power cables with the isolation circuit breaker turned OFF  Connect cables in accordance with the electrical schematic provided in the Technical Drawing Package (TDP)

Rain Cover

VFD House Typical

 Lockwire all connector nuts  Earth the control house with the Ground Rod Kit

Figure 3-6. Installing Power Cables

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SM00856 Revision D Page 3-8 of 48

Installation

Pre-Installation Grounding the Control House (Land Rigs)

Copper Plated Steel Rod Cable Clamp

Cable Lug Copper Wire 10 ft

The control house must be properly grounded to prevent injury to personnel

Procedure  Insert the grounding rod into the soil (the rod must be in contact with ground water)  Connect the rod to the control house (connection must be clean)

Ground Rod Kit

Grounding Points Located at opposite corners of the house floor

For offshore installations the control house must be grounded to the ground point on the rig structure

Figure 3-7. Grounding the Control House (Land Rigs)

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Installation

3

Installation Checklist The following assumes that all pre-installation planning and rig-up is complete prior to installation of the guide beam assembly and top drive. This includes: 

Make sure the derrick/mast is vertical, with the block over the center of the rotary table.



Derrick/mast modifications are completed (if required) and the guide bean support bracket and torque reaction beam are installed per recommendations on the general arrangement drawing.



The service loop bracket is installed in the derrick/mast.



The control panel and the variable frequency drive (VFD) are installed.



All rigging is inspected to ensure there is no interference with the top drive.



The hook or adaptor becket is installed. The hook should open toward the drawworks when possible.

Identifying Guide Beam Sections Thoroughly review the Guide Beam Kit engineering drawing in the TDP prior to beginning the guide beam installation procedure. The guide beam sections must be installed in the correct order. Failure to install them in the correct order may result in a guide beam section falling to the rig floor. The bottom hinge joint on the bottom intermediate guide beam section is specifically designed to be connected to the upper hinge joint on the top drive shipping skid/guide beam section.The bottom intermediate guide beam section has a warning label identifying where it connects to the top drive shipping skid/guide beam section (see the section titled "Bottom Intermediate Section Warning Label" on page 3-23).

Always make sure to identify the bottom intermediate guide beam section and the location where the top drive skid/guide beam section connects to it. If these are installed improperly, a guide beam section could fall to the rig floor. A falling guide beam section will damage equipment and could result in severe injury or death.

If the warning label on the bottom intermediate guide beam section is worn, dirty, or otherwise illegible, clean it or order a new warning label to affix to the same place on the bottom-intermediate guide beam. Failure to adhere to this warning could result in severe injury or death.

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SM00856 Revision D Page 3-10 of 48

Installation

Installation Raising the Top Guide Beam Section to the Drill Floor Procedure  Locate the top guide beam section near the V-Door  Ensure the hoist carriage is free to slide the entire length of the guide beam  Ensure the latch moves freely  Attach lifting slings to the lifting eyes of the hoist carriage  Eusure the transport shipping pins are in place and secure  Hoist the guide beam section to the drill floor using a tugger line with a backup line to tail  Remove tugger line after top guide beam is in position on drill floor

Hoist Carriage

30,000 lb Tugger Pull

Tugger Line Attachment Points (Rig DOWN)

RIG DOWN UP

Tugger Line Attachment Points (Rig UP)

Top Guide Beam Latch

Shipping Pins 2 places

Drill Floor

Backup Line

Figure 3-8. Raising the Top Guide Beam Section

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Installation

Installation Attaching the Carriage Sling to the Hook

Hoist Carriage

Cable Sling Attachment Points (RIG DOWN)

RIG DOWN UP

Cable Sling Attachment Points (RIG UP)

Top Guide Beam

Disengage Shipping Pins

Hoist

Procedure Cable Sling

 Attach a short cable sling from the hook/block to the hoist carriage at the RIG UP attachment points  Disengage the shipping pins  Hoist the top guide beam using the drawworks

Figure 3-9. Attaching the Carriage Sling to the Hook

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SM00856 Revision D Page 3-12 of 48

Installation

Installation Moving Guide Beam Sections

Procedure

Do not move the bottom intermediate guide beam section until all other sections are moved to the rig floor. The bottom intermediate guide beam section is designed to be hooked to the top drive shipping skid/guide beam section only. Connecting the bottom intermediate section out of order may result in a guide beam section falling to the rig floor.

 Locate the remaining guide beam sections near the V-Door  Attach tugger lines to the lifting eyes of the first guide beam section to be hoisted  Hoist the guide beam section to the drill floor using the rear tugger line or tailing line to stabilize and balance the guide beam Tugger Line

3,200 lb (1450 kg) 24 ft. Guide Beam Section

Tugger Line

3 Guide Beam Section Hoist to the drill floor

Guide Beam Section

Tugger Line Tugger Line

2 Lifting Eyes Attach tugger lines for hoisting

Drill Floor

1 Guide Beam Sections Prior to Installation

Figure 3-10. Moving Guide Beam Sections

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Installation

Installation Hooking the First Guide Beam Section Guide Beam Top Section

1

2

Present

Match

Grease the bores on both joint halves Guide Surface Radius locks joint from unhooking at 8° rotation Hook Pin

Grease the bores on both joint halves

3

4

Engage

Hook

Hook Pin In fully engaged position

Present and Hook the first guide beam section

Guide Beam Section Hooked

Hook Pin Saddle

Tugger Line Leave attached to stabilize the back end of the guide beam

Procedure  Locate the guide beam to be hooked under the top guide beam section  Grease the bores on both joint halves  Align the guide surface with the hook pin as shown  Lower the top guide beam to match and engage the hook pin to the hook pin saddle  Hoist the top guide beam to fully engage the hook pin  Manually stabilize the back end of the guide beam

Figure 3-11. Hooking the First Guide Beam Section

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SM00856 Revision D Page 3-14 of 48

Installation

Installation Hoisting the First Guide Beam Section

Guide Beam Top Section Hoist

Hook Pin

First Guide Beam Section Initially hoisted by the hook pin

Bar and Radius Locates pin bores for easy insertion of pins Hoist Using the drawworks

Figure 3-12. Hoisting the First Guide Beam Section

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3

Installation

Installation Stabbing and Pinning the First Guide Beam Section

Guide Beam Top Section

1 Stab the guide beam joints together

Lynch Pin

2 Joint Pin Install after stabbing

4

3

Secure with the lynch pin

Retainer Pin Apply grease and insert

Stab and Pin the guide beam joint

Block as Required

Procedure  Lower the guide beam to drill floor and stab the guide beam joints together  Block the guide beam in a vertical position if required  Install the cleaned and greased joint pin  Grease and install the retainer pin  Secure the retainer pin with the lynch pin as shown

Figure 3-13. Stabbing and Pinning the First Guide Beam Section

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SM00856 Revision D Page 3-16 of 48

Installation

Installation Completing Guide Beam Section Installation

Do not move the bottom intermediate guide beam section until all other sections are moved to the rig floor. The bottom intermediate guide beam section is designed to be hooked to the top drive shipping skid/guide beam section only. Connecting the bottom intermediate section out of order may result in a guide beam section falling to the rig floor.

Repeat the previous steps until guide beam sections are installed Tugger Line

Tugger Line

Procedure

Drill Floor

 Move the next guide beam section to the drill floor  Present the end of the guide beam to be hooked  Ensure that the bores on both joint halves have been greased  Engage the hook pin saddle around the hook pin  Hoist the guide beam with the drawworks  Lower the guide beam to the drill floor and stab the guide beam joints together  Install the joint pin  Install the retainer pin  Secure the pins with the lynch pin

Figure 3-14. Completing Guide Beam Section Installation

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Installation

3

Installation Hoisting and Attaching the Guide Beam

Latch is held in unlock position when carriage is at top position

Latch locks beam to hang-off link when carriage is lowered

Diverter To Protect Against Accidental Unlatching

Procedure

Hoist Carriage Extension

 Attach guide beam assembly to hangoff link

Procedure  Rotate intermediate tieback handle UP 90 degrees  Insert the intermediate tieback into the slot located on the lower guide beam  Rotate intermediate tieback handle DOWN 90 degrees to lock the guide beam in place  Adjust the tieback bracket so the center of the guide beam is 30 inches from well center Intermediate Tieback

Tieback Handle

Guide Beam Slot

Attach Intermediate Tieback into Lower Guide Beam Slot

Figure 3-15. Hoisting and Attaching the Guide Beam

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SM00856 Revision D Page 3-18 of 48

Installation

Installation Removing the Hoist Carriage

Hoist Carriage Drill Floor

Procedure  Lower hoist carriage to drill floor  Remove hoist carriage from drill floor and store (to be used again for rig down and transport)

Figure 3-16. Removing the Hoist Carriage

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3

Installation

Installation Moving the Top Drive to the Rig Floor Procedure Ensure the safety of all personnel  Locate the Top Drive at the bottom of the V-Door ramp  Attach a lifting sling to the bail  Attach backup lines to the skid  Hoist the Top Drive and skid to the drill floor

35,000 lb Crane Lift

35,000 lb (15,876 kg) TDS-11SA on the skid

Lifting Block Hoist using the drawwork Optional Crane Placement

Side Bracket

2

TDS hoisted up V-Door Ramp Bail

Drill Floor

Lifting Detail 60 ft Slings

1

TDS on skid

Backup Line

Figure 3-17. Moving the Top Drive to the Rig Floor

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SM00856 Revision D Page 3-20 of 48

Installation

Installation Attaching the Top Drive to the Hook There are two basic methods for installing the TDS-11SA top drive, depending on the travelling equipment configuration. Follow the installation procedures for option 1 or option 2 as appropriate for the rig.

Bail

Bail Lock

TDS-11SA

V-Door Post

Attach Sling or Tugger Lines to Secure Skid

V-Door Ramp

Procedure  Remove hoist cable slings  Attach bail to block or hook  Secure lower end of skid to prevent movement toward or down V-door ramp  Hoist using drawworks

Figure 3-18. Attaching the Top Drive to the Hook

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3

Installation

Installation Lifting the Top Drive into the Rig

Option 1 Procedure

Option 2 Procedure

 Set TDS on the rig floor  Secure the bottom end of the skid to the floor or the v-door posts to prevent the TDS from moving back down the v-dor ramp  If the traveling equipment and the TDS bail length allows, the bail can be connected directly to the hook/block (refer to the general arrangement drawing)

 Hoist the TDS from the v-door to a vertical position using slings  Connect the TDS skid to the guide beam

Hook open towards drawworks

Hook open towards v-door

Depending on the traveling equipment and bail length, variations of this procedure may be required

Figure 3-19. Lifting the Top Drive into the Rig

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SM00856 Revision D Page 3-22 of 48

Installation

Installation Connecting the Top Drive to the Guide Beam 1

Bottom Intermediate Section

Present

Hook

Insert hook pin into hook pin saddle

Lower TDS/Skid until it makes contact with Lower Tieback

Hook Pin

Grease the bores on both joint halves

2

Grease the bores on both joint halves

Hook Pin In fully engaged position

Hook Pin Saddle

Guide Beam /Skid Section Skid not shown

3 Attach Lower Tieback OPTION 2 Lower Tieback Present and Hook TDS to the guide beam section

Guide Beam /Skid Section Skid not shown

Hook Joint

OPTION 1

Lower Tieback

Procedure Backup Line

 Locate the TDS skid to be hooked under the bottom intermediate guide beam section  Grease the bores on both joint halves  Align the guide surface with the hook pin as shown  Lower the TDS skid to match and engage the hook pin to the hook pin saddle  The bottom intermediate guide beam section and skid will contact the lower tieback

Figure 3-20. Connecting the Top Drive to the Guide Beam

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Installation

3

Installation Bottom Intermediate Section Warning Label

Bottom Intermediate Guide Beam Section

Warning Plaque (P/N P614000138)

If an equipment warning plaque is worn, dirty, or otherwise illegible, clean it or order a new warning label. Failure to adhere to this warning could result in severe injury or death.

Top Drive Shipping Skid/ Guide Beam Section

Figure 3-21. Bottom Intermediate Guide Beam Section Warning Label

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SM00856 Revision D Page 3-24 of 48

Installation

Installation Attaching the Torque Tieback

Tieback Retainer Pins

Tieback Pivot Pin

Tieback Hook

OPTION 2

Tieback Pivot Pin

OPTION 1

Tieback Hook

Procedure  Engage tieback hooks to secure the lower guide beam/skid  Insert retainer pins

Figure 3-22. Attaching the Torque Tieback

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3

Installation

Installation Pinning the Top Drive to the Guide Beam

Guide Beam Bottom Section

4 Secure with the lynch pin

Lynch Pin

2 Lower Tieback

Joint Pin Install

Seating Surfaces

3 Retainer Pin Apply grease and insert

OPTION 2

1 Guide Beam /Skid Section Hoist until it seats Skid not shown

Hoist Using the drawworks

OPTION 1

Drill Floor

The bottom end of guide beam/skid should be approximately 7 ft plus or minus 6 inches above the drill floor

Procedure  Hoist guide beam/skid section until it seats  Install the joint pin  Grease and install the retainer pin  Secure the retainer pin with the lynch pin as shown

Figure 3-23. Pinning the Top Drive to the Guide Beam

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SM00856 Revision D Page 3-26 of 48

Installation

Installation Releasing the Top Drive from the Skid

After hoisting the TDS disengage the Lower Carriage Latch and pin it as shown.

Pin

1

View of Carriage from Rear

Upper Latch Engaged

Lower Latch Disengaged

Pin

Pin

OPTION 2

Latches Both sides engaged Pin

2

Pin

Upper Latch Disengaged

OPTION 1

Lower the TDS, disengage the Upper Carriage Latch and pin it as shown.

Lower Latch Disengaged

Pin

Procedure  Lower the blocks (option 2 only)  Remove the slings (option 2 only)  Connect the hook/block to the bail (option 2 only)  Disengage the carriage latches  Remove the Bail Lock and store it for future use Figure 3-24. Releasing the Top Drive from the Skid

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3

Installation

Installation Installing Derrick Termination Hoist Line Attachment Point

Derrick/ Mast Leg

Derrick Leg Plate

Hoist Line Attachment Points

Service Loop Brackets

Mount Derrick Termination Plate as recommended

83 ft from drill floor

Recommendations  Mount on the side of the derrick adjacent to the service loop brackets on the Top Drive Drill Floor

!

 Mount as far as practical from well center, to maintain a 36 inch minimum bend radius Maintaining a larger radius increases loop life and reduces damage due to “pinching”  Location must ensure that the loops do not catch under the guide beam during operations and provide clearance for tong lines, the stabbing board, tugger lines, etc

Figure 3-25. Installing Derrick Termination

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SM00856 Revision D Page 3-28 of 48

Installation

Installation Installing Service Loops at the Derrick Hoist

Derrick Termination Plate

1,000 lb (450 kg) Each Service Loop Sling

! Avoid damage to the service loops by using care when dragging it near sharp edges and allow room for passing under the V-door

TDS Service Loop

Lifting Eyes Do not remove Derrick Service Loop

Recommendations

!!

 Do not unpack the service loops until they are ready to hang  Use a sling attached to the lifting eyes to hoist each service loop  Use the swivel at the tugger line attachment to allow each service loop to uncoil without twisting

Avoid damage to the service loops by maintaining a 40 inch minimum bend radius Service Loop and Storage Tub 3,600 lb (1600 kg)

!

Take care so the service loop pigtails are not damaged during installation.

Figure 3-26. Installing Derrick Service Loops at the Derrick

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Installation

3

Installation Installing Service Loop Jackets There are service loop jackets that are assembled around the service loops. Install the jackets after the service loops have been attached at the derrick termination plate.

! The double Velcro construction is hard to disassemble. Make sure the orientation of the jacket is correct before you close the strap.

Refer to Installation Instructions, Service Loop Jackets (D614000166-PRO-001) for annotated photographs showing how to install a service loop jacket. This engineering procedure is located in the equipment user manual. To install each jacket: 1. Velcro the inner straps around the biggest cable/hose. 2. Close the flaps around the whole bundle and close the double Velcro edge. Leave a little room so the cables/hoses can move up and down the jacket. 3. Secure the double Velcro edge with the two lock straps.

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Installation

Installation

Drawworks

Installing the Driller’s Control Console

V-Door Ramp

TDS

Recommended Area for Driller’s Control Console Location INC

Y NC GE ER OP EM ST

UE RQ

T KE SE MA

UP

INC

DR

OR EN AT OP

L

RA

NE

GE

AN

EH

PIP

ES PR OIL SS LO

E

PM

UP KE MA

ILL

DR OR AT EV EL ED BX CLOS

AU

S TD

MO SP

DE

TO

RQ

UE

TE CW

TA

PH CC

IN

RO

W

T TILT

K TIL

/

LIN ILL DR

ILL DR

E

AK

BR AU

N

IO

TO

TD

P IBO OS CL

AS RE

U HP / ON TO

S

ER OW BL SS LO

Profibus Cable

E

SR TD

T

TIL K T LIN OA FL

TE

DR ER OV

CE EN SILECK M AR CH AL MP LA

P AM LD CL HO TWAND SH PU

E

E DECREAS

ER

DL

D VF T UL FA

MS AR TOR AL ILL MOMP

EL

INC

BX D ME AR CE AN P AL UM RB DJ TE AN UN ST CO / ILL DR

AS RE

E DECREAS

BX EV

24 VDC Power  hard-wired E-Stop

AS RE

E DECREAS

S TO TD ILL LE AB EN

ED FO

RW

AR

CT IREF

SD

RS

E

VE

RE

OF

D

E AK BR OFF / ON

P IBO

OS CL

E

EN OP

! Customers who choose to use control systems not manufactured by NOV should be aware that NOV systems are specifically designed with operational interlocks and safety devices to prevent possible injury to personnel and damage to the system. Other control systems must meet NOV requirements. NOV highly recommends the use of its system, as it is specifically made for use with the Top Drive.

Recommendations  Mount within easy reach and in plain view of the driller while the drawworks brake and clutches are being operated  Location must ensure that the gauges are easily seen by the driller during drilling operations  Location must be visible and readable at night

Figure 3-27. Installing the Driller’s Control Console

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Installation

Installation Installing the Console Cabling 24VDC Power / Hard-Wired E-Stop to Driller’s Console Profibus Serial Link to Driller’s Console C1 COM

P P AUX 5 PW

R

P6 VDC

P7 HM I

C2 VDC

Typical installation

C3 HM I

P10

-A

P11

-B

P12

-C

P10 BLK

Plug Panel

P11 WH T P12 RED

P10 BLK P11 WH T

P12 RED

Recommendations  Ensure that the Driller’s Control Console is properly located  Connect the power cables with the isolation circuit breaker turned OFF

Plug Panel Rain Cover

VFD House Typical

 Connect cables in accordance with the electrical schematic provided in the Technical Drawing Package  Tighten connector nuts  Lockwire connector nuts to prevent loosening

Figure 3-28. Installing the Console Cabling

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SM00856 Revision D Page 3-32 of 48

Installation

Installation Motor Rotation Checkout Procedure Direction of Rotation Counterclockwise

Procedure  Assign the Top Drive and inverter by selecting FORWARD or REVERSE TDS DIRECTION on the driller’s console  Check the rotation direction of the cooling and oil pump motors  Rotate the drill stem using the TDS RPM knob on the driller’s console and observe proper operation S ES PR OIL OSS L

Direction of Rotation Clockwise

UE

RQ

TO

E

S TD

D MO

Cooling Motors 2 Places

IN

SP

LI ILL

DR

ILL

DR

E

AK

BR

E RS

VE

N

RE

IO

T EC

IR

TO

AU

SD

F OF

TD D

AR

RW

FO

Driller’s Control Console I NC

CY GEN ER OP EM ST

EUP

S

QUE TOR I NC

L DRIL

BLE

OR N VAT OPE ELE I NC

BX ED ARM CE LAN UMP RBA NDJ NTESTA COUL / DRIL

L ERA GEN

HA

PIPE

TD

MP D CLA HOL TWAND H PUS

S MO

ILL

DR

HPU/ ON O AUT

QUE TOR

DE

PM SR TD

P KEU MA

OR VAT ELESED BX CLO

TILT LINK AT FLO

DRIL RTE OVE

A SE RE

E DECR EAS

R

LE

ND

VFD LT FAU

MS AR AL L MOTMPOR SS PRE OIL S LOS

A SE RE

E DE CR EAS

BX

ENA

WER BLO S LOS

A SE RE

E DE CR EAS

SET MAK

TD

ATE CW PH

ROT

CCW

SPIN

TILT TILT

/

LINK

NCE SILECK RM CHE ALA P LAM

L DRIL

L DRIL

E

AK

N

IO

BR

TD

SED CLO

E ERS REV

CT

RE

O AUT

IBOP

S DI

OFF

D WAR FOR

KE BRAOFF / ON

SE CLO IBOP N

INC

OPE

ASE RE

INC

E DECREAS

PM

SR TD

ASE RE

E DECREAS

INC

P

R

E EAS

EU

K MA

E DECREAS

ILL

DR

Direction of Rotation Counterclockwise Oil Pump Motor Drill Stem Direction of Rotation Forward

Reverse

Figure 3-29. Motor Rotation Checkout Procedure

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Installation

Installation Installing the Elevator Links Procedure  Rotate the pipehandler 90˚ (positioning the link catch under the front of the motor guard)  Lubricate the elevator link eyes with pipe dope  Hoist the elevator link onto the rotating link adapter (small eye at bottom)  Secure the link catch with the pin and fasteners  Secure the elevator link to the link tilt  Rotate the pipehandler 180˚ and install the other elevator link  Install the elevator (refer to the elevator manual)

Link Catch Pin

Link Tilt

Link Catch

Clevis Pin Rear Pipehandler Rotate Switch

UN ST CO L / IL DR

L

RA

NE

GE

ER

DL

N HA

E

PIP

PU

P AM LD CL HO TWAND SH

ILT K TT LIN OA FL

U HP / ON TO

Link

AU UE

E AT CW

RQ

TO

PH CC

T RO

W

T

ILT TIL

Front

KT

LIN ILL

DR

E RS VE RE

Driller’s Control Console

600-2,400 lb (270-1100 kg) Elevator Link

I NC

CY GEN ER OP EM ST

EUP

S

QUE TOR I NC

L DRIL

OR N VAT OPE I NC

ELE

A SE RE

L ERA

DR

DRIL

GEN

R LE D ND CLAMP HOL HA TWH AND PUS PIPE

VFD LT FAU

AR

MS OR

TILT LINK AT FLO

MA

TD KEU

PM SR

P

E DECR EAS

LAN UMP RBA NDJ NTESTA COUL /

MP L MOT DRIL RTE OVE

A SE RE

E DE CR EAS

BX BX ED ARM CE

AL

A SE RE

E DE CR EAS

SET MAK

TD BLE ENA

ILL

OR VAT ELESED BX CLO

HPU/ ON O AUT

SS PRE OIL S LOS

QUE

TD

ATE CW

TOR

DE

WER BLO S LOS

PH

S MO

ROT

CCW

SPIN

TILT TILT

/

LINK

NCE SILECK RM CHE ALA P LAM

L DRIL

L DRIL

BR

AK

E

N

IO

E ERS REV

CT

RE

O AUT

TD

OP

IB

SED

S DI

OFF

D

CLO

WAR FOR

KE BRAOFF / ON

SE CLO IBOP N OPE

Take care when installing elevator links. Links weigh up to 2,400 lb (11,00 kg) and can fall if handled improperly. Figure 3-30. Installing the Elevator Links

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SM00856 Revision D Page 3-34 of 48

Installation

Installation Installing the Counterbalance Procedure  Refer to Setting up the circuits in the Hydraulic section of this manual for initial system set up  Install the pear links to the ears on the hook  Turn on the Top Drive power  Rotate the counterbalance mode valve from the RUN position to the RIG-UP position  When the cylinders reach the end of stroke, slide the cylinder clevis over the pear link and install the cylinder clevis pin  After securing the counterbalance cylinder to the pear link, rotate the counterbalance mode valve to the RUN position  Adjust PCC clockwise to raise the pressure at test port CB until the bail just begins to lift off of the block  Reduce the pressure slowly (25 psi) to allow pressure to stabilize Cylinder Clevis Pin 2 Places Rig-up/Run/ Shutdown Valve Shown in RIG-UP position (switch to RUN after the counterbalance is installed)

Hook

Pear Link 2 Places

Cylinder Clevis 2 Places

Counterbalance Cylinder 2 Places (8.5 inch stroke) Bail

RIG-UP

SHUTDOWN

RUN

S

H

N

U T

D

U R

O

W

N

COUNTERBALANCE MODE

E C

N LA

-U P

BA

R

TE

R IG

N U

O

C E

D

O

M

Hydraulic Manifold

Figure 3-31. Installing the Counterbalance

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Installation

3

Commissioning Initial Checkout Procedure Initial Rig-Up  Pre-charge all accumulators (See the Hydraulics System section of this manual)  Adjust the hydraulic system  Bleed the air from the hydraulic system  Constantly monitor the hydraulic fluid level, and never allow the level to fall below the middle of the sight glass (power OFF)

Cork Ball (Level Indicator)

Checkout Procedure  Lubricate all grease points (See Lubrication)  Check for loose or missing connectors  Lockwire all connector nuts  Check for interference along entire mast  Remove exhaust covers from AC drilling motors  Check blower inlets and outlets for blockage  Set the air conditioner to 75˚F (27˚C)  Turn on the main breaker

Sight Glass Hydraulic Oil Sight Gauge

TOP DRIVE

Exhaust Cover 4 Places

INS T WH ALL UN EN ST IT IS OR ED

VARCO

Air Inlet Between motor and brake housing, 2 Places

Exhaust Outlet Through louvers at bottom of AC drilling motors, 6 Places

Figure 3-32. Initial Checkout

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Installation

SM00856 Revision D Page 3-36 of 48

Commissioning Hydraulic System Checkout Procedure

Cork Ball (Level Indicator)

Red “Pop-up” Dirt Alarm

Sight Glass Hydraulic Oil Sight Gauge

Hydraulic Oil Filter

Procedure  Ensure that the pipehandler clamp cylinder is unclamped, the counterbalance cylinders are connected to the hook, the bail is resting in the hook, and the system power is OFF  Check to see that the hydrulic fluid level is at the middle of the sight glass  If the fluid is low, add hydraulic fluid (see the Lubrication and Maintenance section of this manual  Check the red “pop-up” alarm on the hydraulic filter for contamination  Replace the filter if the indicator has popped up  Use care to prevent contamination from entering the hydraulic system during maintenance activities Figure 3-33. Hydraulic System Checkout

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3

Installation

Commissioning Electrical System Checkout Procedure

Emergency Stop

INC

Y NC GE ER OP EM ST

S TD

TO

RQ

UE

P T KEU SE MA

ILL

INC

DR

R N ATOOPE

EV

EL

INC

BX

ASE RE

MED

E NC P M ALA DJU

24 VDC Power  hard-wired E-Stop

AN

EH

PIP

TO MO P ILL TEM DRVER O

ES PR OIL SS LO

D R

ATO D

AU

DE

TO

RQ

UE

HPU/ ON TO

TE CW

TA

PH

O SM TD SPIN

RO

K

MA

L RIL

EV EL SE BX CLO

LT K TIT LIN OA FL

S

WER BLO SS LO

RPM Meter

W CC LT TILT

K TI

LIN

E/ NC K SILE EC RM CH ALA MP LA

ILL

DR

ILL

DR

E

AK

N

BR

IO CT

SD TD

IB

D

REV

SE ER

Torque Meter

IRE

TO AU

OP

SE CLO

MP LD CLA HO TWAND SH PU

PM

SR

P EU

E DECREAS

ER

DL

D VF LT U FA

S RM R

AR

RB TE AN UN ST CO L / IL DR

A AL

TD

E DECREAS

BX

LE

AB

EN

AL ER GEN

ASE RE

E DECREAS

ASE RE

OFF

D AR RW FO

E AK BR OFF / ON

P

IBO OPE

Profibus Cable

SE CLO

N

Procedure All personnel must stand clear  All personnel operating the top drive should be trained in rig safety and tool operation  Operate each control on the driller’s control console (See the Operations chapter)  Check for alarm conditions and resolve any alarms at this time (See the Operations chapter)  Check all connectors for tightness and lockwire  Check operation of meters  Check operation of emergency stop  Check the latches on the driller’s console for tightness

Figure 3-34. Electrical System Checkout

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SM00856 Revision D Page 3-38 of 48

Installation

Commissioning Mechanical Checkout Procedure

Procedure  With the drive motors and hydraulic system off, check to see that the oil level (identified by a floating cork ball) is at the middle of the glass located on the lube pump adapter plate mounted on the side of the gearbox  Always check the oil level, not foam level (oil is dark brown, foam is tan) after the unit has been running and the transmission oil is warm  If the oil level is low, add gear oil (see the Lubrication and Maintenance section of this manual  Check the red “pop-up” alarm on the gear oil filter for contamination  Replace the filter if the indicator has popped up

Cork Ball (Level Indicator)

Sight Glass

i Gearbox Oil Fill Clean area before removing plug,then use a 1 3/8 inch, 12 point socket to remove plug

Gear Oil Sight Gauge Check with Top Drive “OFF”

“Pop-up” Dirt Alarm

Gear Oil Filter Figure 3-35. Mechanical Checkout

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Installation

3

Commissioning Adjusting the Link Tilt

Jam Nut Adjust the derrickman position with the adjusting screw and lock in position with the jam nut Link Tilt Crank Assembly Pin

26 inches (660 mm) Typical

Clamp

Mousehole Position Cable Pull “up” or “down” to set mousehole position

3-4 inches (76-102 mm)

Link Mousehole Position Derrickman’s Position Link clamps should be adjusted so that the elevator does not hit the diving board in this position

Well Center Float Position

Drill Down Position Bottom of elevator should be above the bottom of the stabbing guide

Elevator

Figure 3-36. Adjusting the Link Tilt

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SM00856 Revision D Page 3-40 of 48

Installation

Decommissioning Securing the Top Drive for Rig-Down Procedure  Lower the Top Drive to the drill floor  Remove the mud hose, drill pipe elevator and links  Power may be needed to turn rotating head into position for removing the links  Locate the RIG-UP/RUN/SHUTDOWN valve on the hydraulic manifold  With the hydraulic power ON select the “RIG-UP” position and remove the extended counterbalance cylinders from the hook ears  Select the “SHUTDOWN” position and turn off the Top Drive  Isolate and lock out ALL power to the Varco control house

N

Hydraulic Manifold

O

W

RU

H

U

T

D

N

S

CO

UN

TE

RB

-U

ALA

IG

R

NC

P

Lower TDS to drill floor

EM

OD

E

Rig-up/Run/ Shutdown Valve Rotate from RIG-UP to SHUTDOWN for Top Drive rig-down

RIG-UP

Drill Floor

SHUTDOWN

RUN

COUNTERBALANCE MODE

Figure 3-37. Securing the Top Drive for Rig-Down

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Installation

Decommissioning Removing and Storing Cables and Service Loops Derrick Termination Plate

Lower

1,000 lb (450 kg) Each Service Loop

Sling

! ! Avoid damage to the service loops. Use care when dragging them near sharp edges and allow room for passing under the V-door

Derrick Service Loop

TDS Service Loop

!! Avoid damage to the service loops by maintaining a 36 inch minimum bend radius

! An electrical short can occur if quick connectors are not kept clean and dry. Whenever separating quick connector(s), immediately install the weather plugs to prevent connectors from becoming contaminated with water or debris. When the connector is not in use secure/locate the connector so that is does not lie on the ground and make sure to minimize any exposure to water, mud, etc. Prior to re-connecting, inspect the inside of the connectors to make sure they are clean and dry.

Service Loop and Storage Tub 3,600 lb (1600 kg)

Lifting Eyes Do not remove

Procedure  Position the service loop tubs for convenient loading of the service loops  Disconnect the derrick service loop from the derrick termination plate and the control house  Disconnect jumper cables (if installed)  Cap all connectors and lower the derrick service loop into a service loop tub  Use a sling attached to the lifting eyes to lower each service loop and a swivel at the tugger line attachment to allow each service loop to coil without twisting  Disconnect the top drive service loop and repeat the above procedure  Remove the service loop tubs from the area  Remove the derrick termination plate if necessary

Figure 3-38. Removing and Storing Cables and Service Loops

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SM00856 Revision D Page 3-42 of 48

Installation

Decommissioning Setting the Latches and Locking the Bail Counterbalance Cylinders Disconnect from the hook

TOP DRIVE

Exhaust Cover 4 Places

INST WH ALL UN EN ST IT IS OR ED

Bail Lock

VARCO

View of Carriage from Rear

Pin

Lower TDS to drill floor

Latches Both sides engaged

Pin

Procedure

Drill Floor

 Lower the top drive to the drill floor  It is NOT necessary to drain gear oil or hydraulic fluid for rig down  Attach the bail lock by placing u-bolt behind the gooseneck and attaching it to the tube as shown  Disconnect the counterbalance cylinders from the hook  Install exhaust covers  Engage the upper and lower carriage latches as shown Figure 3-39. Setting the Latches and Locking the Bail

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Installation

3

Long Term Storage When the top drive will be idle for six months or more, use the following long-term storage recommendations in order to preserve the top drive and to properly store equipment associated with its care and maintenance.

General Guidelines Before leaving the factory, top drives are protected only for shipment to the destination. The following guidelines and procedures should be followed for storage after arrival or extended storage (six months or longer) on the rig.

Safety Safety must be a prime consideration during application of any rust inhibitors, since they are combustible and generate explosive vapors. Follow the manufacturer’s recommended safety precautions. All personnel must understand these precautions and be properly protected.

Before using combustible products on the rig, make sure to read and understand the manufacturer’s safety precautions.

Storage Location and Position Store the top drive and accessories under cover, or indoors, if possible. Top drives should be stored away from blowing dust, salt spray, sources of vibration, etc. Also, avoid storage areas where rapid temperature changes occur as this type of environment produces condensation. Store the top drive in a vertical position if possible. If the top drive cannot be stored in a vertical position, store the top drive on its shipping skid. Racks or pallets should be used for all other parts of the top drive to make sure they are stored off the ground, concrete, etc. Care must be given to positioning of stored components to allow periodic reapplication of rust inhibitors, rotating of machinery, and so forth.

Cleaning Steam cleaning is acceptable, but should be limited to painted surfaces. Unpainted surfaces must be thoroughly dried and protected with rust inhibitors. Care must be used to avoid getting steam or water into gearboxes, hydraulic system, bearing housings, and bushings. No diesel-based cleaners should be used in cleaning junction boxes, hoses and electrical items.

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Installation

SM00856 Revision D Page 3-44 of 48

Long Term Storage Pre-Storage Procedure In addition to the items indicated in the section titled "Storage Procedure" on page 3-45, perform the following procedures at initial long-term storage of the top drive. 1. If the top drive is to be stored in vertical position, drain oil from gearbox. Refill to the full level in the sight glass full with an AGMA mild EP gear oil with rust inhibitor, or equivalent (see the Recommended Lubricants and Fluids document located in the User Manual). Rotate gears and bearings to distribute lubrication. 2. Relieve all hydraulic pressure, including accumulators. If the top drive is stored in a horizontal position, drain hydraulic lines to prevent hydraulic fluid leaking out into the immediate storage area. 3. Seal or plug exposed ends of air, hydraulic, water and lube/oil lines. 4. Remove washpipe packing assembly, disassemble and remove O-rings and packing rings. Clean and coat washpipe assembly with rust preventative and store separately. Protect all exposed threads on washpipe, gooseneck and stem (grease all threads before installing threaded protectors). 5. Cover all electrical control boxes (junction boxes, etc.) with paper impregnated with a volatile-type inhibitor followed by thick black plastic sheeting (at least .006" thick). All sharp corners should be protected with wood blocking. Add desiccant packs to keep dry. The instrument junction box will stay on the top drive. Seal all openings with plastic NPT caps, and add desiccant packs inside each box.

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SM00856 Revision D Page 3-45 of 48

3

Installation

Long Term Storage Storage Procedure Complete the following steps at the monthly intervals indicated. Step

Procedure Description

0.0 mo

1.5 mo

1

2

Rotate all rolling elements, and raceways (gearbox, handling ring etc) to prevent etching or staining.

X

X

• Coat all exposed bare metal and moving parts with rust preventative (dry-film type rust inhibitors can also be used). • Remove all covers/guards to gain access to all moving parts when necessary. • Rotate parts involved while applying rust preventative to ensure parts are fully coated. Make sure that covers/guards are replaced after coating.

X

X

• Grease all pins and dowels. • Rotate parts while applying grease to ensure parts are fully coated.

X

X

4

Add/replace desiccant packs inside each electrical box.

X

X

5

If the top drive is to be stored in a horizontal position: • drain gear box and bearing cavities, then • coat the inside of gear box (all gears, pinions, etc.) and bearing cavities with grease type rust inhibitor and then drain. • Rotate gears and bearings while applying rust inhibitor to ensure parts are fully coated.

X

X

6

Perform recommended Lubrication and Maintenance procedures as indicated in this service manual.

X

X

7

• Thoroughly grease all fittings with rust inhibiting grease. Use enough to completely coat all rotating surfaces. • Rotate/actuate all parts involved while applying grease to ensure full distribution.

X

X

8

Make sure all openings and covers are tightly sealed.

X

X

9

• Clean exterior of the top drive to remove all mud, dirt or other foreign material. • Remove any rust and then coat area with red oxide or zinc rich primer.

X

X

3

3.0 mo

6.0 mo

For long-term storage procedures of original equipment manufacturer (OEM) parts and components, see the manufacturer’s documentation located in the User Manual supplied with the equipment.

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Installation

SM00856 Revision D Page 3-46 of 48

Long Term Storage Returning the Top Drive to Service

For bringing OEM parts and components out of storage for use, see the manufacturer’s documentation located in the User Manual supplied with the equipment.

1. Remove all protective covers, wrappings and desiccant packs. Inspect for corrosion or damage. Repair as required. 2. Remove all storage plugs. 3. Drain and flush all oil, preservatives, and inhibitors. 4. Change all filters and clean all strainers. 5. Check and replace (as needed) all rubber/elastomer parts. For example: air hoses, water hoses, hydraulic hoses, seals, and counterbalance bags. 6. Replace all parts removed for separate storage, such as the washpipe assembly. 7. Fill all lubrication systems to correct levels with specified lubricants (see the Recommended Lubricants and Fluids document located in the User Manual). 8. Perform recommended lubrication and maintenance procedures (see Revision DMaintenance). 9. A qualified electrician must test motor windings and service loops.

Accumulated moisture in motor windings and service loops should be driven out by several hours of low amperage use.

10. Prior to starting and operating the top drive: 

perform a thorough inspection and checkout to verify that all of the top drive's systems are fully functional and operational before returning the top drive to service. Refer to the mechanical and electrical inspections in the appropriate installation documents or mechanical and electrical checkout procedures.



lubricate the rotating head or link adapter with 25ml of hydraulic fluid. Manually rotate the component clockwise and then counter-clockwise for two rotations.

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

Installation

3

make sure the top drive is oriented vertically for two hours prior to energizing the top drive hydraulic system.

! Allow adequate run-in time. Start slowly with no load for two hours to assess the top drive for wear or damage.

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Installation

SM00856 Revision D Page 3-48 of 48

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SM00856 Revision D

Operation

4

! All procedures and methods provided in this manual are superseded by the procedures and methods approved for use at the location where the equipment is installed and commissioned.

Stateless Driller’s Control Console Overview A stateless NOV Driller’s Control Console is typically used to operate the TDS-11SA Top Drive. Some top drive installations may also include an Amphion™ Human-Machine Interface (HMI) system, in addition to the stateless driller’s control console. In this chapter, the controls on the stateless driller’s control console are provided to explain top drive operations. All the operator controls described are replicated in the Amphion HMI. The control console provides the control circuitry for all top drive and pipe handler functions. The console enclosure also contains Intrinsically Safe (I.S.) barrier components that support Zone 2 certification. The control console is integrated with the Variable Frequency Drive (VFD). The VFD is located in an environmentally-controlled drive house. The communication path from the driller’s control console to the VFD is via a common data bus. Functional changes can be implemented by NOV using utilities that are common for NOV top drive systems. Control commands from the console are processed through a single-board computer (SBC). The SBC controls the actions of the cooling system, the solenoid valves, the brakes, IBOP functions, switches and sensors. The SBC also monitors all component sensors and switches, and acts as a safety interlock to prevent inadvertent tool operation. Additionally, the SBC notifies the driller of the operational status of the top drive and diagnoses abnormal operating conditions. Refer to the section titled "Installing the Driller’s Control Console" on page 3-30 for installation information.

The illustrations in this chapter show a typical control console panel layout. Depending on the top drive system options, the layout of the console controls may vary. Refer to the engineering drawings in the Technical Drawing Package (TDP) for the rig-specific console layout for the equipment order.

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Operation

Stateless Driller’s Control Console Front Panel Figure 4-1 shows the front panel for a typical stateless NOV Driller’s Control Console. Figure 4-2 shows the internal components with the front panel opened.

Refer to later sections of this chapter for console button, switch, and gauge descriptions.

Front Panel (Door Closed)

For Reference Only. The illustrations in this supplement show a typical control console panel layout. Depending on the top drive system options, the layout of the console controls may vary. Refer to the engineering drawings in the Technical Drawing Package (TDP) for the rig-specific console layout for the equipment order.

Figure 4-1. NOV Stateless Driller’s Control Console (Front Panel Closed)

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Stateless Driller’s Control Console Internal Components Figure 4-2 shows the internal components with the front panel opened. Low Voltage Wiring Only

I. S. Wiring Only

I. S.

1.5 x 3

1.5 x 3

1.5 x 3

N. I. S.

N. I. S.

I. S.

2x3

AC Voltage

Field Cabling

1.5 x 3

Front Panel (Door Opened)

Segregated I.S. Wiring

For Reference Only. Refer to the engineering drawings in the Technical Drawing Package (TDP) for the rig-specific console wiring diagrams and other details. Figure 4-2. NOV Stateless Driller’s Control Console (Front Panel Opened)

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Operation

Stateless Driller’s Control Console Specifications Enclosure

ATEX, Zone 2

Weight

120 lb (54 kg)

Power Input Range (non I.S. terminals)

• 0-24 V DC, 0-9.5 A • 120 V AC, 1.1 A

Power Input Range (I.S. terminals)

28 V DC, 4-20 mA, 0.65 W

Operating Temperature Range

- 40°C to 45°C (-40°F to 113°F)

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4

Stateless Driller’s Control Console Alarms

Alarms

Figure 4-3. Alarms



Alarm Silence / Lamp Check 

When any alarm indicator light flashes and the horn sounds, press this button to silence the alarm. The indicator will remain lit until the fault is cleared. If the fault is not cleared in five minutes, the alarm horn sounds and the indicator flashes.



When the button is pressed and held for two seconds, the console indicators are tested. When the button is pressed and held for four seconds, the TORQUE and RPM meters go to full scale for a meter test.



Hyd Press Loss – Indicator flashes and horn sounds when hydraulic system pressure loss is detected.



Oil Press Loss – Indicator flashes and horn sounds when oil pressure loss is detected.



Drill Motor Overtemp – Indicator flashes and horn sounds when high temperature is detected for the drilling motor.



Cooling Water Flow – Indicator flashes and horn sounds when a loss of pressure in the cooling system flow is detected.



VFD Fault – Indicator flashes and horn sounds when a fault in the VFD is detected.



General – Indicator flashes when any of the alarms activate. For example, this indicator flashes and the horn sounds when IBOP Close pressure loss is detected.

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Operation

Stateless Driller’s Control Console Controls Top Drive TDS

TDS Mode

TDS Direction

Figure 4-4. Top Drive Controls



TDS – There is a green button and a three-position momentary switch in this console area. 

Enable – Pushing this illuminated button enables top drive operation from the Driller’s Control Console. When the green indicator is illuminated, the operator has control of the top drive from the console, the lubrication pump and cooling system are turned on, and the hydraulic supply is ready for top drive operation.



Torque Set – This three-position momentary switch allows the operator to set maximum drill and makeup torque setpoints. Turning the switch to DRILL and then turning the DRILL encoder knob sets the maximum drill torque for DRILL mode. Turning the switch to MAKEUP and then turning the MAKEUP encoder knob sets the maximum makeup torque for TORQE mode, in the FORWARD direction. This switch automatically returns to the center position (off) when released.

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4

Stateless Driller’s Control Console Controls Top Drive 



TDS Mode – There are three illuminated buttons in this console area. 

Drill mode – When pushed, the green indicator illuminates to show that the top drive is in DRILL mode. This mode is used for normal drilling operations. When in this mode, the driller uses the DRILL and TDS RPM incremental encoder knobs to set drilling operation limits.



Spin mode – When pushed, the green indicator illuminates to show that the top drive is in SPIN mode. This mode is used for shouldering up pipe while making up connections. When in this mode, the RPM and torque settings are fixed at standard SPIN mode rotational speed and torque values.



Torque mode – When pushed and held, the green indicator illuminates to show that the top drive is in TORQUE mode. This mode is used for making up and breaking out connections. When this mode is selected in the FORWARD direction, RPM is fixed and torque gradually ramps up to the makeup torque setpoint. When this mode is selected in the REVERSE direction, RPM is fixed and torque gradually ramps up to the maximum torque of the top drive, or until the connection is broken, whichever happens first.

TDS Direction – There are three buttons in this console area. 

Forward – When pushed, the rotational direction of the top drive is set to forward (clockwise), the lubrication pump starts, and rotation ramps up to the RPM setpoint. The green indicator illuminates when the top drive is assigned to rotate clockwise (forward).



Off – When pushed, the top drive is de-assigned and rotation will stop.



Reverse – When pushed, the rotational direction of the top drive is set to reverse (counterclockwise), the lubrication pump starts, and rotation ramps up to the RPM setpoint. The green indicator illuminates when the top drive is assigned to rotate counter-clockwise (reverse).

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SM00856 Revision D Page 4-8 of 30

Stateless Driller’s Control Console Controls IBOP and Brake

IBOP

Brake

Figure 4-5. IBOP and Brake Controls



IBOP – The IBOP area has a yellow indicator and a switch. The yellow indicator is illuminated when the IBOP is closed. Turning the switch will open or close the IBOP.



Brake – There are two controls in this console area: 

Auto – When pressed, the green indicator on this button illuminates to show that the motor brakes are in AUTO mode. In this mode, the brakes are automatically released when a speed command is sent to the VFD (in FWD or REV mode). The brakes are automatically set when the speed command is removed (OFF mode).



On / Off – The red indicator on this button lights whenever the motor brakes have been applied and are engaged (ON). This indicator lights any time the brake is set, regardless of whether or not the button has been pressed. When this button is pressed once, the brakes are set and the light comes on. When pressed again, the light goes out to show the brakes have been released.

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4

Stateless Driller’s Control Console Controls Pipe Handler

Pipe Handler

Figure 4-6. Pipe Handler Controls



Link Tilt Float – When pressed, the elevator links float to the center position. When the elevator links are in float position, the green indicator illuminates. When the elevator links are in float position, the pipe handler can be rotated.



Link Tilt Drill / Tilt – This is a three-position momentary switch. 

When switched to DRILL, the elevator links tilt to the Drilldown position. This position allows the top drive to continue operating close to the drill floor.



When switched to TILT, the elevator links extend the elevator to the Derrickman position. If the switch is released at Derrickman position, then reapplied, the links will tilt out to Mousehole position.



When the switch is in the center position, the elevator links are held in the current position.

Any time the switch is released, tilt motion stops immediately.

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Stateless Driller’s Control Console Controls Pipe Handler 

TW Clamp Push and Hold – When this button is pressed and held: 

the pipe handler rotates counter-clockwise into position



the pipe handler locking mechanism locks the pipe handler in place



the torque wrench clamp engages

Once engaged, the clamp is used to make up and break out connections. 

The clamp is used to make up connections when the top drive is in TORQUE mode and when the FORWARD direction is selected. The torque will gradually ramp up to the MAKEUP torque limit setpoint.



The clamp is used to break out connections when the top drive is in TORQUE mode and when the REVERSE direction is selected. The torque will gradually ramp up to 125% of the preset make-up torque limit. If break-out torque is insufficient to break out the connection, exit TORQUE mode and increase the MAKEUP torque limit setpoint.

The clamp disengages when the TW Clamp Push and Hold button is released.

The pipe handler clamp will not engage if the top drive motor brakes are applied.

The pipe handler clamp will not engage if the elevator links are not in float position

Refer to the section titled "Torque Wrench Auto Mode" on page 4-11 for information about the Torque Wrench Auto Mode button. 

PH Rotate CCW / CW – Turning this three-position momentary switch to the right rotates the pipe handler clockwise. Turning the switch to the left rotates the pipe handler counterclockwise. When released, the spring-centered switch returns to the off position (center) and the pipe handler stops.

The pipe handler will not rotate if the elevator links are tilted to any off-center position.

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4

Stateless Driller’s Control Console Controls Pipe Handler Torque Wrench Auto Mode When this button is pressed, the light turns green and the torque wrench will operate automatically. When the torque wrench is in Auto Mode, the operator can move directly from Drill mode to Torque mode and initiate automatic make-up or break-out operations, depending on the direction of rotation. Auto Mode Sequence: FORWARD Rotation 1. Operator switches from Drill mode to Torque mode. 2. Rotating Link Adapter jogs and the shot pin locks rotation. 3. The torque wrench clamp closes. 4. The top drive spins in the connection. The VFD provides feedback that the connection is shouldered. 5. The top drive ramps up torque to the make-up torque setpoint.

If the pipe slips or the operator releases the Torque mode button before the sequence reaches the make-up torque setpoint, the sequence is aborted, the top drive is turned off, and the brake is set.

6. The operator releases the Torque mode button. 7. Torque ramps down and the clamp releases. Auto Mode Sequence: REVERSE Rotation 1. Operator switches from Drill mode to Torque mode. 2. Rotating Link Adapter jogs and the shot pin locks rotation. 3. The torque wrench clamp closes. 4. The top drive gradually ramps up torque to the maximum torque of the top drive, or until the VFD provides feedback indicating the connection is broken. When the connection breaks, the torque drops back to the spin torque setpoint. 5. The top drive spins out the connection. 6. The operator releases the Torque mode button. 7. Rotation stops and the clamp releases.

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Operation

Stateless Driller’s Control Console Controls E-Stop, BX Elevator, Counterbalance, and Dolly E-Stop

Counterbalance

Dolly BX Elevator

Figure 4-7. E-Stop, BX Elevator, Counterbalance, and Dolly Controls



Emergency Stop – The Emergency Stop button is hard-wired to the Variable Frequency Drive (VFD). When pressed, the: 

VFD slows down the shaft speed and then shuts off



power to the top drive shuts off



hydraulic supply shuts off



motor brakes are applied

To reset the system, reset the VFD and physically pull this switch back to its original position.

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Stateless Driller’s Control Console Controls E-Stop, BX Elevator, Counterbalance, and Dolly 



BX – There are two controls in this console area: 

BX Elevator – This is a three-position switch. (The center position is neutral.) Open opens the elevator and releases the pipe. Armed arms the elevator. This readies the hydraulic cylinders in the elevator. In Armed mode, the elevator will automatically close and hold a pipe that enters the elevator. The yellow indicator illuminates when the elevator has closed on a pipe.



BX Rotate – This is a three-position switch. (The center position is neutral.) Down tilts the elevator down. Up tilts the elevator up. This allows the elevator to be better positioned for pipe handling from multiple locations.

Counterbalance – The counterbalance area has a green button indicator. When pressed once, the light illuminates to indicate the counterbalance system is in Stand Jump mode, retracting the counterbalance cylinders. When pressed again, the light goes out to indicate that the counterbalance system has returned to DRILL mode. Stand Jump mode is typically used immediately before breaking out a connection. When the button is pressed, the top drive is lifted slightly off the connection by elevated pressure to the cylinders. Normally, the counterbalance pressure is set to about 1100 psi. During Stand Jump, 300 psi is added.



Dolly – The dolly area has a three-position momentary switch. The switch is used to extend the dolly or retract the dolly to the guide beam.

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Operation

Stateless Driller’s Control Console Meters and Limit Adjustment Knobs Torque Meter RPM Meter

Limit Knobs

Figure 4-8. Meters and Limit Adjustment Knobs



TORQUE meter – Shows the drill pipe torque in ft-lb (x 1000) increments from 0 to 80,000 ft-lb. In DRILL mode, the torque limit is set by the DRILL torque encoder knob below the meter. In TORQUE mode and in the FORWARD direction, the torque limit is set by the MAKEUP torque encoder knob below the meter.



RPM meter – Shows the rotational speed of the top drive from 0 to 250 RPM. Rotational speed is controlled using the TDS RPM knob below the meter.



Drill knob – Sets the maximum allowable drill pipe torque when in DRILL mode. The drilling torque limit is adjusted by turning the knob and observing the ft-lb of torque displayed in the TORQUE meter.



Makeup knob – Sets the maximum allowable makeup torque in TORQUE mode, in the FORWARD direction. The makeup torque limit is adjusted by turning the knob and observing the ft-lb of torque displayed in the TORQUE meter.



TDS RPM knob – This is the top drive throttle. It controls the speed of the drilling motor when in DRILL mode. The drilling speed is adjusted by turning the knob and observing the RPM displayed in the RPM meter.

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Amphion™ Touchscreen Controls The equipment and rig configuration may include one or more Amphion™ Control System Touchscreen units in place of, or in addition to, the NOV Driller’s Control Console. This control system interface allows the driller to control top drive operations using a touchscreen display.

Refer to the Amphion Operator’s Guide included with the complete NOV rig equipment documentation package for detailed Amphion control system information.

Figure 4-9 shows an example of an Amphion touchscreen display. This is a typical display and may not represent your configuration.

Figure 4-9. Default Top Drive Amphion Touchscreen

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Operation

Basic Usage Drilling Ahead with Singles Step 1 Set slips on string

Step 2

Step 3

Step 4

Tilt links to mousehole

Pickup single with elevator

Latch drill pipe elevator around single

Release link tilt

Stop circulation Close IBOP Breakout connection using pipehandler and drilling motor (in reverse)

Stab bottom of single onto string

Step 5

Lower block to stab motor into top of single

Pull slips

Spin in motor and single

Start circulation

Open IBOP

Begin drilling Makeup both connections with motor in torque mode

Makeup

Open IBOP Link Tilt Close IBOP Stab

Makeup

Figure 4-10. Drilling Ahead With Singles

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Basic Usage Drilling Ahead with Triples Step 1

Step 2

Step 3

Set slips on string

Raise block

Stop circulation

Tilt link tilt to derrickman

Breakout connection using pipehandler and drilling motor (in reverse)

Pickup stand with elevator Stab bottom of stand onto string

Step 4

Step 5

Lower block to stab motor into top of stand

Pull slips

Spin in motor and stand

Begin drilling

Start circulation

Makeup both connections with motor

Makeup

Link Tilt

Start Circulation

Stop Circulation Stab

Makeup

Figure 4-11. Drilling Ahead With Triples

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Operation

Basic Usage Back Reaming Step 1 Hoist while circulating and rotating When 3rd connection surfaces, stop rotation and circulation

Step 2 Set slips on string

Step 3 Hoist free stand with elevator

Step 4

Step 5

Setback stand using link tilt

Lower block, stab motor into string

Break out connection using pipehandler and drilling motor (reverse)

Spin in motor and make up connection with motor

Break out and spin out stand at floor

Start circulation, pull slips, hoist and rotate

Breakout

Hoist

Setback

Hoist and Rotate Breakout

Figure 4-12. Back Reaming

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4

Making and Breaking Tool Joint Connections

Tool joint locks become a pinching hazard once they are loosened. Make sure to support them as they are loosened. The tool joint locks can fall and injure rig personnel.

Breaking out the Saver Sub During normal operation, the torque backup clamp cylinder is sitting on the springs, which are supported by the spring plate of the torque arrestor. Refer to Figure 4-13 for the following steps. 1. Loosen the tool joint lock between the saver sub and the lower IBOP valve by unscrewing all the bolts. Refer to the tool joint lock assembly and disassembly procedures in the Maintenance chapter. Slide the tool joint lock down until it rests on the clamp cylinder body. 2. Raise the clamp cylinder until the clamp cylinder positioning slot lines up with the first hole on the torque arrestor. Insert the safety pin through the clamp cylinder and torque arrestor. 3. Select TORQUE mode. Pressurize the clamp cylinder to clamp on the saver sub by pressing and holding the TW CLAMP PUSH AND HOLD button. 4. Switch the drilling motor to REVERSE to break out the connection. 5. Once the connection is broken out, switch to SPIN and allow the motor to spin until the saver sub and lower IBOP valve separate. Remove the safety pin. Lower the clamp cylinder with the saver sub. The saver sub is ready for removal. 6. Unclamp the saver sub by releasing the TW CLAMP PUSH AND HOLD button.

Stand clear. The saver sub must be supported before unclamping it. It will fall through the bottom of the stabbing guide if not supported.

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SM00856 Revision D Page 4-20 of 30

Operation

Making and Breaking Tool Joint Connections Breaking Out the Saver Sub

CB1

CB2

V1

CB1

CB2

V2

V1

V2

Upper IBOP Valve

Clamp Body Positioning Holes

Lower IBOP Valve

1 Tool Joint Lock Loosen Screws

Torque Arrestor

Clamp Cylinder Safety Pin

2 Tool Joint Lock Rest on Clamp Cylinder Positioning Slot

Saver Sub

3

Clamp Cylinder

4

Select TORQUE mode.

5

TW CLAMP PUSH AND HOLD.

6

Drilling Motor REVERSE.

7

Drilling Motor SPIN.

Raise to Next Hole In Torque Arrestor

8

Support Saver Sub and release from Torque Back-up Clamp Cylinder.

Figure 4-13. Breaking Out the Saver Sub

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Making and Breaking Tool Joint Connections Making up the Saver Sub 1. Manually screw in the replacement saver sub into the lower IBOP valve. To manually screw in the replacement saver sub into the lower IBOP valve: a. Raise the clamp cylinder until the lower IBOP valve is exposed below the stabbing guide (a pup joint may be used). b.

Lower the clamp cylinder until the hole and the correct clamp position lines up.

c.

Insert the clamp positioning safety pin.

2. Select TORQUE mode. Pressurize the clamp cylinder to clamp on the saver sub by pressing and holding the TW CLAMP PUSH AND HOLD button. 3. Switch the drilling motor to FORWARD. Select SPIN mode and rotate the drilling motor until the saver sub shoulders against the lower IBOP valve. Select TORQUE mode and apply the correct torque. 4. Release the TW CLAMP PUSH AND HOLD button to unclamp. Lower the clamp cylinder all the way to its lowest position. 5. Position the tool joint lock correctly and follow the proper assembly procedure described in the Tool Joint Locks section.

Breaking out the Lower IBOP Remove the saver sub first, as described in the previous section. Refer to Figure 4-14 for the following steps. 1. Loosen the tool joint lock between the lower IBOP valve and the upper IBOP valve by unscrewing the bolts. Slide the tool joint lock down until it rests on the tool joint lock sitting on the clamp cylinder body. 2. Raise the clamp cylinder (along with the two tool joint locks) until the clamp cylinder positioning slot lines up with the second hole on the torque arrestor. Insert the pin. 3. Select TORQUE mode. Pressurize the clamp cylinder to clamp on the lower IBOP by pressing and holding the TW CLAMP PUSH AND HOLD button. 4. Switch the drilling motor to REVERSE to break out the connection. 5. Once the connection is broken out, switch to SPIN and allow the motor to spin until the lower IBOP valve and upper IBOP valve separate. 6. Remove the safety pin. Lower the clamp cylinder with the lower IBOP. The lower IBOP is ready for removal. 7. Unclamp the IBOP valve by releasing the TW CLAMP PUSH AND HOLD button.

Stand clear. The lower IBOP valve and saver sub must be supported before unclamping them. They will fall through the bottom of the stabbing guide if not supported.

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SM00856 Revision D Page 4-22 of 30

Operation

Making and Breaking Tool Joint Connections Breaking out the Lower IBOP

CB1

CB2

V1

CB1

CB2

V2

V1

V2

Torque Arrestor

Upper IBOP Valve

Lower IBOP Valve

7

Clamp Cylinder Safety Pin

Loosen Screws

8

1

Rest on Clamp Cylinder

Tool Joint Lock Loosen Screws

9 Raise Clamp Cylinder to Next Hole

2 Tool Joint Lock Rest on Clamp Cylinder

Clamp Cylinder

3 Raise to Next Hole In Torque Arrestor

4

Select TORQUE mode.

10

Select TORQUE mode.

5

TW CLAMP PUSH AND HOLD.

11

TW CLAMP PUSH AND HOLD.

6

Drilling Motor REVERSE.

12

Drilling Motor REVERSE.

13

Drilling Motor SPIN.

14

Support IBOP Valve and Release From Torque Back-up Clamp Cylinder

Figure 4-14. Breaking out the Lower IBOP

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4

Making and Breaking Tool Joint Connections Making up the Lower IBOP 1. Screw in the replacement saver sub and the lower IBOP valve together manually and stand them under the clamp cylinder (a pup joint may be used to support it). Position the clamp cylinder by stabbing over the lower IBOP valve. Make sure the lower IBOP valve comes up through both tool joint locks sitting on the clamp cylinder body. 2. Tighten four alternate screws on the top tool joint lock to secure it to the lower IBOP valve to provide a temporary shoulder to support the weight of the lower IBOP valve and the saver sub.

Make sure all four screws are tightened sufficiently so that the tool joint will not slide through when the clamp cylinder is raised.

3. Select SPIN and FORWARD modes. 4. Raise the clamp cylinder with the lower IBOP valve and saver sub while rotating the upper IBOP to engage the threads. Once the upper IBOP valve and the lower IBOP valve start to spin together, stop the drilling motor. 5. Lower the clamp cylinder and line up the first slot and hole on the clamp cylinder and the torque arrestor. The clamp cylinder jaws line up with the saver sub. 6. Select TORQUE mode. Pressurize the torque backup clamp cylinder to clamp on the saver sub by pressing and holding the TW CLAMP PUSH AND HOLD button. 7. Switch the drilling motor to FORWARD. Select SPIN mode and rotate the drilling motor. Select TORQUE mode, apply desired torque and make up both connections. 8. Release the TW CLAMP PUSH AND HOLD button to unclamp. Lower the clamp cylinder all the way down. 9. Loosen the temporarily made-up tool joint lock. Position both tool joint locks correctly and assemble. (See the Tool Joint Locks section.)

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Making and Breaking Tool Joint Connections Breaking out the Upper IBOP Refer to Figure 4-15 for the following steps. 1. Remove the saver sub and the lower IBOP first, as described previously.

The saver sub and lower IBOP can be removed as one unit by breaking out the connection between the upper and lower IBOPs.

2. Lower the clamp cylinder with the broken out lower IBOP valve and the saver sub. 3. Unclamp the lower IBOP valve/saver sub assembly by releasing the TW CLAMP PUSH AND HOLD button. 4. Remove the two tool joint locks sitting on the clamp cylinder.

Stand clear. The lower IBOP valve and saver sub must be supported before unclamping them. They will fall through the bottom of the stabbing guide if not supported.

5. Remove the IBOP actuator yoke by unpinning it. 6. Remove the two upper IBOP cranks by unscrewing the two sets of screws. 7. Loosen the top tool joint lock and let it sit on the actuator shell. 8. Raise the clamp cylinder with the actuator shell and the tool joint lock until the third slot and hole line up. Insert the safety pin. 9. Select TORQUE mode. Pressurize the clamp cylinder to clamp on the upper IBOP valve by pressing and holding the TW CLAMP PUSH AND HOLD button. 10. Switch the drilling motor to REVERSE to break the connection. 11. Once the connection is broken out, switch to SPIN and allow the motor to spin until the upper IBOP valve and drive stem separate. 12. Remove the safety pin. Lower the clamp cylinder with the upper IBOP. The upper IBOP is ready for removal from the clamp cylinder. 13. Unclamp the upper IBOP valve by releasing the TW CLAMP PUSH AND HOLD button. 14. Remove the tool joint lock and actuator shell.

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Operation

Making and Breaking Tool Joint Connections Breaking out the Upper IBOP

CB1

CB2

V1

CB1

CB2

V2

V1

V2

10

9

Upper IBOP Valve

Tool Joint Lock Loosen Screws

Clamp Cylinder Safety Pin

Remove Actuator Yoke

1 Tool Joint Lock Loosen Screws

2 Tool Joint Lock Rest on Clamp Cylinder

11 Clamp Cylinder

Raise to Next Hole In Torque Arrestor

8

3 Raise to Next Hole In Torque Arrestor

Support Saver Sub/ Lower IBOP Valve and release from Clamp Cylinder. Remove Lower Tool Joint Locks.

4

Select TORQUE mode.

11

Select TORQUE mode.

5

TW CLAMP PUSH AND HOLD.

12

TW CLAMP PUSH AND HOLD.

6

Drilling Motor REVERSE.

13

Drilling Motor REVERSE.

7

Drilling Motor SPIN.

14

Drilling Motor SPIN.

Figure 4-15. Breaking out the Upper IBOP

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Operation

SM00856 Revision D Page 4-26 of 30

Making and Breaking Tool Joint Connections Making up the Upper IBOP 1. Place the upper IBOP valve on the floor under the clamp cylinder so that the clamp cylinder can be stabbed over it (a pup joint may be used to support it). Lower the clamp cylinder so that the upper IBOP comes up through the clamp cylinder. 2. Place the actuator shell and tool joint lock over the upper IBOP and tighten four alternate locking screws to secure it to the upper IBOP, providing a temporary shoulder to support its weight. 3. Install the actuator shell and cranks. (Refer to the engineering drawing the Technical Drawing Package for details about actuator and crank installation.) 4. Raise the clamp cylinder with the upper IBOP valve while rotating the drive stem clockwise to engage the threads. Once the drive stem and upper IBOP valve start to spin together, stop the motor, switch to FORWARD and SPIN and press and hold the TW CLAMP PUSH AND HOLD button to spin in. 5. Spin the lower IBOP and saver sub into position (refer to the appropriate procedures in the previous sections). Make sure that the two tool joint locks are properly installed on the clamp cylinder and in the correct sequence. 6. Release the TW CLAMP PUSH AND HOLD button to unclamp. Lower the clamp cylinder until it lines up with the first hole, which is lined up with the saver sub. 7. Select TORQUE mode. Pressurize the clamp cylinder to clamp on the saver sub by pressing and holding the TW CLAMP PUSH AND HOLD button and apply desired torque to makeup all three connections. 8. Place the three tool joint locks at their respective joints. Install the three tool joint locks. (See the section titled Tool Joint Locks.) 9. Install the IBOP actuator yoke and secure it.

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SM00856 Revision D Page 4-28 of 30

Well Control The TDS-11SA can stab into the string at any point in the derrick. While drilling, the remotely controlled upper IBOP valve is available for immediate use as needed. On indication of a kick, use the following well control procedure in conjunction with standard well control procedures. Refer to section titled "Making and Breaking Tool Joint Connections" on page 4-19 for information about breaking out and making up connections.

Procedure 1. On indication of a kick, set the slips and stab the top drive into the drill string connection. 2. Make up the connection. 3. Remotely close the upper IBOP. 4. Lower the string to the drill floor and reset the slips. 5. Manually close the lower IBOP. 6. Loosen the intermediate and bottom tool joint locks. Let them both slide down until they rest on top of the clamp cylinder body. 7. Raise the clamp cylinder and clamp onto the lower IBOP. 8. Break out the lower IBOP. 9. Remove the two joint locks loosened earlier. 10. Lower the clamp cylinder to Drill position and hoist the top drive clear of the connection. 11. Install the crossover sub and a well control check valve (provided by others) onto the lower IBOP. Make up both connections using the floor tongs or iron roughneck. 12. Slide the intermediate joint lock over the crossover sub and check valve and let it rest on top of the clamp cylinder body. 13. Place the spacer sub onto the check valve, lower the top drive and stab into the spacer sub. 14. Energize the clamp cylinder and make up the spacer sub to upper IBOP connection. 15. Lift the intermediate joint clamp and secure the connection between the upper IBOP and spacer sub. 16. Spin out the spacer sub to check valve connection while hoisting the top drive. 17. Proceed with standard well control procedures.

Figure 4-16 shows the component configuration for normal drilling operations and for well control.

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4

Operation

Well Control Component Configuration Normal Drilling

Well Control main shaft

 upper joint lock

main shaft  upper joint lock

NC50 connection

NC50 connection upper ibop

 intermediate joint lock

NC50 connection upper ibop

 intermediate joint lock

spacer sub drill pipe connection

NC50 connection lower ibop

 bottom joint lock

drill pipe NC50 connection saver sub drill pipe connection drill pipe drill pipe

drill pipe connection check valve (supplied by others) drill pipe connection crossover sub NC50 connection

The intermediate and bottom joint locks are removed when changing over to well control operations. The upper lock is not removed.

lower ibop NC50 connection saver sub drill pipe connection

The bottom joint lock is not used during well control operations. Reinstall this lock when the stack is reconfigured for normal drilling operations.

drill pipe

TDS11156

Figure 4-16. Well Control Component Configuration

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Operation

SM00856 Revision D Page 4-30 of 30

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SM00856 Revision D

Maintenance

5

Introduction The following sections describe periodic inspections and routine maintenance required to keep the TDS-11SA Top Drive functioning properly.

In general, inspect all hoses and connections weekly. Inspect pins, bushings, and bearings monthly.

Pre-Maintenance Checklist Documentation You Will Need 

Electrical Interconnects and Hydraulic Schematics



TDS-11SA Technical Drawing Package



TDS-11SA User Manual



Recommended Lubricants and Hydraulic Fluids (D811000719)



Links Service Manual (D6350000870)



Design Specification, Design Torque Standard (DS00008)



Safety Wiring Procedure (ASP00019)

Regulatory Standards You Will Use 

ASTM A 275, Standard Practice for Magnetic Particle Examination of Steel Forgings



ASTM E 709, Standard Guide for Magnetic Particle Testing



ASTM A 388, Standard Practice for Ultrasonic Examination of Heavy Steel Forgings



API RP 8B, Recommended Practice for Procedures for Inspections, Maintenance, Repair, and Remanufacture of Hoisting Equipment



API SPEC 8C, Specification for Drilling and Production Hoisting Equipment (PSL 1 and PSL 2)

Spare Parts You May Need Refer to the documents that list spare parts in your User Manual and contact your NOV representative or an NOV Service Center.

Spare Parts and Fluids Disposal The equipment owner is responsible for conforming to applicable regulatory policies, standards, and recycling guidelines when removing the equipment, dismantling equipment components, disposing of fluids, and disposing of consumable spare parts during and after maintenance.

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Maintenance

SM00856 Revision D Page 5-2 of 98

Safety Precautions Warnings Avoid equipment damage or injury to personnel by paying close attention to the important safety notes highlighted as Notes, Cautions, and Warnings used throughout this manual. To avoid serious injury or death, read and understand the following warning advisories before performing maintenance or troubleshooting procedures.

Complete all appropriate job safety analysis (JSA), permits, and crew safety briefings immediately prior to each maintenance activity or session. If, at any point during the maintenance session, the planned activities change for any reason, review the job safety requirements again to ensure the crew involved is aware of the changes in activities. Ensure all appropriate personal safety equipment is in good condition and used when necessary.

Unless specifically noted in this manual, properly lock out the main power source before performing lubrication, inspection, or replacement procedures. Wear protective glasses to prevent eye injuries from fluids under pressure, as well as other hazards. Do not attempt any adjustments while the machine is moving. Read and understand all safety precautions and warnings before performing maintenance procedures. Do not attempt repairs you do not understand. Use caution when draining lubricant. It can be hot. Never check for hydraulic leaks with your hands. Oil under pressure escaping from a hole can be nearly invisible and can penetrate skin causing serious injury. Always check for leaks with a piece of wood or cardboard and always wear protective eyewear when working on hydraulic components. Always discharge all accumulators before servicing the hydraulic system.

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Maintenance

5

Safety Precautions

Top drive maintenance requires personnel working at height and there exists the potential for injury or dropped objects.

Equipment Records Keep a record book of all maintenance procedures performed. Date each procedure, followed by a description and the technician who performed it. This data is valuable for fault finding and problem solving, should technical problems arise.

Procedures in this chapter relate to NOV-only components. See the appropriate vendor-supplied OEM manuals for inspection schedules and maintenance procedures for non-NOV equipment and components.

Torque Values Refer to the Design Torque Standard (DS00008) in the equipment User Manual for the torque standards to follow when tightening component fasteners.

Install bolts with anti-seize compound and tighten based on the Design Torque Standard (DS00008). This document is included in the equipment User Manual.

Safety Wire (Lockwire) Procedures Refer to the Safety Wiring Procedure (ASP00019) in the equipment User Manual for the procedures required for installing safety wire (lockwire) on component fasteners.

Secondary Retention Guidelines Refer to Design Guideline, Secondary Retention and Prevention of Dropped Objects (D411000342-SPC-001) in the equipment User Manual for information related to secondary retention of equipment components. Adhering to the recommendations and guidelines in this specification will greatly reduce any risk of components falling from installed equipment.

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Maintenance

Equipment Inspection

The following service intervals are based on average operating conditions. More frequent service intervals are required if you operate the equipment in conditions where excessive load, dusty or corrosive operating atmosphere, or extreme temperatures occur.

Inspecting Rig Interface Components Inspection Schedule Daily Inspection

Page Number



Check guide beam lynch pins and retainer pins

page 5-6



Make sure the top drive is aligned over well center

page 5-7



Check all detent pins in the carriage

page 5-9

Weekly Inspection

Page Number



Check crown padeye and hang-off link welds and fasteners

page 5-5



Check guide beam joint pin bushing

page 5-6



Check main and intermediate tieback welds and fasteners

page 5-7, page 5-8



Check all carriage rollers

page 5-9

Monthly Inspection

Page Number



Check crown padeye, cotter pin, shackle, and hang-off bores

page 5-5



Check guide beam joint pin

page 5-6

Yearly Inspection

Page Number



Check crown padeye

page 5-5



Check guide beam joints

page 5-6



Check main tieback link

page 5-7



Check all carriage bogeys

page 5-9

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5

Maintenance

Equipment Inspection Inspecting the Guide Beam and Carriage Crown Padeye and Hang-Off Link Crown Cotter Pin Replace if missing

2.1" (52 mm) minimum

Yearly

Monthly

Crown Padeye

Monthly Crown Padeye Visually inspect weld for cracks

Shackle 2.0" (50 mm) minimum Monthly Shackle Inspect and replace if worn Monthly Hang-off Link Bores Inspect and repair if worn

1.5" (37 mm) minimum

Hang-off Link Bores

Weekly Typical all welds and connections Inspect clamped connections for tightness and double nuts. Inspect welds for cracks.

Figure 5-1. Inspecting the Crown Padeye and Hang-Off Link

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Maintenance

Equipment Inspection Inspecting the Guide Beam and Carriage Guide Beam Joints

! Verify that the joint pins, retainer pins and lynch pins are in place and secure. Inspect joint pins and bushings for wear. Replace any worn or damaged components.

Component Replace when

Secure

Bushings

Inside diameter is more than 2.050 in (52.07 mm).

Joint Pins

Outside diameter is less than 1.963 in (49.86 mm).

Daily Lynch Pin

Weekly Bushing Inspect for wear replace as needed

Yearly Typical Guide Beam Joint

Monthly Joint Pin Inspect for wear replace as needed

Daily Retainer Pin Monthly Inspect welds for cracks

Figure 5-2. Inspecting the Guide Beam Joints

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Maintenance

5

Equipment Inspection Inspecting the Guide Beam and Carriage Main Tieback Guide Beam Bottom Section

Daily Check that the tool is aligned directly over well center

Main Spreader Beam

Tieback Plate

Yearly Tieback Link Inspect retainer pins, tieback hooks, and pivot pins for wear.

Weekly Typical all welds and connections Inspect clamped connections for tightness and double nuts. Inspect welds for cracks. Auxiliary Spreader Beam

Mast Leg

Figure 5-3. Inspecting the Main Tieback

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Maintenance

Equipment Inspection Inspecting the Guide Beam and Carriage Intermediate Tieback

Intermediate Tieback (Shown in Locked Position)

Locking Bolt Pivot Point

Weekly Typical all welds and connections Inspect clamped connections for tightness and double nuts. Inspect welds for cracks.

Figure 5-4. Inspecting the Intermediate Tieback

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5

Maintenance

Equipment Inspection Inspecting the Guide Beam and Carriage Carriage

Weekly Typical all rollers Inspect for uneven wear, damage and looseness, replace as required

Yearly Bogey (16) Disassemble, inspect for wear, and relubricate

Daily Typical all detent pins Verify that pins are in place and secure

Figure 5-5. Inspecting the Carriage

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Maintenance

Equipment Inspection Inspecting the Motor Housing and Transmission Illustrated Index

Bail Page 5-19

S-Pipe Page 5-20 AC Motor Brakes (2) Page 5-28

AC Drilling Motors (2) Page 5-29

Washpipe Assembly Page 5-22

Gearbox Lubrication Pump Assembly Page 5-16

Gearbox Assembly Page 5-13

Gear Oil Filter Page 5-66

For AC motor and transmission lubrication see Page 5-66, 5-67 Figure 5-6. Motor Housing and Transmission Illustrated Index

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Maintenance

5

Equipment Inspection Inspecting the Motor Housing and Transmission Inspection Schedule Daily Inspection

Page Number



Check for missing lockwire and cotter pins



Check for loose or broken parts and leaks



Check for damaged hoses and fittings



Check the wash pipe assembly for leaks

page 5-22



Check fluid levels and filter condition

page 5-65

Weekly Inspection

Page Number



Check the AC motor louvers for damage

page 5-29



Check the AC motor screens for contamination

page 5-29

Monthly Inspection 

Check the flow of oil throughout the main body while the lube pump is running



Check the blower motor assemblies for loose bolts



Check brake pads for wear

6 Month Inspection

Page Number page 5-13

page 5-28

Page Number



Check the gear teeth for pitting and corrosive wear

page 5-18



Check for primary and secondary gear set backlash

page 5-18



Check the S-pipe for pitting, corrosion, or erosion

page 5-20



Check the upper main shaft liner for erosion caused by leaking wash pip packing

page 5-21

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Maintenance

Equipment Inspection Inspecting the Motor Housing and Transmission Inspection Schedule Yearly Inspection

Page Number



Check the gearbox lubrication pump assembly for wear or damage

page 5-17



Check bail, bushings and bail pins for wear

page 5-19



Check the upper bearing retainer o-ring, bearing isolator, and oil seal for wear

page 5-25



Check the radial grooves on the main shaft and the load collar for wear

page 5-26



Perform a Magnetic Particle Inspection (MPI) on the main shaft, landing collar, and split load collar

page 5-26



Check the main shaft for axial movement

page 5-27



Meggar motors

5 Year Inspection 

Perform a Magnetic Particle Inspection (MPI)

Page Number page 5-56

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5

Maintenance

Equipment Inspection Inspecting the Motor Housing and Transmission Internal Lubrication Flow Procedure  Remove the 3 in pipe plugs from the main body and check the flow of oil coming from the four spray nozzles (two in the body, two in cover) while the lube pump is operating  Check that oil is running out of the upper gear drain holes in each compound gear set (indicates upper orifice is not blocked) and that oil is running through the spillway running from the thrust bearing (indicates orifice is not blocked)

Pipe Plug

Pipe Plugs Monthly Upper Compound Gear Drain Hole Check flow

Monthly Body Spray Nozzles Cover spray nozzles not shown

Monthly Spillway Check flow

Pipe Plug Remove using a 2 inch, 12 point socket Main Body

Figure 5-7. Inspecting Internal Lubrication Flow

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SM00856 Revision D Page 5-14 of 98

Maintenance

Equipment Inspection Inspecting the Motor Housing and Transmission Belt-Driven Encoder Adjustment

Certain top drive models are equipped with non belt-driven encoders. Refer to the detailed engineering drawings in the Technical Drawing Package for information about non beltdriven encoders.

Use the following procedure to adjust the encoder belt tension: 1. Remove the access covers. 2. Disconnect all of the electrical connectors from the encoder. 3. Remove the lockwire and loosen the four sled hold-down screws. 4. Allow the sled to move freely, allowing the belt tension spring to apply the proper tension to the belt.

! Do not tighten the belt by hand.

5. Carefully tighten the sled hold-down screws and torque them to 7 ft-lb. 6. Lockwire the sled hold-down screws. 7. Reconnect the encoder electrical connections. 8. Replace both access covers and tighten the access cover screws to 15 ft-lb and lockwire them.

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5

Maintenance

Equipment Inspection Inspecting the Motor Housing and Transmission Belt-Driven Encoder Adjustment

Belt Tension Spring

Sled Hold-down Screws 4 Places

View from Side

Encoder Belt

Sled

View from Top (Blower Motor removed for clarity)

Sled

Electrical Connector

Encoder Belt

Encoder

Belt Tension Spring

Sled Hold-down Screws (Allow the sled to move freely before tightening) 4 Places

Figure 5-8. Adjusting the Belt-Driven Encoder

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SM00856 Revision D Page 5-16 of 98

Maintenance

Equipment Inspection Inspecting the Motor Housing and Transmission Gearbox Lube Pump Assembly Disassemble the gearbox lubrication pump assembly and inspect the pump assembly components yearly for wear and damage as follows: 1. Drain the gearbox oil and disconnect the hydraulic lines from the pump assembly. 2. Remove the pump assembly by removing the eight lockwired capscrews that attach the pump adapter plate to the main body. 3. Disassemble the spline adapter, pump, and housing using the pump vendor service instruction HS15 (located in the User Manual). 4. Inspect the pump assembly components, replacing any parts that are worn or damaged. Pay particular attention to the spline between the pump and motor, the gears, and the motor and pump side plates. 5. Assemble the lubrication pump assembly in the reverse order of disassembly.

! Follow the pump vendor service instruction HS15 (located in the User Manual) when assembling the lubrication pump components, and torque all fasteners in accordance with DS00008.

! When reinstalling the pump assembly into the main body, inspect the O-ring for damage. Replace the O-ring if any flat spots, nicks, or other damage is found.

6. Install the pump assembly into the main body. Torque the fasteners in accordance with DS00008, and reconnect the hydraulic and electrical connections.

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Maintenance

5

Equipment Inspection Inspecting the Motor Housing and Transmission Gearbox Lube Pump Assembly End Cover Thrust Plate 2 Places

Yearly Gearbox Lubrication Pump Assembly Check parts for wear or damage

Ring Seal

Body Seal 2 Places Gear Housing

Roller Bearing 4 Places

Gear Set

Pump Adapter Plate Capscrew 10 Places

Hydraulic Motor Low-Speed/High-Torque O-ring

Main Body

Procedure  Drain the gearbox oil and disconnect the hydraulic lines from the pump assembly  Remove the pump assembly by removing the ten lockwired capscrews that attach the pump adapter plate to the main body  Disassemble using the drawings in the Technical Drawing Package as well as the pump vender service instruction  Inspect and relace any parts that are worn or damaged Figure 5-9. Inspecting the Gearbox Lube Pump Assembly

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Maintenance

Equipment Inspection Inspecting the Motor Housing and Transmission Gear Backlash

A

6 Months Gear Teeth Check for wear, pitting, and gear set backlash

B

A

Solid Wire Solder

B

Dim. A + Dim. B = Backlash

Procedure Inspect the pump adapter plate at the same time the gear backlash is checked  Drain the gearbox oil  Remove the access cover and the pump adapter plate to check primary and secondary gear set backlash  Run a piece of solid wire solder through the primary and secondary gear meshes and measure the thickness of the two flat spots made by the gear teeth surfaces with a micrometer  If the primary gear mesh backlash exceeds .030 in. or the secondary gear mesh backlash exceeds .040 in., excessive gear wear or bearing failure may be indicated

Check the gear teeth for pitting or corrosive wear at the same time the gear set backlash is checked Record backlash data for future reference Figure 5-10. Inspecting Gear Backlash

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Maintenance

5

Equipment Inspection Inspecting the Motor Housing and Transmission Bail and Main Body

Component

Replace when

Bushing

Inner diameter is more than 4.450 in.

Bail Pin

Outer diameter is less than 4.125 in.

Bail Yearly

Bushing 2 Places Yearly

Main Body Cover 5 Years

Main Body 5 Years

Bail Pin 2 Places Yearly

Figure 5-11. Inspecting the Bail and Main Body

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SM00856 Revision D Page 5-20 of 98

Maintenance

Equipment Inspection Inspecting the Motor Housing and Transmission S-Pipe Procedure Wing Nut

 Unscrew the two nuts that hold the S-pipe in place along with the six bolts that secure the clamp to remove and inspect the S-pipe  Clean the bore of the S-pipe and inspect for visible signs of pitting, corrosion, or erosion

Seal Ring Plug

Use a flashlight and mirror to visually inspect the bore of the S-pipe. A Bore-o-Scope is best for inspection, if available.

6 Months Pressure test to rated working pressure

 Remove and perform an ultrasonic inspection on the S-pipe if visual inspection indicates erosion or corrosion  Check condition of the seals  Apply pipe dope to the threads before re-installing

6 Months S-Pipe Check for visible signs of pitting, corrosion, or erosion (pitting or corrosion should be no deeper than 0.125 inch)

Clamp

Bolts

Seal Ring Right-hand (inside of guard) configuration shown. Your S-pipe configuration may vary.

Wing Nut

Figure 5-12. Inspecting the S-Pipe

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5

Maintenance

Equipment Inspection Inspecting the Motor Housing and Transmission Upper Main Shaft Liner Procedure  Remove the wash pipe assembly  Check the upper mainshaft liner for erosion caused by leaking wash pipe packing and replace the liner if erosion is found. The upper surface of the mainshaft liner must be flat and smooth The Polypack Seal must also be replaced whenever the upper stem liner is replaced  Grease the Polypack Seal and clean the mainshaft bore before re-installing  Make sure the O-ring of the seal is facing down when the seal is installed on the liner

Wash Pipe Assembly

6 Months Upper Mainshaft Liner Replace ONLY if erosion is found during inspection

Polypack Seal

Polypack Seal Replace the Polypack Seal when the upper mainshaft liner is replaced Main Shaft Remove any corrosion found on bore of mainshaft

Upper Mainshaft Liner

Figure 5-13. Inspecting the Upper Main Shaft Liner

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Maintenance

SM00856 Revision D Page 5-22 of 98

Equipment Inspection Inspecting the Motor Housing and Transmission Standard Washpipe

If the optional NOV mechanical washpipe is installed in the unit, refer to the NOV Mechanical Washpipe Service Manual (D811000200-PRO-001) for detailed maintenance information. This manual is provided in the equipment User Manual.

Assembly and Disassembly 1. With the packing box upside down, assemble the packing seals and spacers into the packing box using care to line up the upper spacer slot with the dowel pin. 2. Hand pack all seals with multipurpose lithium-based or high temperature molybased grease using care not to grease the outside diameter of the spacers. 3. Install the socket head dog nose screw, ensuring that the screw nose is fully engaged in the groove of the lower spacer. 4. Install the grease fitting and turn the packing box upright. 5. Install the wash pipe into the packing box assembly (slotted end up). 6. Install the wash pipe nut onto the wash pipe. 7. Grease the packing seal and install into the holding ring using care not to grease the outside diameter of the holding ring. 8. Install the packing seal and holding ring over the slotted end of the wash pipe. 9. Install the snap ring. 10. Install the upper and lower o-rings using grease to hold them in place. 11. Compress the assembly to the length of the wash pipe. Disassemble the washpipe packing in the reverse order of the above procedure. Refer to the Standard Washpipe Manual, SM01053, for additional information. Figure 5-14 shows disassembly and Figure 5-15 shows components that need to be inspected after disassembly.

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5

Maintenance

Equipment Inspection Inspecting the Motor Housing and Transmission Standard Washpipe

! The wash pipe nut and the packing box have left-handed threads

Slide the wash pipe nut and the packing box together for installation

Dowel Pin

Hand pack all seals with multipurpose lithium-based or high temperature moly-based grease completely filling the void

Ensure that the nose of the socket head dog nose screw is fully engaged in the groove of the lower spacer

Special Tools

3" Bore Wash Pipe Wrench

Recommended for proper tightening of the wash pipe nut and packing box Figure 5-14. Inspecting the Washpipe (1 of 2)

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SM00856 Revision D Page 5-24 of 98

Maintenance

Equipment Inspection Inspecting the Motor Housing and Transmission Standard Washpipe O-Ring Snap Ring

Holding Ring

Daily

Packing Seal 5 per set

Wash Pipe Assembly Inspect for leaks

Wash Pipe Nut

Upper Spacer

Middle Spacer

Wash Pipe

Middle Spacer

Packing Assembly Box

Straight Ext. Grease Fitting

Lower Spacer

Socket Head Dog Nose Screw

O-Ring

Procedure  Visually inspect the wash pipe assembly for leaks  Replace any worn or damaged parts  Apply pipe dope to the threads before installing in the Top Drive Figure 5-15. Inspecting the Washpipe (2 of 2)

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Maintenance

5

Equipment Inspection Inspecting the Motor Housing and Transmission Upper Bonnet Seals Procedure  Remove the bearing shield, the bearing retainer cap screws, and the bearing retainer  Inspect the bearing isolator, the oil seal, and the retainer o-ring for wear  Replace any worn or damaged parts Align the shims so that the bearing lube tube bore is not blocked

Bearing Retainer Cap Screw 6 Places

Bearing Shield

Bearing Retainer

Lube Tube Oil Seal Bearing Shield

Bearing Isolator

Bearing Retainer Cap Screw 6 Places Bearing Retainer

Retainer O-Ring

Lube Tube O-Ring 2 Places

Yearly Retainer O-Ring Yearly Bearing Isolator Yearly Oil Seal

Lube Tube

Shims Hand pack the void with grease

Figure 5-16. Inspecting the Upper Bonnet Seals

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Maintenance

Equipment Inspection Inspecting the Motor Housing and Transmission Main Shaft and Load Collar Component

Replace when

Stem Grooves

Groove width (female) is greater than 0.650 in.

Load Collar Grooves

Groove width (male) is less than 0.579 in.

Stem 5 Years Split Load Collar Yearly

Radial Grooves Inspect for groove wear and pitting 0.650 max

Radial Grooves Inspect for groove wear and pitting

Yearly

Yearly

0.579 min

Retainer Ring Figure 5-17. Inspecting the Main Shaft and Load Collar

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5

Maintenance

Equipment Inspection Inspecting the Motor Housing and Transmission Main Shaft End Play

Dial Indicator Bearing Retainer Cap Screw 6 Places

Mainshaft Check for axial movement Yearly

Shims Bearing Retainer

Procedure  Check mainshaft endplay with every washpipe changeout  Remove the washpipe assembly  Check the mainshaft axial movement by applying an upward force to the mainshaft and measuring the amount of axial movement with a dial indicator  If axial shaft movement is not .001 in. to .002 in., remove the bearing retainer and adjust the number of shims under the bearing retainer as required to allow .001 in. to .002 in. of axial shaft movement (end play) with the bearing retainer capscrews tightened to 250-270 ft lb

Figure 5-18. Inspecting Main Shaft End Play

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SM00856 Revision D Page 5-28 of 98

Maintenance

Equipment Inspection Inspecting the Motor Housing and Transmission Motor Brakes Procedure  Remove the brake housing covers to access the drilling motor brakes  Inspect the brake pads for wear, and replace the pads if worn below the allowable lining wear limit  If the brake pads are wearing unevenly, adjust the pads by adjusting the bolts on the brake calipers to acheive an equal gap as descibed below

Calipers and Pads Check pads for wear

 Inspect the brake hydraulic lines for leaks Never check for hydraulic leaks with your hands. Oil under pressure escaping from a hole can be nearly invisible and can penetrate skin causing serious injury. Always check for leaks with a piece of wood or cardboard.

Caliper Mounting Bolts

Monthly

Brake Rotor

Steel Plate 0.09 in. Min.

Adjust

Caliper Mounting Bracket

Brake Pads

Equal Gap

Figure 5-19. Inspecting the Motor Brakes

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Maintenance

5

Equipment Inspection Inspecting the Motor Housing and Transmission Drilling Motors Procedure  Check for missing or damaged louvers  Check screens for contamination  Check motor leads for damage  Check for missing lockwire  Megger motors yearly

Weekly Motor Leads Check for damage

Weekly Louvers Check for damage

Weekly Screen Check for contamination

Figure 5-20. Inspecting the Drilling Motors

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Maintenance

Equipment Inspection Inspecting the Motor Housing and Transmission Transmission Stem Sleeve Taper Roller Bearing

Main Body Cover Cap Screw

Upper Spray Nozzles

Dowel Pin

Upper Compound Roller Bearing

Lock Washer

Dowel Pin

Bull Gear

Internal Retaining Ring Compound Gear

Upper Stem Liner

Internal Retaining Ring Spacer Ring Lower Compound Roller Bearing

Poly Pack Seal

Oil Gallery O-Ring

Bearing Lock Washer Main Shaft Stem

Internal Locknut Retainer Main Body O-Ring

Tapered Roller Thrust Bearing

Main Body

Main Shaft Sleeve

Lower Main Bearing

Lube Plate Oil Assembly

Lock Washer

Bearing Retainer

Main Lower Roller Bearing

Wear Sleeve

Cap Screw Figure 5-21. Disassembling/Assembling the Transmission

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Maintenance

5

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SM00856 Revision D Page 5-32 of 98

Maintenance

Equipment Inspection Inspecting the PH-75 Pipe Handler Illustrated Index Rotating Link Adapter Page 5-52

Link Tilt Page 5-38 IBOP Actuator Yoke and Cylinder Page 5-46

Stabilizer Page 5-44 IBOP Stack Page 5-49 Clamp Cylinder Body Page 5-40 to 5-43

Stabbing Guide Page 5-42

For pipehandler lubrication see Page 5-64

Drill Pipe Elevator and Elevator Links Page 5-36 Figure 5-22. PH-75 PIpe Handler Illustrated Index

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SM00856 Revision D Page 5-33 of 98

Maintenance

5

Equipment Inspection Inspecting the PH-75 Pipe Handler

Before beginning any inspection procedures, make sure to read and understand the warnings in the section titled "Safety Precautions" on page 5-2. Failure to adhere to these warnings could result in severe injury or death.

Inspection Schedule Daily Inspection

Page Number



Check for missing lockwire and cotter pins



Check for loose or broken parts and leaks



Check for damaged hoses and fittings



Check tong dies for wear

page 5-42



Check clamp cylinder for leaks

page 5-42



Check hoses for wear or damage

page 5-46



Check tool joint locks for tightness

page 5-48



Check upper and lower IBOP valves for proper operation

page 5-49

Weekly Inspection

Page Number



Check link tilt clamps for position and tightness

page 5-37



Check stabbing guide and flippers for damage and wear

page 5-42



Check clamp cylinder gate hinge pin for wear

page 5-42



Check IBOP actuator cylinder for leaks

page 5-46



Check IBOP actuator cam followers for wear or excessive play

page 5-46



Check upper and lower IBOPs and IBOP crank for damage (if equipped)

page 5-49



Check shot pin assembly for leaks

page 5-51

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SM00856 Revision D Page 5-34 of 98

Maintenance

Equipment Inspection Inspecting the PH-75 Pipe Handler Inspection Schedule Monthly Inspection

Page Number



Check elevator link eyes for wear

page 5-36



Check link tilt bushings for wear

page 5-39



Check link tilt actuator cylinders for leaks

page 5-39



Check link tilt actuator cylinder pins for wear

page 5-39



Check clamp cylinder body wear bushings for wear

page 5-42



Check stabilizer springs for damage

page 5-44



Check front and rear stabilizers for wear

page 5-44



Check pins and bushing on IBOP actuator cylinder and yoke for wear

page 5-46



Check shot pin assembly for wear

page 5-51

Yearly Inspection

Page Number



Check piston ring for pitting and chipping

page 5-53



Check stem for pitting, grooves and chipping

page 5-53



Replace GLYD rings, o-rings, and bushings on rotating link adapter

page 5-53

5 Year Inspection 

Perform a Magnetic Particle Inspection (MPI)

Page Number page 5-56

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SM00856 Revision D Page 5-35 of 98

Maintenance

5

Equipment Inspection Inspecting the PH-75 Pipe Handler Stopping and Starting the Top Drive Shutting Down the Top Drive

Starting Up the Top Drive

Use the following procedure before performing any work on the top drive.

Before turning the main power back on, be sure that all rig personnel are well clear of the top drive, pipehandler and all link tilt system components.

 Operate the Link Tilt control on the console to the FLOAT position prior to shutting down the top drive.  Make sure that the elevator links are hanging vertically.  Turn the IBOP valve control to the OPEN position on the console.  Turn the main power OFF at the main power breaker in the VFD house.  Turn the hydraulic control switch on the top drive hydraulic manifold from RUN to SHUTDOWN mode.  Attempt to function test the LINK TILT (Derrickman and Drilldown), the IBOP, and pipehandler left and right rotation. If none of these functions operate, all hydraulic pressure is off.

Rig-up/Run/ Shutdown Valve Shown in RIG-UP position (switch to RUN after the counterbalance is installed)

Typical location for Rig-up/Run/ Shutdown Valve. This valve may be in a different location on your top drive.

RUN

RIG-UP

SHUTDOWN

 Turn the hydraulic control switch on the top drive from SHUTDOWN to RUN mode.  Turn the main power ON at the main power breaker in the VFD house. Reset brake. You may then function test the top drive after repairs have been made.

S

H

N

U T

U

R

D O

W

N

COUNTERBALANCE MODE

E

C

N

P

LA

-U

BA

R

IG

TE

R

N

U

O C E D

O

M

Hydraulic Manifold

Figure 5-23. Stopping and Starting the Top Drive

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5

Maintenance

SM00856 Revision D Page 5-36 of 98

Equipment Inspection Inspecting the PH-75 Pipe Handler Elevator Links Once a month, use calipers to measure the amount of wear on the elevator link eyes. Compare the measurement with the link wear charts in the Links User Manual (D6350000870). This manual is included in the equipment User Manual. Complete the following steps to remove the elevator links for inspection: 1. Disconnect and remove the drill pipe elevator from the elevator links. 2. Using the driller’s control console, rotate the pipe handler 90° to position one of the elevator links directly below the front of the motor guard. (There is a recess at the front of the motor guard that allows the elevator link to be hoisted away from the pipe handler.) 3. Remove the catch link bolt from the catch link. 4. Remove the clevis pin from the link, which connects the link tilt to the elevator link. 5. Using the sling, hoist the elevator link away from the pipe handler. 6. Rotate the pipe handler 180°, repeat the procedure to remove the other elevator link.

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SM00856 Revision D Page 5-37 of 98

5

Maintenance

Equipment Inspection Inspecting the PH-75 Pipe Handler Elevator Links

Recess in Motor Guard Catch Link Pin

Elevator Link

2 Lift and remove

Link Tilt Link Catch

Monthly 26" (635mm) Typical

Clevis Pin

Elevator Link Eyes Inspect for wear (see table)

Rear

Pipehandler Rotate Switch Weekly EH

Link Tilt Clamps Inspect for position and tightness

T AN SH PU

PIP T

IL K TT LIN OA FL

U HP / ON TO

AU

QU

E

Front

E AT CW

OT

R PH CC

W

T

ILT TIL

T INK

L

1

ILL

DR

Rotate

Driller’s Control Console

E RS VE

I NC

CY GEN ER OP EM ST

EUP QUE TOR

L DRIL

I NC

TD

BX

OR N VAT OPE

ELE I NC

BX ED

A SE RE

ARM CE LAN UMP RBA NDJ NTESTA COUL / DRIL

L ERA GEN

R LE D ND CLAMP HOL HA TWH AND PUS PIPE

VFD LT FAU

AR

MS OR

MP L MOT DRIL RTE OVE

TILT LINK AT FLO

A SE RE

TD

MA

KEU

P

E DECR EAS

DR

ILL

OR VAT ELESED BX CLO

HPU/ ON O AUT

SS PRE OIL S LOS

QUE

TD

ATE CW

TOR

DE

WER BLO S LOS

PH

S MO

ROT

CCW

SPIN

TILT TILT

/

LINK

NCE SILECK RM CHE ALA P LAM

L DRIL

L DRIL

BR

AK

E

N

IO

TD

SED

D

CLO

WAR FOR

KE BRAOFF / ON

SE CLO IBOP N OPE

E ERS REV

CT

RE

O AUT

IBOP

S DI

Monthly

PM SR

ECREASE

D

BLE ENA

AL

A SE RE

E DE CR EAS

SET MAK

S

OFF

Take care when inspecting elevator links. Links weigh up to 2,400 lb (11,00 kg) and can fall if handled improperly.

Elevator Link Eyes Inspect for wear (see table)

Figure 5-24. Inspecting the Elevator Links

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5

Maintenance

SM00856 Revision D Page 5-38 of 98

Equipment Inspection Inspecting the PH-75 Pipe Handler Link Tilt 1. Shut down the power and bleed the system (turn the valve on the bottom of the gearcase to the SHUT DOWN position). 2. Disconnect the hydraulic lines from the link tilt cylinders and cap all connections. 3. Unpin and remove the link tilt cylinders. 4. Unpin and remove the link tilt crank.

Use the recommended spanner wrench to remove the rod gland seal.

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SM00856 Revision D Page 5-39 of 98

5

Maintenance

Equipment Inspection Inspecting the PH-75 Pipe Handler Link Tilt

Pins Inspect for wear replace as needed Monthly

Bushings should be pressed in using the mating pin as an installation mandrel.

Monthly Bushings Inspect for wear replace as needed

Monthly Link Tilt Actuator Cylinders Inspect the hydraulic connections for leaks

Yearly Pipehandler Dissassemble and inspect per illustration

Link Tilt

Monthly

Component

Replace when

Pins

Wear exceeds .06 in. on diameter as measured by comparing worn surfaces to un-worn surfaces

Bushings

Metal backing is visible through the lining End cap of the metal backing exceeds .04 in. wear

Bushings Inspect for wear replace as needed Monthly Moving Components Observe operation and look for excessive wear and replace as needed

Figure 5-25. Inspecting the Link Tilt

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5

Maintenance

SM00856 Revision D Page 5-40 of 98

Equipment Inspection Inspecting the PH-75 Pipe Handler Torque Wrench Assembly Disassembling/Assembling the Clamp Cylinder Body 1. Shut down the power and bleed the system (turn the valve on the bottom of the gearcase to the SHUT DOWN position). 2. Disconnect the hydraulic lines on the clamp cylinder body and cap all connections. 3. Support the clamp cylinder body. 4. Remove the two hex-head capscrews and lockwashers that hold the end cap in place. 5. Remove the end cap, spring spacer, spring sleeve, and spring. 6. Slowly lower the clamp cylinder body off the torque wrench frame and move it to a suitable work area. 7. Remove the 16 hex-head screws and lockwashers that hold the wear bushings on the clamp cylinder body. 8. Remove the four wear bushings, and replace the wear bushings as necessary. 9. Remove the two hinge pin retainer hex-head screws. 10. Swing out the two hinge pin retainers. 11. Remove the two hinge pins. 12. Remove the gate, front jaw, front stabilizer, and front stabbing guide. 13. Remove the two socket-head capscrews and hi-collar washers from the front jaw. 14. Remove the front jaw from the gate. 15. Repeat steps 11 and 12 for the rear jaw. 16. Push the cylinder head in enough to relieve the load on the cylinder head ring. Remove the cylinder head ring. Use care in this operation. 17. Slowly pull out the cylinder head using the threaded holes. Remove and discard the piston seal. 18. Carefully push the piston out of the body. Remove and discard the piston seal. 19. Remove the wiper rod and rod seal from the body. Discard the seals. 20. Clean the piston, cylinder head, and the body. Clean and lightly lubricate the new seals and seal surfaces prior to reassembly.

Use recommended spanner wrench to remove the rod gland seal.

Assembly is performed in reverse order of disassembly.

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SM00856 Revision D Page 5-41 of 98

Maintenance

5

Equipment Inspection Inspecting the PH-75 Pipe Handler Torque Wrench Assembly

Clamp Cylinder Safety Pin Store Position

Torque Arrestor

Clamp Cylinder Safety Pin

Clamp Cylinder Hanger

Clamp Cylinder Assembly Spring

Spring Post

Bottom Plate

Support clamp cylinder body before removing Bottom Plate.

Figure 5-26. Removing the Clamp Cylinder Body

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SM00856 Revision D Page 5-42 of 98

Maintenance

Equipment Inspection Inspecting the PH-75 Pipe Handler Torque Wrench Assembly

Socket-head Capscrews Stabilizer Liner Jaw

Retainer Hex-head Screw Hinge Pin Retainer

Hi-collar Washers

Rod Seal Wiper Rod

Stabilizer Liner

Rear Jaw Screw

Front Stabilizer Washer Hinge Pin

Front Jaw

Gate Nut Spring Front Stabbing Guide Retainer

Cylinder Head Ring

Front Stabbing Guide

Arm Guide

Cylinder Head

Spring Piston Seal Piston Seal

Piston

Figure 5-27. Disassembling the Clamp Cylinder Body

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SM00856 Revision D Page 5-43 of 98

5

Maintenance

Equipment Inspection Inspecting the PH-75 Pipe Handler Torque Wrench Assembly

CB1

CB2

Component

Replace when

Stabilizer

Wear exceeds 1/8 in. (radius >3.625")

Flippers

Wear exceeds 1/8 in. (radius >3.625")

Gate Hinge Pins

Wear exceeds .06 in.

V1

V2

Front and Rear Stabilizers Inspect for wear

Clamp Cylinder Gate Hinge Pin Check for pin wear, replace as necessary

Weekly

6 Months

Tong Dies Inspect for excessive wear

Daily Clamp Cylinder Check for leaks, replace seals as necessary

Daily

Swing Clear

Weekly Clamp Cylinder Gate Shown open

Weekly Flippers Inspect for damage and excessive wear

Stabbing Guide Inspect for damage

Figure 5-28. Inspecting the Clamp Cylinder Body

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5

SM00856 Revision D Page 5-44 of 98

Maintenance

Equipment Inspection Inspecting the PH-75 Pipe Handler Stabilizer Procedure  Remove the two screws (with slotted nuts and cotter pins) that hold the front stabilizer  Check the springs for damage and replace if needed  Pack spring cavities with grease and reassemble  Be sure all safety wire, cotter pins, and screws are tight, and tighten or replace as necessary.

Screw

Washer

Nut 6 Month Stabilizer Springs Check for damage, replace as necessary

Cotter Pin

Figure 5-29. Inspecting the Stabilizer

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SM00856 Revision D Page 5-45 of 98

Maintenance

5

Equipment Inspection Inspecting the PH-75 Pipe Handler IBOP Actuator Cylinder and Yoke Disassembling the IBOP Actuator Cylinder and Yoke 1. Shut down the power and bleed the system (turn the valve on the bottom of the gearcase to the SHUT DOWN position). 2. Remove one gate hinge pin, open the gate, and pull back the torque wrench assembly. 3. Disconnect the hydraulic lines from the IBOP actuator cylinder and cap all connections. 4. Unpin and remove the IBOP actuator cylinder and yoke. 5. Replace the hydraulic lines as necessary. 6. Check for cylinder leaks.

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SM00856 Revision D Page 5-46 of 98

Maintenance

Equipment Inspection Inspecting the PH-75 Pipe Handler IBOP Actuator Cylinder and Yoke Daily

Weekly

6 Months

Hoses Replace if worn or damaged

Actuator Cylinder and Yoke Check for looseness, etc.

Actuator Cylinder and Yoke Dissassemble and inspect per illustration

Weekly IBOP Actuator Cylinder Check for leaks, tighten fittings Monthly Pins and Bushings Check for wear or excessive play

Monthly

Weekly

IBOP Actuator Yoke Check pins and bushings for wear or excessive play

IBOP Actuator Yoke Check cam followers for wear or excessive play

Component

Replace when

Pins

Wear exceeds .06 in. on diameter

Bushings

Metal backing is visible through the lining End cap of the metal backing exceeds .04 in. wear

Bushings should be pressed in using the mating pin as an installation mandrel Figure 5-30. Inspecting the IBOP Actuator Cylinder and Yoke

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SM00856 Revision D Page 5-47 of 98

Maintenance

5

Equipment Inspection Inspecting the PH-75 Pipe Handler Tool Joint Locks Assembling/Disassembling the Tool Joint Locks

! Do not reuse locking screws.

1. Lubricate the locking screw threads, screw head bearing area, and the tapers of the inner rings with molybdenum disulfide grease, such as Molykote Gn paste. 2. Make sure the save sub, IBOPs, and main shaft are free of “high spots”, such as tong marks. If high spots exist, remove with file or light grinding. 3. Slide the tool joint lock over the main shaft, IBOP valves, and saver sub. 4. Clean the IBOP valves, main shaft, and saver sub surfaces thoroughly. Make sure these surfaces are smooth and free of grease, oil, and pipe dope. 5. Locate the tool joint lock symmetrically at each joint.

! Never tighten locking screws before the tool joint lock is at the correct location, otherwise it will not slide freely.

6. Take any three or four locking screws equally spaced and tighten them to establish parallel or perpendicular position of the tool joint lock collars relative to the main shaft, IBOP valves, and saver sub respectively. This properly seats the collars on the taper of the inner ring and aligns the collars. 7. Using a torque wrench, tighten all locking screws gradually in either a clockwise or counterclockwise sequence (not in a diametrically opposite sequence). Continue tightening all of the screws until they reach 185 +/- 5 ft-lb. 8. Make sure no screw turns any more. The gap between the tool joint collars should be as equal as possible all the way around. 9. Safety wire all screws.

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SM00856 Revision D Page 5-48 of 98

Maintenance

Equipment Inspection Inspecting the PH-75 Pipe Handler Tool Joint Locks Tool Joint Lock to be Equally Spaced on Upper IBOP and Main Stem Joint Connection 1.4"

Tool Joint Shoulder

1.4"

Remove O-Ring and Look through this Space and Split on Inner Ring

Tapered Inner Ring

Tool Joint Lock to be Offset on Upper and Lower IBOP Joint Connection Tool Joint 1.0" Shoulder

I.D. Groove First Line Up this Point with the Tool Joint Shoulder. Then Move Inner Ring Down 3/8" with the Outer Assembly. Replace O-Ring

Daily

1.4" 1.4"

Tool Joint Shoulder

Tool Joint Locks Inspect for loose bolts. Repair or replace if necessary. Torque to 1855 ft lb.

Tool Joint Lock to be Equally Spaced on Lower IBOP and Saver Sub Joint Connection

Removing the Tool Joint Locks  Gradually release the locking screws all the way around. Initially release each screw about a quarter of a turn, avoid tilting and jamming the collars. Do not remove the screws completely at this time, otherwise the collars may spring off.  Remove any rust formed or dirt collected adjacent to the tool joint lock. Once the screws are loose, remove the tool joint lock from the saver sub, IBOP valves, and main shaft. Figure 5-31. Inspecting the Tool Joint Locks

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SM00856 Revision D Page 5-49 of 98

Maintenance

5

Equipment Inspection Inspecting the PH-75 Pipe Handler IBOP Valves and Saver Sub

Close

Component

Replace when

Saver Sub

Threads have been recut to a minimum shoulder-to-shoulder length of 5 in.

Weekly

Daily

Upper IBOP (Remote) Inspect for damage

Valve Check for proper operation and pressure test for leaks

Weekly Open

IBOP Crank (Remote) Inspect for damage

Weekly

Daily

Lower IBOP (Manual) (Optional) Inspect for damage

Valve Check for proper operation and pressure test for leaks

5 Years Upper and Lower IBOP

Figure 5-32. Inspecting the IBOP Valves and Saver Sub

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5

Maintenance

SM00856 Revision D Page 5-50 of 98

Equipment Inspection Inspecting the PH-75 Pipe Handler Shot Pin Assembly Disassembling the Shot Pin Assembly 1. Disconnect the hydraulic and electrical lines. 2. Remove the capscrews that attach the shot pin assembly to the main body. 3. Remove the capscrew and lockwasher holding the shot pin cover in place. 4. Remove the shot pin components as shown in Figure 5-33 (end cap, o-rings, rod seal assembly, shot pin). 5. Inspect the shot pin bearing and press the bearing out of the shot pin mounting bracket if the bearing is scored or damaged. 6. Remove the capscrew and lockwasher that hold the pinion gear in place, and remove the gear. 7. Remove the capscrews and lockwashers that hold the hydraulic motor in place and remove the motor. 8. Inspect the disassemble parts and replace any worn or damaged parts. Assemble the shot pin in the reverse order of disassembly.

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SM00856 Revision D Page 5-51 of 98

5

Maintenance

Equipment Inspection Inspecting the PH-75 Pipe Handler Shot Pin Assembly Component

Replace when

Shot Pin

Outer diameter is less than 1.375 in.

Shot Pin Sleeve

Inner diameter is greater than 1.510 in.

Gear Shaft

Flanged Bearing Hydraulic Motor Compound Gear Hydraulic Manifold

Dowel Pin

Flanged Bearing

Bearing

Weekly Shot Pin Assembly Check for leaks, tighten fittings

Drive Gear Bearing

Shot Pin Housing Assembly

Rod Seal Assembly Monthly Shot Pin Check for wear, remove burrs

Bearing Retainer

Rod Seal Assembly Monthly Shot Pin Sleeve Check for wear

O-ring Retaining Ring Shot Pin Flange Bushing

Figure 5-33. Inspecting the Shot Pin Assembly

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SM00856 Revision D Page 5-52 of 98

Maintenance

Equipment Inspection Inspecting the PH-75 Pipe Handler Rotating Link Adapter and Load Stem Removing the Rotating Link Adapter (while the top drive is in the mast) 1. Drain the oil from the gearbox. 2. Disconnect and cap all tubing, remove the shot pin assembly and the landing collar. 3. Build a support over well center to support the weight of the link adapter. 4. Lower the top drive to the support built in Step 3. 5. Remove the bolts that attach the load stem to the main body. 6. Raise the top drive slowly to separate the link adapter from the main body. 7. Move the link adapter assembly to a clean, safe work area. 8. Orient the assembly with the stem flange up and block the entire assembly so that it is secure in this position.

Disassembling the Rotating Link Adapter 1. Attach a 3-point sling to the stem and pull the stem out of the link adapter. 2. Turn the stem over and place it on its flange.

! Protect the internal surfaces of the rotating link adapter and the surfaces of the drive stem when separating the two components. When removing the rotating link adapter from the stem, carefully tap with a mallet. There can be misalignment between the two bores when raising the drive stem and gear assembly.

The piston ring is assembled with a light press fit. Provide a support under the gear so that it does not drop when it breaks loose.

3. Remove and discard all rotary seals, O-rings, thrust ring, and the wear bushings from inside the rotating link adapter and gear inside dimension. 4. Remove and discard the stem flange O-rings and stem bore shaft seals.

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SM00856 Revision D Page 5-53 of 98

5

Maintenance

Equipment Inspection Inspecting the PH-75 Pipe Handler Rotating Link Adapter and Load Stem Eye Bolts

Rotary GLYD Ring (10 Places) Remove, discard and replace Yearly

Rotary GLYD Ring Remove, discard and replace Yearly Rotary Link Adaptor O-Ring Remove, discard and replace Yearly

Thrust Ring Remove, discard and replace

Retainer Ring

Yearly

Turcite Bushing Remove, discard and replace

O-Ring

Yearly

Rotary GLYD Ring Wiper Seal Yearly Piston Ring Inspect for pitting and chipped plating

Rotating Link Adapter Gear

Wear Allowances Component

Replace when

Thrust Ring

Thickness is less than 0.105 in.

Turcite Bushing

Thickness is less than 0.112 in.

Yearly Stem Inspect for pitting, grooves and chipped plating

Stem O-Ring Remove, discard and replace

Index Mark Indicates front of stem

Yearly

Level Work Surface Figure 5-34. Inspecting the Rotating Link Adapter and Load Stem

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5

Maintenance

SM00856 Revision D Page 5-54 of 98

Equipment Inspection Inspecting the PH-75 Pipe Handler Rotating Link Adapter and Load Stem Assembling the Rotating Link Adapter 1. Orient the stem so the drive stem flange is down on a suitably protected surface. 2. Install the gear with its rotating seal and wiper in place. 3. Install the O-ring for the piston ring. 4. Install the piston ring by tapping on it lightly with a mallet to press it into place (heat to 220-250°). 5. Install the retainer ring. 6. Install all of the rotary seals on the rotating link adapter, and an O-ring on the top surface. 7. Install the two wear bushings and the thrust ring in the rotating link adapter. 8. Rest the rotating link adapter on its bottom surface. 9. Clean and then lubricate (with hydraulic oil) the sealing surface of the stem and the inside diameter of the rotating link adapter. 10. Attach three lifting slings symmetrically through the holes on the top of the stem flange and slowly lower the assembly into the rotating link adapter body. Hammering with a large plastic mallet is an aid when assembling the stem to the link adapter.

Make sure the seals do not twist in the grooves.

11. Install the gear onto the link adapter and install the bolts. 12. Pressure test each port at 1,000 psi and inspect for leaks at the adjacent ports. 13. Grease all lubrication points on the assembly. 14. Inspect the lower gearbox seal (located inside the stem flange), and replace as necessary.

Installing the Rotating Link Adapter (while the top drive is in the mast) 1. Check the condition of the main shaft wear ring and replace if there is any evidence of grooving. 2. Place the rotating link adapter assembly back on the support built over well center, orienting the assembly so that the stem flange is up, and so that the index mark faces forward. 3. Carefully lower the top drive to engage the main shaft in the stem bore and then the stem flange pilot diameter is in the main body bore. 4. Install the flange bolts. 5. Install the link tilt cylinders, pin, and secure in place. This procedure continues on the next page.

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SM00856 Revision D Page 5-55 of 98

Maintenance

5

Equipment Inspection Inspecting the PH-75 Pipe Handler Rotating Link Adapter and Load Stem Installing the Rotating Link Adapter (while the top drive is in the mast), continued 6. Install the link tilt crank and pin, and secure in place. 7. Install all hose assemblies. 8. Install tubing. 9. Install the shot pin assembly. 10. Fill the gearcase with gear oil (see the Lubrication section of this chapter). 11. Check and fill the hydraulic oil as necessary. 12. Turn on the top drive and perform all pipe handler functions several times, checking for proper function and any leaks. 13. Re-check the hydraulic oil level and fill as necessary.

! Always install a new main shaft seal and use care not to damage the seal or the case.

A light coating of grease applied to the O-ring helps in installing the rotating link adapter assembly into the main body.

! Always install a new drive stem O-ring and use care not to damage the O-ring or the case.

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5

Maintenance

SM00856 Revision D Page 5-56 of 98

Equipment Inspection Nondestructive Examination Yearly (or after approximately 3,000 operating hours), perform a Nondestructive Examination (NDE) of all critical load path items. NDE inspection includes visual examination, dye penetrant examination, magnetic particle inspection, ultrasonic inspection, x-ray examination, and other methods of nondestructive testing for metallurgical integrity.

Making Visual Inspections Use calipers on a regular basis to measure the amount of wear on the elevator link eyes. Compare the measurements with the information provided in the Links User Manual (D635000870) to determine the current strength of the elevator links. The capacity of the links equals the capacity of the weakest link.

Magnetic Particle Inspection (MPI) Every five years, NOV recommends that customers inspect all top drive hoisting equipment using the wet fluorescent method of Magnetic Particle Inspection (MPI). Refer to the documentation listed in the following section before beginning the MPI for any equipment component. Refer to the following standards that define the use of the wet fluorescent method of MPI when examining machined surfaces for any equipment component. 

ASTM A-275, Standard Method for Magnetic Particle Inspection of Steel Forgings



ASTM-E-709, Standard Recommended Practice for Magnetic Particle Inspection



I.A.D.C., Drilling Manual



API RP 8B, Recommended Practice for Procedures for Inspection, Maintenance, Repair and Remanufacture of Hoisting Equipment



API 8C, Specification for Drilling and Product Hoisting Equipment (provides MPI inspection acceptance criteria)

Any indications found are a potential cause for replacing one or more of the following: 

Main shaft (lower portion)



Bail



Split Load Collar



Upper and lower IBOP



Link adapter



Saver, crossover, and spacer subs



Power subs



Power swivels



Elevator links

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SM00856 Revision D Page 5-57 of 98

Maintenance

5

Equipment Inspection Nondestructive Examination The drilling operator may determine that the MPI schedule should occur more frequently, based on one or more of the following factors: 

environment



load cycles



regulatory requirements



operating time



testing



repairs

Please contact your NOV Service Center if you have any questions.

Ultrasonic Inspection In addition to the MPI, NOV also recommends performing an ultrasonic Inspection of the previously listed components to detect any erosion of the inside diameter. Any erosion reduces the load carrying capability of the part. Any subsurface irregularity can also compromise a component’s integrity. Details on Ultrasonic Inspection procedures are in the publication: ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy Steel Forgings

IBOP Inspection Upper and lower IBOP valves, because of their internal grooves and shoulders, are particularly susceptible to corrosion fatigue cracking. These internal diameter changes act as stress risers for bending and tensile loads. It is especially important to properly inspect the IBOP valves on a frequent basis.

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SM00856 Revision D Page 5-58 of 98

Maintenance

Recommended Lubricants and Fluids Refer to Recommended Lubricants and Fluids (D811000719) in the equipment User Manual for recommended lubricants and hydraulic fluids for NOV drilling equipment. The lubrication intervals described in this manual are based on lubricant supplier recommendations. Severe conditions such as extreme loads or temperature, corrosive atmosphere, and so on, may require more frequent lubrication. Worn bushings, binding parts, rust accumulations, and other abnormal conditions indicate more frequent lubrication is necessary.

Lubrication Schedules

! Replace the gearbox oil in new units after initial break-in (the first month of operation). New units can contain metal contaminants and contaminants caused by initial break-in.

! Do not over-lubricate parts. Over-lubricating a fitting can cause a bearing seal to pop out. Over-lubricated parts may also drip, creating a slipping hazard.

The following service intervals are based on average operating conditions. More frequent service intervals are required if you operate the equipment in conditions where excessive load, dusty or corrosive operating atmosphere, or extreme temperatures occur.

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5

Lubrication Schedules

Unless otherwise specified, use general purpose grease to lubricate top drive components. Refer to Recommended Lubricants and Fluids (D811000719) in the User Manual.

Daily Lubrication 

Standard washpipe (twice daily) (one place)

Note: If installed, the optional NOV mechanical washpipe does not require daily lubrication. Refer to the NOV Mechanical Washpipe Service Manual for maintenance information (D811000200-PRO-001 in the User Manual). 

Page Number

Upper bonnet (main body) seal: If a grease fitting is installed in the location shown in Figure 5-35, lubricate the upper bonnet seal daily.

page 5-62

page 5-62

Note: If a pipe plug is installed in this location, do not lubricate daily (refer to the six-month lubrication schedule). 

IBOP actuator yoke and cylinder pins

page 5-63



IBOP actuator cranks

page 5-63



Stabilizer liner

page 5-63



Clamp cylinder gate

page 5-63

Weekly Lubrication

Page Number



Bail pins (2 places)

page 5-62



Rotating link adapter gear

page 5-62



Rotating link adapter (2 places)

page 5-62



Shot pin assembly

page 5-51



Upper IBOP valve (1 place)

page 5-63



Torque arrestor at clamp cylinder

page 5-41



Elevator link eyes (4 places)

page 5-63

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Maintenance

Lubrication Schedules Monthly Lubrication 



After the first month of initial break-in: Replace the gearbox oil. New top drives can contain metal contaminants and other contaminants caused by initial break-in.

Page Number

page 5-65

Traveling Block Sheaves (3 places) Refer to the Traveling Block Supplement (10668162-MAN) for additional block maintenance information. This manual is included in the equipment User Manual.

Every Three Months Lubrication

Page Number

Replace the top drive lubrication system filter, the top drive hydraulic filter, and any hydraulic filters supplying hydraulic system pressure to the equipment (optional NOV HPU or other hydraulic system).

page 5-65



Lubricate the AC drilling motors (4 places)

page 5-66



Lubricate the AC blower motors (4 places)

page 5-66



Lubricate the hydraulic pump AC motor (2 places)

page 5-66



Use Chevron Black Pearl® EP2 motor grease (do not substitute) to lubricate AC motors. NOV recommends that the rig electrician lubricate all AC motors.

Every Six Months Lubrication 

Upper bonnet (main body) oil seal: If a pipe plug is installed in the location identified in Figure 5-35, lubricate the upper bonnet seal every six months. Remove the pipe plugs (front and rear) and install a grease fitting and relief fitting. Replace plugs after lubricating the seals.

Page Number

page 5-62

Note: If a grease fitting is installed in this location, lubricate daily (see daily lubrication schedule). 

Landing collar (1 place). Use Jet Lube™ Arctic™ extreme service grease.



Guide beam (grease running surfaces) (12 places)



Replace the lubrication system oil (and filter element).

page 5-26

page 5-65

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5

Lubrication Schedules Every Six Months Lubrication

Page Number



Perform an oil analysis. Oil viscosity should be adjusted based on the expected ambient conditions for the next six months.



Perform a hydraulic system oil analysis. (If oil analysis recommends it, replace the hydraulic fluid; otherwise, change hydraulic fluid once a year.)

Yearly and As Required Lubrication

Page Number



Replace the hydraulic fluid used by the top drive equipment.

page 5-80



Remove, clean, and replace the magnetic drain plug.

page 5-65



Every Two Years – Replace the hydraulic reservoir bladder.

page 5-74

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Maintenance

SM00856 Revision D Page 5-62 of 98

Lubrication Procedures General Lubrication

Apply general purpose grease to designated grease fittings with grease gun. Use a brush when greasing other parts.

The NOV Mechanical washpipe (if installed) does not require daily lubrication.

Daily Standard Wash Pipe Assembly Apply one pump twice daily

Upper Bonnet Seal One pump Use Hand Pump Only

Weekly Upper Bonnet Seal lubrication frequency can vary based on component design. See lubrication schedule for details.

Bail Pins (2) Two pumps each side

Weekly Rotating Link Adapter Gear Brush with grease

Weekly Rotating Link Adapter Three pumps each

Figure 5-35. General Lubrication (1 of 3)

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Maintenance

Lubrication Procedures General Lubrication

Apply general purpose grease to designated grease fittings with grease gun. Use a brush when greasing other parts.

Daily IBOP Actuator Yoke One pump each side

Daily IBOP Actuator Cranks One pump each side

Daily Weekly

Stabilizer Liner One pump each side

Upper IBOP Valve Remove 1/4" NPT plug, install grease fitting Apply ten pumps

!

Weekly

Replace plug before operating

Clamp Cylinder Gate One pump each side

Daily

Weekly

Stabilizer Liner One pump each side

Elevator Link Eyes (4) Pipe Dope

Figure 5-36. General Lubrication (2 of 3)

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Maintenance

Lubrication Procedures General Lubrication

Apply general purpose grease to designated grease fittings with grease gun

Weekly Guide Rollers 4 Places One pump each (if equipped)

Weekly Guide Rollers 16 Places One pump each (if equipped)

Weekly Bogies 4 Places One pump each (if equipped)

Figure 5-37. General Lubrication (3 of 3)

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Maintenance

Lubrication Procedures Gearbox Lubrication

Cork Ball (Level Indicator)

Sight Glass

Gearbox Oil Drain

Gear Oil Sight Gauge Check with Top Drive “OFF”

Replace gear oil every 6 Months Gearbox Oil Fill Clean area before removing plug, then use a 1 3/8 inch, 12 point socket to remove plug

“Pop-up” Dirt Alarm

Procedure  Check oil level, prior to adding oil (do not mistake the tan colored foam for the dark brown oil)  Make sure the unit is turned OFF  The area must be wiped clean prior to adding gearbox oil  Recheck oil level and replace the plug after adding oil  Run the unit and recheck the oil level (not foam level), after the unit has been running and the transmission oil is warm

Gear Oil Filter Replace every 3 Months Yearly Magnetic Drain Plug Remove and clean contamination Figure 5-38. Gearbox Lubrication

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Maintenance

Lubrication Procedures Motor Lubrication

!

Grease Fittings

NOV recommends that the rig electrician lubricate all AC motors.

Grease Fitting 1/8 inch

! Pipe Plug 1/8 inch (remove and reinstall after lubricating)

3 Months AC Blower Motor (2) 3 pumps (2 grease fittings each motor)

As Viewed From Below

3 Months AC Drilling Motor (2) 5 pumps (2 grease fittings each motor)

3 Months Hydraulic Pump AC Motor 3 pumps (2 grease fittings)

Procedure  Remove the lubrication point plug  Install a grease fitting  Grease with a hand pump only  Re-install the plug Apply motor grease to designated grease fittings with hand grease gun Figure 5-39. Motor Lubrication

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5

Hydraulic System Maintenance Overview The hydraulic control system is a completely self-contained, onboard system. A 10-horse power, 1800 rpm, AC motor, drives two hydraulic pumps and powers the hydraulic system. A fixed displacement pump drives the lube oil system motor. A variable displacement pump provides hydraulic power for the AC motor brakes, powered rotating head, remote actuated IBOP, pipe backup clamp cylinder, link tilt, and counterbalance system. Three hydro-pneumatic accumulators are located on the main body. The hydraulic manifold attaches to the main body and contains solenoid, pressure and flow control valves. A sealed stainless steel reservoir supplies hydraulic oil, eliminating the need for draining and refilling during normal rig moves. The reservoir is mounted between the AC drilling motors and is equipped with strainers and an oil level sight gauge.

The hydraulic system diagrams provided in this section are for reference only. Refer to the engineering hydraulic schematics provided in the Technical Drawing Package (TDP) for rig-specific schematics.

Refer to Appendix A, titled "Hydraulic Symbols" for a description of the hydraulic symbols used in the schematic diagrams shown in this section.

General Inspection Schedule Daily Inspection

Page Number



Check the condition of the hydraulic filter indicator.

page 5-73



Check hydraulic fluid levels.

page 5-73



Check for hydraulic fluid leaks.



Check the condition of hydraulic hoses.

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Maintenance

Hydraulic System Maintenance Location of Hydraulic Components Specifications Pump Motor

10 hp, 1,800 rpm, AC motor

Reservoir Capacity

25 gal

Hydraulic Oil Filter Page 5-73

Counterbalance Manifold Page 5-88

Counterbalance Accumulator Page 5-77

Main Hydraulic Manifold Page 5-76

Upper IBOP TimeDelay Accumulator Page 5-77, -78 Hydraulic Oil Fill Page 5-81

Link Tilt Manifold Page 5-95

Oil Pressure Switch Page 5-79

Link Tilt Cylinders Page 5-95

System Accumulator Page 5-77

Counterbalance Cylinders Page 5-88

IBOP Pressure Switch Page 5-79

Hydraulic Oil Reservoir Page 5-74

Upper IBOP Actuator Cylinder Page 5-77, -78

Front Rear

Front

Rotating Head Motor and Shot Pin Assembly Page 5-93 10 HP AC Motor and Pump Assembly Page 5-83

Rear

Figure 5-40. Hydraulic System Major Components

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Maintenance

Hydraulic System Maintenance System Diagram Drilling Motor Brake

Upper IBOP Actuator Cylinder

Link Tilt Cylinders

Pipehandler Clamp Cylinder

Link Tilt Manifold

Counterbalance Accumulator

Rotating Head (Elevator Positioner)

Shot Pin Cylinder

Counterbalance Cylinders

Rotating Link Adapter Lift

Rotating Head Motor

Gearbox Lube Oil Distribution

Pre-Fill Valve Manifold

Main Hydraulic Manifold

Low Speed Hydraulic Motor Upper IBOP Time-Delay Accumulator

System Accumulator

Lube Oil Pump

Gearbox Sump

M 10 HP A.C. Motor

Variable Displacement Pump

Fixed Displacement Pump (Mtr. Lube)

Hydraulic Reservoir

Figure 5-41. Hydraulic System Diagram

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Maintenance

SM00856 Revision D Page 5-70 of 98

Hydraulic System Maintenance Precautions To avoid serious injury or death, read and understand the following precautions before performing inspection and maintenance procedures.

Properly lockout the main power source before performing lubrication, inspection, or replacement procedures, unless specifically noted in this manual.

Wear protective glasses to prevent eye injuries from fluids under pressure, as well as other hazards.

Do not attempt any adjustments while the machine is moving.

Use caution when draining lubricant. It can be hot.

Never check for hydraulic leaks with your hands. Oil under pressure escaping from a hole can be nearly invisible and can penetrate skin causing serious injury. Always check for leaks with a piece of wood or cardboard and always wear protective eyewear when working on hydraulic components.

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Maintenance

5

Hydraulic System Maintenance Precautions

Always discharge the three accumulators before performing hydraulic system.

hydro-pneumatic repairs on the

Do not attempt repairs you do not understand.

Read and understand all safety precautions and warnings before performing maintenance procedures.

Release all hydraulic oil pressure by bleeding accumulators before disconnecting hydraulic lines. Turn the counterbalance valve to shutdown mode to bleed the hydraulic system. Hydraulic oil under pressure can penetrate skin and cause serious injury.

Before opening the hydraulic system, thoroughly clean work area, and maintain system cleanliness by promptly capping all disconnected lines. Dirt is extremely harmful to hydraulic system components and can cause equipment failure and subsequent injury to personnel.

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Maintenance

Hydraulic System Maintenance Precautions

Hydraulic fluid escaping under pressure can penetrate the skin causing serious injury. Avoid injury by discharging the three accumulators and relieving pressure before disconnecting hydraulic lines. Always search for hydraulic leaks with a piece of cardboard or wood-not with your bare hands. Get immediate medical attention for hydraulic fluid injuries. Fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Do not tighten hydraulic fittings while they are under pressure.

! Inspect the hydraulic system daily for leaks at fittings, damaged hose covers, kinked or crushed hoses, hard or stiff hoses, and damaged or corroded fittings. In addition, during the inspection, tighten or replace any leaking port connections, and clean any dirt build-up from hydraulic components. Use care when handling components to prevent nicking close tolerance finishes.

Replace worn or damaged components immediately.

hydraulic

system

! Inspect the hydraulic fluid level in the hydraulic reservoir located between the AC drilling motors daily. Inspect the hydraulic filter located on the upper left AC drilling motor daily.

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5

Hydraulic System Maintenance Inspection Hydraulic Fluid Level and Indicator

Cork Ball (Level Indicator)

Daily Red “Pop-up” Dirt Alarm

Sight Glass Hydraulic Oil Sight Gauge

Hydraulic Oil Filter

See the Lubrication section for fluid replacement instructions

Procedure  Check the red “pop-up” alarm on the hydraulic filter daily  Replace the filter if the indicator has popped up or as recommended  Use care to prevent contamination from entering the hydraulic system during maintenance activities Figure 5-42. Inspecting the Hydraulic Fluid Level and Indicator

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Maintenance

Hydraulic System Maintenance Inspection Hydraulic Reservoir Bladder (Yearly) Reservoir Breather Reservoir Cover

!

Hydraulic Oil Reservoir Between AC Drilling Motors

Never put oil in the reservoir bladder. Add oil at the hydraulic oil fill only.

Apply gasket sealing compound to prevent leaks

Yearly Reservoir Bladder Check for wear and damage

Gasket Front

Apply gasket sealing compound to prevent leaks

Rear

Hydraulic Oil Reservoir

Procedure  Drain hydraulic fluid and clean area before inspecting the reservoir bladder  Remove the 10 cap screws and lock washers from the cover  Remove cover with bladder attached  Check the bladder yearly for wear or damage  Replace the bladder every two years  Replace the bladder if fluid is found inside or if fluid escapes the reservoir breather when the top drive is on its back Figure 5-43. Inspecting the Hydraulic Reservoir Bladder (Yearly)

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Maintenance

5

Hydraulic System Maintenance Inspection Heat Exchanger

Blower and Brake Covers

Monthly Oil Heat Exchanger Remove any dirt and inspect for leaks, corrosion, and cleanliness

Drill Motor Assembly Left side

Figure 5-44. Inspecting the Heat Exchanger

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Maintenance

Hydraulic System Maintenance Inspection Using the Hydraulic System Ports

Stand Jump SV9 L4

PV

Brake SV1

Clamp/ Shot Pin SV5

P1 IBOP SV4

PF

Float Link SV8 Tilt SV6

* B8

G5

A4 CB

* SA * P

* T1

C4 SV2 Rotating Link Adapter Z1

B9 B1

A6 C5 B5

B6

* These test ports are on sides or bottom of manifold.

As Viewed From Below Figure 5-45. Using the Hydraulic System Test Ports

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Maintenance

Hydraulic System Maintenance Inspection Precharging the Accumulators Accumulator

Setting

System Accumulator

(125-cubic inch displacement)

800 psi precharge

SA

Counterbalance Accumulator

(728-cubic inch displacement)

900 psi precharge

CB

Time-Delay Accumulator

(30-cubic inch displacement)

800 psi precharge

C4

Port

Bleed the accumulator if the pressure is higher, or add nitrogen if the pressure is lower than specified above

Accumulator Charging Assembly Counterbalance Accumulator

Upper IBOP Time- Delay Accumulator

Hydraulic Manifold (Reference)

System Accumulator

Procedure  Disconnect the hydraulic lines to the accumulators and drain them of all hydraulic fluid  With the hydraulic system shut down, and the counterbalance mode valve in the “shut down” position, test the hydraulic pressure at CB, SA and C4 on the hydraulic manifold, mounted to the transmission housing  Verify that all three points measure 0 psi

Front Rear

Note that there is a time delay in pressure decay on port C4  Test the precharge pressure on the three nitrogen-filled accumulators

Figure 5-46. Precharging the Accumulators

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Maintenance

Hydraulic System Maintenance Inspection IBOP Timing Circuit

IBOP Actuator Cylinder 2.500" Dia. Bore X 2.00" Stroke 1.750" Dia. Rod

Hydraulic Cylinder

Open Close

Time-Delay Accumulator 30 Cubic Inches 800 PSI Precharge

Gas Charged Accumulator

-6

A4

B4

A4

B4

IBOP Close Solenoid (Solenoid Valve 4) Double Solenoid Valve

-6

-6

Rotating Link Adapter

-6

(Small)

IBOP Close

Cable ID Number

A

B

P

T

b

SV4

A4

B4

-6

-6

-6

C04

C4

Manifold Assembly

D03

500 PSI

CV4

Flow Control Valve

D4 1

T-11A 3

T-11A 2

2

1 3

PC4

System Pressure

Tank

Figure 5-47. Inspecting the IBOP Timing Circuit

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Maintenance

Hydraulic System Maintenance Inspection IBOP and Oil Pressure Switch

Hoses Inspect for wear or damage. Replace yearly or as required. Yearly

IBOP Pressure Switch Configuration

Oil Pressure Switch Configuration

Pressure Adjusting Screw

Yearly Wires Inspect for wear or lose connections.

Component

Setting

IBOP Pressure Switch

Factory preset at 1500 psi (102.0 BAR) rising +0 Factory preset at 10.0 -1.0 psi decreasing

Oil Pressure Switch

Figure 5-48. Inspecting the IBOP and Oil Pressure Switch

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Maintenance

Hydraulic System Maintenance Lubrication

Before disconnecting hydraulic lines, release all hydraulic oil pressure by bleeding accumulators. Turn the counterbalance valve to shutdown mode to bleed the hydraulic system. Hydraulic oil under pressure can penetrate skin and cause serious injury.

Before opening the hydraulic system, thoroughly clean the work area. Maintain system cleanliness by promptly capping all disconnected lines. Dirt is extremely harmful to hydraulic system components and can cause equipment failure and subsequent injury to personnel.

! Use care when handling components to prevent nicking close tolerance finishes.

! Use care to prevent contamination from entering the hydraulic system during maintenance activities.

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Maintenance

Hydraulic System Maintenance Lubrication Adding Hydraulic Fluid Procedure  The area must be clean prior to adding hydraulic fluid  Remove dust plug from the male quick disconnect at the TDS hydraulic oil fill  Remove dust plug from the female quick disconnect on the lubrication kit and connect it to the male fitting  Pump fluid until the level reaches the middle of the sight glass as shown  After adding fluid, replace the dust plugs

Reservoir capacity is 25 gallons

Cork Ball (Level Indicator)

Red "Pop-up" Dirt Alarm

Sight Glass

Replace every

Hydraulic Oil Sight Gauge

3 Months Hydraulic Oil Filter

Hydraulic Oil Fill Male Quick Disconnect

Replace hydraulic fluid Yearly or earlier based on oil analysis

Dust Plug Female Quick Disconnect

Hydraulic Lubrication Kit 55 gal Drum

Hydraulic Oil Drain Figure 5-49. Adding Hydraulic Fluid

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Maintenance

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Hydraulic System Maintenance Lubrication Draining Hydraulic Fluid

Precautions  Hydraulic fluid may be hot  Use care when opening the valve  Avoid spills  Holds 25 gallons

Valve Handle

Pump Inlet/Drain Adapter 10 HP AC Pump Motor

Procedure  Isolate power to the pump motor  Ensure that the valve is closed  Remove the plug and attach a hose  Open the valve and drain the fluid  Close the valve and remove the hose  Replace the plug

Fixed Displacement Pump Variable Displacement Pump

Figure 5-50. Draining Hydraulic Fluid

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Maintenance

Hydraulic System Maintenance Setting Up Hydraulic Circuits Hydraulic Pumps and Unloading Circuit

There are two pumps – a fixed displacement pump runs the transmission lubrication system and a variable displacement pump provides hydraulic flow to the hydraulic system.

Pump Pressure Compensator Adjustment Point

Guide Beam

Pump/Motor

Variable Displacement Pump

Fixed Displacement Pump

10 HP AC Pump Motor

Figure 5-51. Hydraulic Pumps and Unloading Circuit

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Maintenance

Hydraulic System Maintenance Setting Up Hydraulic Circuits Fixed Displacement (lube) and Variable Displacement Pumps

! Make sure the top drive is properly filled with hydraulic fluid and lube oil before performing this procedure. Also make sure the Rig-Up/Shutdown valve is in the SHUTDOWN position.

1. Locate the tube connecting manifold port PF to the lubrication motor. Disconnect the tube at the manifold end, cap the tube and plug the PF port using steel fittings. 2. Set the relief valve RV1 for the variable displacement pump to a minimum setting, fully counterclockwise, which allows the hydraulic system to operate without building up pressure, and turn the motor off. 3. Set the relief valve RV2 to minimum pressure, fully counterclockwise. 4. Jog-start the electric motor to make sure the direction of rotation is correct (clockwise when looking into pump shaft/ electric motor fan). Correct as required. 5. Start the electric motor and allow both hydraulic pumps to circulate oil. Listen for unusual noises that would indicate cavitation; check for leaks. 6. Connect a gauge to test point PF. Increase the pressure by adjusting relief valve RV2 clockwise until the pressure increases to 400 psi at test point PF. Set the jam nut on RV2. A steel cap is installed over the adjustment screw to discourage unauthorized adjustment.

! While adjusting valves, verify a linear relationship between turning the adjustment screw and observing the pressure change.

7. Turn off the electric motor. Reconnect the tube between manifold port PF and the lubrication motor. 8. Connect an ammeter to the electric motor. Note the full-load amps on the motor nameplate. 9. Restart the hydraulic system electric motor. 10. Set the counterbalance mode valve to the RUN position. 11. Adjust UV1, fully clockwise, to maximum pressure.

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Maintenance

Hydraulic System Maintenance Setting Up Hydraulic Circuits Fixed Displacement (lube) and Variable Displacement Pumps 12. Connect a gauge to test point PV. Note the ammeter reading while RV1 is at minimum setting. 13. Raise the setting of relief valve RV1 from 0 psi to 1,500 psi at a steady rate. During the pressure rise, observe the ammeter. The motor current should rise to a maximum value at 800 psi, then drop off and begin to rise again. The point where the current drops is the pump pressure compensator setpoint. 14. Adjust relief valve RV1 to its minimum setting. If maximum motor current does not occur at 800 psi, adjust the pump pressure compensator as required. 15. Adjust relief valve RV1 again from 0 psi to 1,500 psi, and back to 0 psi to verify maximum motor current at 800 psi. 16. Connect a gauge to test point SA, and leave the gauge on PV. 17. Adjust relief valve RV1 to 2,200 psi and secure the jam nut. 18. Install steel cap over the adjustment screw to discourage unauthorized adjustment. 19. Adjust unloading valve UV1 counterclockwise until the pressure at PV drops off, then an additional two turns counterclockwise. The pressure cycles like a sawtooth wave.

Pressure at PV

3000

Pressure at SA

2000 Pressure 1700 (psi)

1000 800

150 0

10

20

30

40

50

60

Approximate Time (seconds)

Figure 5-52. Pressure Cycle Graph

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Maintenance

Hydraulic System Maintenance Setting Up Hydraulic Circuits Fixed Displacement (lube) and Variable Displacement Pumps 20. Observe the unloaded pressure at PV (about 0 psi) while SA reads about 2,000 psi. The pressure at SA decays until UV1 reloads. After reloading, the pressure rapidly rises to the unload pressure. 21. Observe several unload-reload cycles to determine the unload pressure. 22. Adjust the setting of UV1 as required to a 2,000 psi unload pressure.

! Perform the adjustment with reasonable speed. The process takes no longer than two minutes. Taking longer increases the temperature of the hydraulic fluid.

23. Observe the cycle of loading and unloading of the relief valve. To verify the setting of UV1, note the difference in pump noise level between the loaded and unloaded condition.

RV1

RV2 CB6

CV5

CA6

CV4

A2

LB6

B2

CDR

CV1

PC1

LC5

LA6

RV2

RV1

PCC

T1

T1 C5

B1

B2

A2

Manifold Side View

Manifold End View

Manifold Bottom View

B6

A6

Z1

DR

P

TF B5

B5

B4

C5

B9 TR T1

SA

CTR

SV5 SV2

B4 E6

G6

E5

SV1

B1

SV9

SA

CV2 PV

P5 C4

B8

SA

CB

PF RIG-UP

MV

1

P/N 0181

XC

PV

SHUTDOWN

DF

COUNTERB NCE MODE

PF RUN

SV4

UV1

G5

UV1

PF Figure 5-53. Pump Setup Manifold Ports

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5

Hydraulic System Maintenance Setting Up Hydraulic Circuits Fixed Displacement (lube) and Variable Displacement Pumps

Manifold Assembly

T-21A

4

UV1

2200 PSI

T-10A RV2

2

2 3

T-11A 1

2000 PSI

3

1 Z1 1

400 PSI

2 RV1

PV

PF

800 PSIG

Variable Displacement Pump-Motor Assembly B 1.00 IN^ 3/REV. L

Fixed Displacement Pump

1.10 IN^ 3/REV. MAX. .50 IN^ 3/REV. MIN.

S

L1

Figure 5-54. Pump Setup Circuit Diagram

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Maintenance

Hydraulic System Maintenance Setting Up Hydraulic Circuits Counterbalance Circuit and Stand-Jump Circuit 1. For the counterbalance circuit there are three adjustments: 

Relief valve (on counterbalance cylinder)



PCC – operator set



SJR – operator set

2. To set the relief valve, make sure the pumps are operating. 3. Adjust pressure reducing valve PCC to the maximum setting, fully clockwise. 4. Connect a gauge to test port CB. 5. Adjust the cylinder-mounted relief valve to mid-scale to lower the pressure setting. 6. Increase the pressure clockwise using a 5/32 in. Allen wrench and 9/16 in. open-end wrench. 7. Observe the relationship of turning the relief valve adjustment clockwise to pressure increase. 8. When the relief valve reaches system pressure, turn the setting one full turn clockwise beyond the setting and set the jam nut. 9. Install a steel cover over the valve. 10. Adjust PCC to 1,200 psi. 11. Measure pressure at test port CB. 12. Prepare the hardware to attach the cylinder pear links to the hook. 13. Rotate the counterbalance mode valve from the RUN position to RIG-UP position. This causes the counterbalance cylinders to slowly extend.

! Cylinders stroke to the end of stroke with the mode valve in the RUN position.

14. Once cylinders reach end of stroke, attach hardware to the pear links on the hook. 15. Rotate the counterbalance mode valve back to the RUN position. 16. Adjust PCC counterclockwise to raise the pressure at test port CB until the rail just begins to lift off of the hook. 17. Reduce the pressure slowly (25 psi) to allow the pressure to stabilize. 18. Rotate the counterbalance mode valve to the SHUTDOWN position to bleed down counterbalance cylinders and system accumulator before shipping or performing maintenance. 19. Adjust pressure reducing valve PCC counterclockwise until the bail rests on the hook. Note the pressure at CB. This procedure continues on the next page.

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Maintenance

5

Hydraulic System Maintenance Setting Up Hydraulic Circuits Counterbalance Circuit and Stand-Jump Circuit 20. Reduce PCC an additional 25 psi. The pressure at CB is about 1,600 psi. 21. Connect a gauge to test point B9. Activate the STAND JUMP mode on the drilling console. Adjust relief valve SJR until the bail lifts off the hook. The gauge at B9 should read about 190 psi. 22. Switch back to DRILL counterbalance mode and observe the pressure at test point CB. 23. Switch back to STAND JUMP mode and observe the pressure CB increase by 200 psi.

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Maintenance

Hydraulic System Maintenance Setting Up Hydraulic Circuits Counterbalance Circuit and Stand-Jump Circuit

PCC CB6

CV5

CA6

CV4

A2

LB6

B2

CDR

CV1

PC1

LC5

LA6

RV2

RV1

PCC

T1

T1 C5

B1

B2

A2

Manifold Side View

Manifold End View

RIG-UP/SHUTDOWN Valve B6

A6

Z1

DR

P

Manifold Bottom View TF

B5

B5

B4

C5

B9

SA

CTR

TR T1

SV5 SV2

B4 E6

G6

E5

SV1

B1

SV9

CV2 PV

C4

SA

CB

P5

B8

PF

UV1

RIG-UP

SV4

PV

MV SHUTDOWN

DF

1

P/N 0181

XC

RUN

PF COUNTERB NCE MODE

G5

CB

Manifold Side View

SJR A4

D4

PC5

AR5

D1

PC4

CV3 SJR

PF

P1 A8

PV A4

A5 D5

C4 CB

G5

DF

2

Figure 5-55. Counterbalance Setup Manifold Ports

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Maintenance

Hydraulic System Maintenance Setting Up Hydraulic Circuits Counterbalance Circuit and Stand-Jump Circuit Pressure Relief Valve

1500 PSI T-3A

-4 OR1

ZC

2 CP

OR2

.075ø

1

CP

-12

CP

-12

.075ø

75 PSI 1 2

75 PSI 1 2

T-13A

T-13A

CV1

Counterbalance Cylinders 4.000" Dia. Bore X 8.50" Stroke 2.000" Dia. Rod

-12

CV2 T

-12 T

.010ø

T

Counterbalance Accumulator

Normally-Open Logic Cartridge Metering

728 Cubic Inches 900 PSI Precharge

-16

5 PSI

-6

90 PSI

XC

Prefill Valve

25mm

Cable ID Number

.047ø

Stand Jump

Counterbalance Mode Rig-up

Stand Jump Solenoid (Solenoid Valve 9)

2 Position Valve

Shut-down Run A

B

A

B

P

T

b C09

3 Position Valve with Detent

T

D03

-6

P

MV

.055ø

CB

Manifold Assembly

SV9 D03

XC CV3 75 PSI T-21A

CB

Test Port B9

B9

1 4 3

CDF 4 PSI DF

2

2 T-10A

1

1

1 SJR

System Accumulator

2

DF

126 Cubic Inches 800 PSI Precharge

2 TF

SA

4

PCC T-21A

T-13A

T-5A 30 PSI

1

2

Pressure Relief Valve

200 PSI

3

System Pressure CTF

To Tank

Figure 5-56. Counterbalance Setup Circuit Diagram

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Maintenance

Hydraulic System Maintenance Setting Up Hydraulic Circuits AC Motor Brake Circuit The AC drilling motor brakes are spring released and hydraulic pressure applied at 1,500 psi. The pressure reducing valve regulates the pressure to 1,500 psi. The solenoid valve operates to apply pressure, setting the brakes, or stop pressure to release the brakes. To test the system, turn the auto brakes switch on the driller’s console to the ON position. Attach a pressure gauge to B1 in the manifold. The pressure reading should be 1,500 psi. If the reading is not 1,500 psi, adjust the pressure control reducing valve PC 1 to 1,500. Turn the auto brakes switch to the OFF position. The pressure reading should be very low.

PC1 CB6

CV5

CA6

CV4

A2

LB6

B2

CDR

CV1

PC1

LC5

LA6

RV2

RV1

PCC

T1

T1 C5

B1

B2

A2

Manifold Side View

Manifold Bottom View

B6

A6

Z1

DR

TF B5

B5

B4

C5

B9 TR T1

SV5 SV2

B4 E6

G6

E5

SV1

B1

SV9

CV2 PV

P5 C4

B8

PF RIG-UP

PV

MV SHUTDOWN

DF

P/N 0181

PF COUNTERB NCE MODE

SV4

RUN

G5

B1 Figure 5-57. Motor Brake Setup Manifold Ports

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5

Maintenance

Hydraulic System Maintenance Setting Up Hydraulic Circuits Shot Pin Circuit 1. Set the adjustable relief valve near the body of the cylinder. The shot pin often misses the hole in the rotating gear. The force the shot pin exerts is limited until the pin engages a hole.

! The electrical system jogs the rotating head until the pin engages a hole.

2. To limit the amount of force, you set the valve by operating solenoid valve SV5 manually, forcing the pin to stop on the face of the gear. 3. When the pin stalls out, measure the pressure at B5. Set the relief valve pressure to 400 psi. 4. Tighten the jam nut on the relief valve. 5. At rest, the SV5 valve is de-energized. 6. Test the pressure at C5. Adjust reducing valve AR5 to 1,000 psi.

Hydraulic Drive Motor SV5

C5 Link Adapter Rotation Gear

Hydraulic Manifold View from Below

Shot Pin Simplified for Clarity

Figure 5-58. Setting up the Shot Pin Circuit (1 of 2)

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Maintenance

Hydraulic System Maintenance Setting Up Hydraulic Circuits Shot Pin Circuit

Rotating Link Adapter Drive Motor and Shot Pin Assembly

10 HP AC Motor and Pump Assembly

(Simplified for Clarity)

Hydraulic Drive Motor

Motor Relief Valve Rotating Link Adapter

B5

A

Shot Pin Relief Valve

B Motor Relief Valve

C5 Link Adapter Rotation Gear

A5

Shot Pin

Figure 5-59. Setting up the Shot Pin Circuit (2 of 2)

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Maintenance

5

Hydraulic System Maintenance Setting Up Hydraulic Circuits Link Tilt Cylinder Circuit 1. There is nothing to adjust on the manifold for the link tilt circuit. 2. Adjust the four load holding valves in pairs – the upper pair and lower pair. Adjust all four counterbalance valves fully clockwise, then one turn counterclockwise.

If the valves are not adjusted correctly, link tilt operation is not synchronized.

3. The correct pressure setting is 1,500 psi. The procedure is the same for both valves. Adjust the valves one at a time. 4. There are two test points on the link tilt cylinder manifold. 5. From the driller’s console, move the link tilt to go to the mousehole position. 6. The cylinders go to full extension and the pressure at the test port C1 is 2,000 psi. 7. Command the link tilt to the OFF position and observe the pressure decay at C1. This decayed pressure is the setpoint of the counterbalance valve. 8. Raise the valve setpoint by turning the adjusting screw 1/4 turn counterclockwise. 9. Repeat steps 6 and 7 until the decayed pressure is 1,500 psi.

This is an iterative process. Continue to set the driller’s console control to the mousehole position and OFF, taking present and decayed pressure readings.

! Turning the counterbalance increases the pressure.

valve

counterclockwise

10. Command the link tilt to the DRILL position and repeat the procedure above, using test port C2 to set the counterbalance valve on the DRILL side.

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Maintenance

Hydraulic System Maintenance Setting Up Hydraulic Circuits Rotating Link Adapter Hydraulic Motor Relief Circuit 1. Set the relief valves mounted on rotation motor. 2. Operate the clamp. The shot pin must go through the hole, which locks up the gear. 3. Turn the manual override on the SV2-rotation circuit to drive the head in the counterclockwise direction. Test the pressure at A and adjust the relief valve to 1,700 psi. 4. Turn the manual override on the SV2-rotation circuit to drive the rotating head in the clockwise direction and test the pressure at B. Adjust the relief valve to 1,700 psi.

Hydraulic Drive Motor

Test Points (3)

Motor Relief Valve (2)

Link Adapter Rotation Gear

Figure 5-60. Setting up the Rotating Link Adapter Hydraulic Motor Relief Circuit

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5

Control Console Maintenance

Inspect the console on a routine basis. Failure to conduct routine inspections and maintenance may result in equipment damage or injury to personnel.

The following is a general maintenance checklist. Maintenance Checklist Location

Procedure

Frequency

Console Indicator Lamps

Test using the Alarm Silence / Lamp Check button on the console.

Each time the top drive is assigned.

Heater

Check operation with an Ohm meter.

Monthly

Console mounting fasteners

Check fastener tightness, especially in vibration-prone areas.

Monthly

Check for integrity.

Monthly

Apply a light film of silicone lubricant.

Every Three Months

Enclosure seals and gaskets



If the console enclosure is damaged or faulty, the enclosure should be returned to an NOV Service Center or other authorized service facility for repair.



If there is a faulty terminal or communication module, contact your NOV representative, NOV Service Center, or authorized service facility for a replacement.

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Maintenance

SM00856 Revision D Page 5-98 of 98

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Troubleshooting

6

Introduction This chapter provides guidelines to inspect and troubleshoot the components and circuits for the TDS-11SA Top Drive.

! All procedures and methods provided in this manual are superseded by the procedures and methods approved for use at the location where the equipment is installed and commissioned.

There is no way to anticipate every issue that may be encountered. If the issue cannot be resolved using the troubleshooting instructions, contact an NOV Service Center. A list of NOV Service Centers is provided in the equipment User Manual.

For top drives using an Amphion™ control system, make sure that all data cables are properly connected to the single-board computer (SBC). Many issues can be resolved by making sure these connections are working properly.

Refer to the Maintenance chapter in this service manual for specific maintenance procedures and other information that may help you identify the cause of the issue.

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Troubleshooting

Introduction Personnel Qualifications Personnel conducting the troubleshooting procedures should be experienced and thoroughly familiar with this NOV top drive. The personnel conducting troubleshooting procedures must read and understand the information in all equipment documentation as well as understand all the functions of the top drive.

! Follow the general system safety practices included in this manual before troubleshooting or performing maintenance on the top drive system.

! Personnel troubleshooting the top drive must be experienced and thoroughly familiar with its function, operation and maintenance requirements.

Failure to follow safe work procedures could result in serious or fatal injury to personnel, significant equipment damage, and/or extended rig down time.

Troubleshooting Guidelines NOV top drive hydraulic and electrical systems use standard components and follow industrystandard design practices. For the hydraulic or electrical systems to function (produce flow at all times and pressure when a load is present), the following basic operating conditions must be present at all times: 

The hydraulic and lubrication pump(s) must be running and rotating in the correct direction.



There must be clean fluid and adequate fluid flow to the top drive.



The temperature of the hydraulic and lubrication fluids must be in the correct range to ensure the viscosity is not too high (low temp) or low (high temp). Refer to Recommended Lubricants and Fluids (D811000719) in the equipment User Manual for recommended lubricants and hydraulic fluids for NOV drilling equipment.

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Troubleshooting

6

Introduction Troubleshooting Guidelines 

The hydraulic and electric circuits must be correctly connected and operable.



The piping, hoses, and service loops must positioned properly and unobstructed.

Make sure all electrical and hydraulic lines and valves are isolated before any work is started on top drive hydraulics. Failure to follow safe work procedures could result in serious or fatal injury to personnel, significant equipment damage, and rig downtime.

Determining the Nature of Problem When troubleshooting the top drive, determine the nature of the problem using the troubleshooting tables, detailed theory of operation information for components, and diagnostic procedures. Potential component failure for most top drives falls into the following three categories: 

Mechanical System components



Hydraulic System components



Electrical System components



Lubrication and Cooling System components

Identifying Troubleshooting Categories Potential top drive system failure typically falls into one or more of the following categories.

Mechanical Components Mechanical problems are usually related to damaged or worn out parts. Another factor that can contribute to mechanical failures is a lack of periodic preventive maintenance. Periodic inspections and equipment maintenance must be completed to ensure proper mechanical operation.

Hydraulic System and Components Hydraulic circuit and component problems are usually related to faulty valves, hydraulic actuators, contamination, fluid leakage, or damage not related to maladjusted hydraulic circuit components. Changes to adjustments should only be made after eliminating all other possible causes.

Electrical System and Components Electrical system and component problems are usually related to faulty discrete control switches, electrical supply voltage, and or improper interconnection wiring.

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Troubleshooting

Introduction Identifying Troubleshooting Categories Lubrication and Cooling System Components Lubrication and cooling system problems are usually related to contamination, faulty discrete control switches, faulty valves and dirty filters. Making changes to the flow rate, system pressure, or other adjustments should only be completed after eliminating all other possible causes.

Make sure to have the hydraulic, electrical, and lubrication engineering schematics available before troubleshooting system problems. These schematics are located in the Technical Drawing Package (TDP).

Pre-Troubleshooting Inspection Complete the following steps before troubleshooting the top drive system: 1. Make sure the top drive is properly installed and positioned in the rig structure. If troubleshooting the top drive prior to rig installation, make sure the top drive is secure and the drill shaft is lifted clear from the floor. 2. Check that all hoses and quick disconnects are properly connected. 3. Check lubrication system pressure output (the unit must be upright).

! Lubrication oil pressure is critical to the performance and proper operation of the top drive. Oil pressure must be carefully monitored and maintained. Failure to adhere to this advisory may result in damage to the top drive.

4. Check the flow and maximum pressure of the NOV hydraulic power unit (HPU) or customer-supplied hydraulic power supply. 5. Check the lubrication system and hydraulic system filters for dirt pop-up indicators. 6. Check whether hydraulic fluid leaks are visible at hydraulic components, hoses, and quick-disconnect couplings. 7. Review the lubrication system maintenance information in the Maintenance chapter in this manual. 8. Determine the nature of the problem using standard diagnostic methods, the troubleshooting tables, maintenance information, and operating information for the equipment.

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Troubleshooting

6

Introduction Service Centers When problems cannot be solved, contact an authorized NOV Service Center. For a directory of NOV Service Centers, see NOV document number D811001337-DAS-001, titled “Service Center Directory.” This document is located in the equipment User Manual. The link below provides after-hours contact information for emergencies or other equipment issues requiring an immediate response by NOV service personnel. www.nov.com/ContactUs/24HrEmergencyContacts.aspx

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SM00856 Revision D Page 6-6 of 22

Troubleshooting

Troubleshooting HPU and Reservoir Bladder Troubleshooting Table Problem

Probable Cause

Remedy

Hydraulic system is overheating.

Relief valves RV1 and RV2 are out of adjustment.

Test pressure and adjust relief valves.

Unloading valve is not working.

Test and adjust UV1 or replace unloading valve.

Counterbalance mode valve left in shut down position too long and pressure bleeds down.

Check system pressure.

No precharge in system accumulator.

Charge system accumulator.

System pressure is down.

First make sure the RIG-UP SHUTDOWN valve is in the correct position. Test pumps and motors. Test relief valve pressures. Adjust as required. Check for leaks, loose fittings, loose cylinders, worn hoses, fluid levels and seals.

Piston pump is not working.

Replace the piston pump.

Flexible coupling is damaged.

Replace flexible coupling.

Lubrication pump is not working.

Replace the lubrication pump.

Pressure at UV1 is too low.

Adjust pressure at UV1.

Pumps are rotating in the wrong direction.

Inspect hydraulic connections and correct rotation.

Suction valve closed.

Open suction valve.

Low oil level in reservoir.

Fill hydraulic reservoir.

Hydraulic components do not operate.

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6

Troubleshooting

Troubleshooting HPU and Reservoir Bladder Schematic Diagram

PV

PF

TR

DR

Manifold Assembly Hydraulic Fill Disconnect

System Pressure 6m

50 PSID

Prefill Valve -12

Pressure Compensator Control

T

Filter with Bypass Valve

T -16

800 PSIG -6 XC B 1.00 In^ 3/Rev. L 1.10 In^ 3/Rev. Max. .50 In^ 3/Rev. Min.

M 10 HP 1800 RPM S

Variable Displacement Pump

L1

Filter (Strainer)

4 PSI Vent

Fixed Displacement Pump

Reservoir Assembly Figure 6-1. HPU and Reservoir Bladder Schematic Diagram

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Troubleshooting

SM00856 Revision D Page 6-8 of 22

Troubleshooting Counterbalance and Stand Jump The accumulator, with precharge pressure of 900 psi, along with check valve CV3, maintains a hydraulic pressure. A three-position manually operated valve controls counterbalance operation for rig-up, run, and shut down modes. In the rig-up mode, system pressure is applied to XC and the prefill valve, causing both cylinders to extend. When the cylinders extend, you make up the mechanical connection to the bail. In the run mode, for counterbalance operation, approximately 1,600 psi is needed at the counterbalance cylinders to lift the TDS-11SA off the hook. The optional stand jump feature is controlled by solenoid valve SV9. With the counterbalance in the run mode and the stand jump switch on, additional pressure of approximately 300 psi is applied to over the normal counterbalance pressure to lift the TDS-11SA and drill string off the hook. In the shutdown mode, the hydraulic system bleeds down the system accumulator and the counterbalance accumulator pressure.

Counterbalance Testing For the counterbalance operation, a lift of approximately 30,000 lb is achieved with a pressure of 1600 psi at CB. Perform the following steps to adjust the force: 1. Set the counterbalance mode valve on the bottom of the manifold to the RUN mode. Set the pressure control valve PCC to the minimum setting (fully counterclockwise). 2. Test the pressure at port B9. There should be a 0 psi reading. 3. Test the pressure at port CB. Observe the position of the top drive on the hook. 4. Adjust the pressure at pressure control valve PCC clockwise, observing pressure at CB, until the top drive just lifts off the hook. Back off the pressure 25 psi, as the top drive rests on the hook.

Stand Jump Testing For the optional stand jump feature, a lift of about 33,000 lb is achieved with a pressure of approximately 1800 psi at CB. The additional 300 psi pressure over the normal counterbalance pressure is provided by energizing the stand jump solenoid valve SV9. Perform the following steps to adjust the pressure: 1. Set the counterbalance mode switch to RUN and engage the stand jump switch. Test the pressure at port CB and B9. Adjust relief valve SJR fully counterclockwise to the minimum setting. 2. Slowly increase the pressure at CB by adjusting relief valve SJR clockwise until the bail lifts off the hook with a stand of pipe in the elevator.

Adjust relief valve SJR slowly to allow pressure at CB to stabilize.

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Troubleshooting

6

Troubleshooting Counterbalance and Stand Jump Troubleshooting Table Problem

Probable Cause

Remedy

Counterbalance does not function.

Cylinder damaged. Seal leaks.

Inspect cylinder and repair or replace seal.

No hydraulic pressure.

Test pressure and adjust pressure reducing valve.

Solenoid valve SV9 is not operating.

Test electrical and hydraulic operation. Replace or repair as applicable.

PCC is not operating.

Replace the valve.

Relief valve is not operating.

Replace the valve.

Precharge on the accumulator is low.

Charge the accumulator.

Cylinder damaged. Seal leaks.

Inspect cylinder and repair or replace seal.

No hydraulic pressure.

Test pressure and adjust pressure reducing valve.

Solenoid valve SV9 is no operating.

Test electrical and hydraulic operation. Replace or repair as applicable.

PCC is no operating.

Replace the valve.

Relief valve is not operating.

Replace the valve.

Precharge on the accumulator is low.

Charge the accumulator.

Stand jump does not function.

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SM00856 Revision D Page 6-10 of 22

Troubleshooting

Troubleshooting Counterbalance and Stand Jump Schematic Diagram Pressure Relief Valve

1500 PSI T-3A

-4 OR1

ZC

2 CP

OR2

.075ø

1

CP

-12

CP

-12

.075ø

75 PSI 1 2

75 PSI 1 2

T-13A

T-13A

CV1

Counterbalance Cylinders 4.000" Dia. Bore X 8.50" Stroke 2.000" Dia. Rod

-12

CV2 T

-12 .010ø

T

Counterbalance Accumulator

Normally-Open Logic Cartridge Metering

T

728 Cubic Inches 900 PSI Precharge

-16

5 PSI

-6

90 PSI

XC

Prefill Valve

25mm

Cable ID Number

.047ø

Stand Jump

Counterbalance Mode Rig-up

Stand Jump Solenoid (Solenoid Valve 9)

2 Position Valve

Shut-down Run A

B

A

B

P

T

b C09

3 Position Valve with Detent

T

D03

-6

P

MV

.055ø

CB

Manifold Assembly

SV9 D03

XC CV3 75 PSI T-21A

CB

Test Port B9

B9

1 4 3

CDF 4 PSI DF

2

2 T-10A

1

1

1 SJR

System Accumulator

2

DF

126 Cubic Inches 800 PSI Precharge

2 TF

SA

4

PCC T-21A

T-13A

T-5A 30 PSI

1

2

Pressure Relief Valve

200 PSI

3

System Pressure CTF

To Tank

Figure 6-2. Counterbalance and Stand Jump Schematic Diagram

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Troubleshooting

6

This page is intentionally blank.

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Troubleshooting

Troubleshooting Motor Brakes Troubleshooting Table Problem

Probable Cause

Remedy

Brake does not release.

Directional valve is stuck.

Test the valve and replace if necessary.

Brake releases but still drags.

Check valve is blocked or tube is pinched.

Replace the check valve or tube as required.

Mechanical problem with brakes.

Repair brake mechanism.

Hydraulic oil on brake pads.

Check for hydraulic leaks and repair.

Pressure is not 1,500 psi or does not rise crisply to 1,500 psi.

Reducing valve is plugged or needs to be adjusted or replaced.

Directional valve is stuck (check pressure at B1).

Replace valve or check electrical signal.

Hydraulic oil is contaminated.

Replace hydraulic oil.

Pressure reducing valve is faulty.

Replace valve.

Brakes do not engage or slip.

Delay in brakes actuating after console switch is turned on.

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Troubleshooting

6

Troubleshooting Motor Brakes Schematic Diagram Brake Calipers

2 Position Solenoid Valve Brakes On Cable ID Number

A

B

P

T

b

-4

C01

B1

SV1

.071ø

Manifold Assembly

D03

Non-Adjustable Orifice P1

Test Point

1500 PSI PC1

Reducing Valve

1

T-11A

2

System Pressure

3

Tank

Drain

Figure 6-3. Brake Circuit Schematic Diagram

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SM00856 Revision D Page 6-14 of 22

Troubleshooting

Troubleshooting Shot Pin Cylinder and Clamp Cylinder Troubleshooting Table Problem

Probable Cause

Remedy

Shot pin does not engage.

Solenoid valve is not operating or relief valve is not adjusted.

Check electrical actuation and test pressure. Adjust as required.

Abnormal pressure change at B5 and C5 indicates a valve problem.

Replace directional control valve.

Normal pressure change indicates plumbing or shot pin cylinder are faulty.

Repair plumbing or shot pin cylinder.

Shot pin applies excessive force to rotating head gear.

Relief valve is not operating or is out of adjustment.

Test pressures and adjust as required.

Clamp cylinder does not actuate.

No pressure or reduced pressure at the cylinder.

Test pressures and adjust and repair as required.

Cylinder is damaged.

Inspect cylinder and repair or replace.

To provide high pressure to the clamp circuit, pressure at C5 must be 2,000 psi and G5 must be less than 100 psi. If this condition is met, pressure at CP should increase from less than 100 psi to higher than 2,000 psi. If not, check the plumbing, rotating link adapter, and clamp cylinder.

Repair plumbing, rotating head, or clamp cylinder.

While clamping, pressure at CR should be 2.7 times the pressure at CP. When the dies contact the pipe, pressure at CR should be less than 100 psi. If the pressure does not fade, check valve CNEC for contamination.

Clean or repair CNEC valve.

Control valve not operating.

Check pressure at C5. Replace valve CV5 if required or the regenerate manifold.

Shot pin engages but clamp cylinder does not activate.

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6

Troubleshooting

Troubleshooting Shot Pin Cylinder and Clamp Cylinder Schematic Diagram Clamp Cylinder 10.000" Dia. Bore X 2.0" Stroke 8.000" Dia. Rod

Hydraulic Cylinder Cavity Plug

CP

CR

1

Pilot-to-Close Check Valve

3 T-2A

CKEB

2 30 PSID 2 1 CNEC

Shot-Pin Cylinder

3

2.000" Dia. Bore X 2.31" Stroke 1.500" Dia. Rod

Relief Valve

T-2A

1 T-5A

COFA .047ø

400 PSI

Shot Pin Cylinder

2

30 PSID

2

2x .094ø

VR

VP 1

2 Position Solenoid Valve 5 Clamp/Shot Pin

Non-Adjustable Flow Control

Cable ID Number

A

B

P

T

b

A5

E5

G5

E5

G5

-8

G5

B5

SV5 D03

.159ø

C5

AR5 2

3

Pressure Reducing Valve

2

1 LC5

1

T-11A

.031ø

50 PSI 3

Logic Cartridge

Rotating Link Adapter Assembly

-6

-6

C05

E5

-8

Clamp

-8

-8

T-10A B5 C5

.031ø

1000 PSI

T-11A

3

2

T-21A CV5

Externally-Drained Pilot-to-Open Valve

1

4 75 PSI P5

Drain

1 3

T-11A

System Pressure

PC5

2

Tank

Drain System Pressure Tank T1

T1

D5

Manifold Assembly

Figure 6-4. Shot Pin Cylinder and Clamp Cylinder Schematic Diagram

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SM00856 Revision D Page 6-16 of 22

Troubleshooting

Troubleshooting Link Tilt Cylinders Troubleshooting Table Problem

Probable Cause

Remedy

Drill pipe elevator does not reach mouse hole/derrickman position.

Link clamp incorrectly adjusted.

Readjust.

Links drift when valve is released.

Pressure at B8 does not decay to less than 100 psi.

Replace the pilot to open check valve.

Pilot to open check valve is stuck open or contaminated.

Replace the pilot to open check valve.

Faulty cylinder seal.

Replace the seal.

Load holding relief valves are out of adjustment, stuck open, or contaminated.

Adjust or replace the load holding relief valve.

Drill pipe elevator does not float back to center position.

Use manual override. If the link tilts, the problem is electrical. If the links do not tilt, the problem is hydraulic.

Test the solenoid and connectors. Test the hydraulic system.

Link tilt does not tilt.

Solenoid valve is not shifting.

Check electrical continuity.

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6

Troubleshooting

Troubleshooting Link Tilt Cylinders Schematic Diagram Link Tilt Cylinder 3.250" Dia. Bore X 10.3" Stroke 1.380" Dia. Rod

Mousehole Drill Down

C1

C1

1500 PSI

CV1 T-11A 1

X1

C2

CV2 T-11A 3

1

X2

3 2

2

2

C2

T-11A CB2

1

3

2

C2

1500 PSI

T-11A CB1

1

3

C1

V1

V2

G6

H

J

Rotating Link Adapter Assembly

Link Tilt "Float" Solenoid (Solenoid Valve 8)

Link Tilt "Tilt" Solenoid (Solenoid Valve 6)

Link Tilt "Drill Down" Solenoid (Solenoid Valve 6)

B

P

T

SV8

Logic Cartridge

D03

B8

LA6 T-11A 1 50 PSI 2 3 A6

A

B

C07 Drill Down P

T

b -8

A

-6

b C08

Link Tilt

E6 .031ø

.071ø

1

SV6

D03 .031ø

75 PSI

.031ø B6

3

3

2

4

.031ø

Logic Cartridge

a C06 M'hole

-8

Link-Tilt Float

X -8

X -8

J

-8 X

-8

H

-8 X

E6

G6

-8

B8 -8

E6

Cable ID Number

-8

-8 G6

X E6

X

-8

-8

-6 B8

X

-6 B8

V2

V1

FL

CA6 T-21A .031ø

G6

T-11A 1

50 PSI 2 LB6

.071ø 4

2

3

1 CB6 75 PSI T-21A

Pressure Tank

Manifold Assembly X

D1 X

A8

Figure 6-5. Link Tilt Cylinders Schematic Diagram

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SM00856 Revision D Page 6-18 of 22

Troubleshooting

Troubleshooting Gearbox Lubrication Hydraulic System Troubleshooting Table Problem

Probable Cause

Remedy

Oil leaking from lower seal.

Worn oil seals.

Replace seals.

Oil leaking from upper bearing retainer.

Worn oil seals.

Replace seals.

Gearbox oil temperature (less than 230° F).

Oil level too low or too high.

Adjust oil level to middle of sight glass.

Incorrect lubricant used.

Check recommended lubricants chart and replace as needed.

Damaged gears or bearings.

Repair and replace as needed.

Oil level is too low. Oil overheated.

Add oil.

Oil pressure switch is out of adjustment.

Adjust the switch (see the section titled "IBOP and Oil Pressure Switch" on page 5-79).

Gear spray nozzle missing.

Replace spray nozzle.

Excessive oil viscosity.

Lower oil viscosity.

Faulty motor. Intermittent operation.

Replace motor.

Oil pump hydraulic motor failure.

Replace motor.

Broken lube pump adapter plate spline.

Replace adapter plate spline.

Faulty fixed displacement pump.

Check pressure at PF. Replace pump if pressure is low.

Low hydraulic fluid in reservoir.

Add hydraulic fluid.

Suction valve closed on fixed displacement pump.

Open suction valve.

Missing inspection plugs.

Replace inspection plugs.

Upper gearbox seals worn.

Replace seals.

Water in oil.

Replace oil.

Excessively viscous oil. Cold oil.

Lower oil viscosity.

Worn gears or damaged bearings.

Replace gears or bearings.

Damaged oil pump.

Replace oil pump.

Foreign particles blocking orifice or nozzle.

Clean orifice or nozzle.

Oil pump loss alarm is on.

Water/mud in oil.

Excessive foaming.

Metal in oil.

Restricted oil flow.

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SM00856 Revision D Page 6-19 of 22

6

Troubleshooting

Troubleshooting Gearbox Lubrication Hydraulic System Schematic Diagram Pressure Switch S04

Spray Nozzles (4)

Orifices (6)

10 PSI Decreasing -16 1.0 GPM Ea.

1.5 GPM Ea.

Upper Compound Gear

Lower Compound Gear

.205ø

.062ø

Upper Mainshaft Bearing

.059ø .059ø

Lower Radial/Main Thrust Bearings

.047ø .047ø

Upper Compound Bearing

L4

Lower Compound Bearing

Lube-Oil Filter Lube Pump

60m

5.10 In.^ 3/Rev. L1 -16

Lube-Oil Pump -10 A

-10

Tank

B

3.0 In.^ 3/Rev.

Lube Pump Motor Hydraulic Motor

Hydraulic Heat Exchanger

Tank

T-10A

2

RV2 1 400 PSI

Manifold

PF

1.00 IN^ 3/REV.

Part of Pump Motor Assembly

Reservoir Assembly

Figure 6-6. Gearbox Lubrication Hydraulic System Schematic Diagram

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SM00856 Revision D Page 6-20 of 22

Troubleshooting

Troubleshooting Tool Rotation and Movement Problem

Probable Cause

Remedy

Tool does not rotate.

Direct control valve or relief valve is sticking

Inspect, repair, or replace the valve. When you override a directional valve, you bypass the safety interlock. Top drive components can then move, possibly causing serious injury or death.

Tool does not return to the home position.

Links are not synchronized.

Solenoid valve is not electrically operating.

Check electrical connections and valve functions.

Motor is worn out or gear teeth are broken.

Replace the motor.

Shot pin is engaged.

Adjust the relief valve.

Mechanical interference.

Inspect and repair.

Directional valve does not shift.

Test pressure left and right. Replace the valve.

Fixed valve orifice is plugged.

Clear orifice or replace the valve.

Hydraulic lines are damaged.

Replace hydraulic lines.

Valve is sticking or relief valve is out of adjustment.

Test pressure and inspect valves. Adjust relief valve as required.

Sensor is broken.

Replace sensor.

If the motor will drive normally, but not drive to the home position, the cause could be the control system.

Check out the control system.

Counterbalance valves are out of adjustment.

Adjust valves together. Make sure pressure is the same for all four valves.

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SM00856 Revision D Page 6-21 of 22

6

Troubleshooting

Troubleshooting Rotating Link Adapter Motor Schematic Diagram Rotating Head Motor

A

B

Fixed Displacement Motor 2

1

T-10A

Pressure Relief Valves

1700 PSI

1700 PSI

T-10A

2

1

A

B

Rotate Left Solenoid

Rotate Right Solenoid

Rotating Head

Cable ID Number

A

Cable ID Number

B

b

a

C03

C02 P

T

-6

Right

-6

Left

A2

SV2 .071ø

Non-Adjustable Orifice

B2

D03

Pressure

Tank

Manifold Assembly

3 Position Solenoid Valve

Figure 6-7. Rotating Link Adapter Motor Schematic Diagram

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SM00856 Revision D Page 6-22 of 22

Troubleshooting

Troubleshooting IBOP Actuator Schematic Diagram IBOP Actuator Cylinder 2.500" Dia. Bore X 2.00" Stroke 1.750" Dia. Rod

Hydraulic Cylinder

Open Close

Time-Delay Accumulator 30 Cubic Inches 800 PSI Precharge

Gas Charged Accumulator

-6 A4

B4

A4

B4

IBOP Close Solenoid (Solenoid Valve 4) Double Solenoid Valve

-6

-6

Rotating Link Adapter

-6

(Small)

IBOP Close

Cable ID Number

A

B

P

T

b

-6

-6

SV4

A4

-6

C04

B4

C4

Manifold Assembly

D03

500 PSI

CV4

Flow Control Valve

D4 1

T-11A 3

T-11A 2

2

1 3

PC4

System Pressure

Tank

Figure 6-8. IBOP Actuator Schematic Diagram

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SM00856 Revision D

Hydraulic Symbols

A

The following pages provide descriptions for hydraulic symbols used in the hydraulic schematic diagrams.

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SM00856 Revision D Page A-2 of 4

Hydraulic Symbols

Description

Symbol

Schematic Reference

2 Position 4 Way Valves (Single Solenoid) Solenoid Operated Valves

SV1, SV4, SV5, SV8, SV9 33-1

3 Position 4 Way Valves (Double Solenoid)

SV2, SV6 33-2

Manual Valve (Rotary)

MV

3 Position 4 Way Valve 33-3

Fixed Displacement 33-4

Pumps Variable Displacement

33-5

RV2, A2R, B2R, SJR

Standard Valve 33-6

Pressure Relief Valves

Ventable Relief Valve

RV1 33-7

UV1

Differential Unloading Valve 33-8

Pressure Reducing Valve

PC1, PC4 33-9

PCC

Pressure Reducing/Relieving Valve 33-10

Chack Valve 33-11

CDF, CTF, CV2, CTR, CDR, CXCD Prefill valve assembly CV1, CV2

Figure A-1. Hydraulic Symbols (1 of 3)

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SM00856 Revision D Page A-3 of 4

Hydraulic Symbols

Description

Symbol

A

Schematic Reference CKCB (Link Tilt)

Pilot-To-Open Check Valves

33-12

CA6, CB6, CV3, CV4 (Clamp Body)

Pilot-To-Close 33-13

1 3

PC5

Cavity Plug 2 33-14

Internal Plug 33-15

CV1

Non Adjustable Flow Control Valves 33-16

Non Adjustable Orifice

Diameter in inches 33-17

CBCA (Link Tilt Circuit)

3 Port (Internal Drain) Counterbalance Valves

33-18

4 Port (External Drain)

CWCK (Link Tilt Circuit) 33-19

Standard Cartridge Logic Cartridge

LA6, LB6, LC5, LODC 33-20

With Metering

See Prefill Assembly 33-21

Quick Disconnect Coupling 33-22

Figure A-2. Hydraulic Symbols (2 of 3)

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SM00856 Revision D Page A-4 of 4

Hydraulic Symbols

Description Description

Symbol Symbol

Schematic Reference Reference Schematic See Lube Oil Circuit

Non Bypass Filter 33-23

Filter with Bypass

See Return Circuit 33-24

Manual Shutoff Valve 33-25

Lube Oil Circuit

Thermostat 33-26

Pressure Switch

Lube Oil Circuit 33-27

Hydraulic Circuit (Inside Brake Housing)

Heat Exchanger 33-28

Pressure Compensator Control

Part of the Pump 33-29

Hydro-Pneumatic Accumulator 33-30

Hydraulic Motor (Bi-Directional) 33-31

Hydraulic Cylinder 33-32

Tank (Reservoir) 33-33

Test Point 33-34

Figure A-3. Hydraulic Symbols (3 of 3)

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SM00856 Revision D

PH-50 Pipe Handler

B

Appendix B provides information about the PH-50 Pipe Handler. Refer to section titled "Inspecting the PH-75 Pipe Handler" on page 5-32 for information about the PH-75 Pipe Handler.

Rotating Link Adapter

Link Tilt

Remote IBOP Actuator

Manual IBOP

Torque Back-up Clamp Assembly

Elevator Links

Drive Pipe Elevator Assembly

Figure B-1. PH-50 Major Components

B-1 www.nov.com Form D811001123-GEN-001/06

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SM00856 Revision D Page B-2 of 28

PH-50 Pipe Handler

Inspection Schedule Each Use

Page Reference

Check wireline adapter sheaves for excessive wear or damage

See page B-26

Daily Check for missing lockwire and cotter pins Check for loose or broken parts and leaks Check for damaged hoses and fittings Check tong dies for wear

See page B-12

Check clamp cylinder for leaks

See page B-12

Check hoses for wear or damage

See page B-16

Check tool joint locks for tightness

See page B-18

Check upper and lower IBOP valves for proper operation

See page B-19

Weekly Check link tilt clamps for position and tightness

See page B-6

Check stabbing guide and flippers for damage and wear

See page B-7

Check clamp cylinder gate hinge pin for wear

See page B-12

Check IBOP actuator cylinder for leaks

See page B-16

Check IBOP actuator cam followers for wear or excessive play

See page B-16

Check upper and lower IBOPs and IBOP crank for damage (if equipped)

See page B-19

Check shot pin assembly for leaks

See page B-21

Monthly Check elevator link eyes for wear

See page B-6

Check link tilt bushings for wear

See page B-8

Check link tilt actuator cylinders for leaks

See page B-8

Check link tilt actuator cylinder pins for wear

See page B-8

Check clamp cylinder body wear bushings for wear

See page B-12

Check stabilizer springs for damage

See page B-14

Check front and rear stabilizers for wear

See page B-12, B-14

Check pins and bushings on IBOP actuator cylinder and yoke for wear

See page B-16

Check shot pin assembly for wear or damage

See page B-21

Yearly Check piston ring for pitting and chipping

See page B-23

Check stem for pitting, grooves and chipping

See page B-23

Replace GLYD rings, o-rings and bushings on rotating link adapter

See page B-23

5 Years MPI Inspection

See page B-27 Figure B-2. PH-50: Inspection Schedule

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SM00856 Revision D Page B-3 of 28

PH-50 Pipe Handler

B

Safety Precautions Warnings Avoid equipment damage or injury to personnel by paying close attention to the important safety notes highlighted as Notes, Cautions, and Warnings used throughout this manual. To avoid serious injury or death, read and understand the following warning advisories before performing maintenance or troubleshooting procedures.

Complete all appropriate job safety analysis (JSA), permits, and crew safety briefings immediately prior to each maintenance activity or session. If, at any point during the maintenance session, the planned activities change for any reason, review the job safety requirements again to ensure the crew involved is aware of the changes in activities. Ensure all appropriate personal safety equipment is in good condition and used when necessary.

Unless specifically noted in this manual, properly lock out the main power source before performing lubrication, inspection, or replacement procedures. Wear protective glasses to prevent eye injuries from fluids under pressure, as well as other hazards. Do not attempt any adjustments while the machine is moving. Read and understand all safety precautions and warnings before performing maintenance procedures. Do not attempt repairs you do not understand. Use caution when draining lubricant. It can be hot. Never check for hydraulic leaks with your hands. Oil under pressure escaping from a hole can be nearly invisible and can penetrate skin causing serious injury. Always check for leaks with a piece of wood or cardboard and always wear protective eyewear when working on hydraulic components. Always discharge all accumulators before servicing the hydraulic system.

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B

PH-50 Pipe Handler

SM00856 Revision D Page B-4 of 28

Safety Precautions

Top drive maintenance requires personnel working at height and there exists the potential for injury or dropped objects.

Equipment Records Keep a record book of all maintenance procedures performed. Date each procedure, followed by a description and the technician who performed it. This data is valuable for fault finding and problem solving, should technical problems arise.

Procedures in this chapter relate to NOV-only components. See the appropriate vendor-supplied OEM manuals for inspection schedules and maintenance procedures for non-NOV equipment and components.

Torque Values Refer to the Design Torque Standard (DS00008) in the equipment User Manual for the torque standards to follow when tightening component fasteners.

Install bolts with anti-seize compound and tighten based on the Design Torque Standard (DS00008). This document is included in the equipment User Manual.

Safety Wire (Lockwire) Procedures Refer to the Safety Wiring Procedure (ASP00019) in the equipment User Manual for the procedures required for installing safety wire (lockwire) on component fasteners.

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SM00856 Revision D Page B-5 of 28

PH-50 Pipe Handler

B

Elevator Links Once a month, use calipers to measure the amount of wear on the elevator link eyes. Compare the measurement with the link wear charts in the Links User Manual (D6350000870). This manual is included in the equipment User Manual.

Disassembly/Assembly 1. Disconnect and remove the drill pipe elevator from the elevator links. 2. Using the Driller’s Control Console, rotate the pipe handler 90° to position one of the elevator links directly below the front of the motor guard. 3. Remove the catch link bolt from the catch link. 4. Remove the clevis pin from the link, which connects the link tilt to the elevator link. 5. Using the sling, hoist the elevator link away from the pipe handler. 6. Rotate the pipe handler 180°, repeat the procedure to remove the other elevator link.

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B

SM00856 Revision D Page B-6 of 28

PH-50 Pipe Handler

Elevator Links Inspection Recess in Motor Guard

950 lb (431 kg) Elevator Link

2 Lift and remove

Link Tilt

Catch Link Pin

Upper Catch Link

26" (635mm) Typical

Monthly Elevator Link Eyes Inspect for wear (see table)

Rear

Clevis Pin Link

Pipehandler Rotate Switch EH

T AN SH PU

PIP

Weekly

T

IL K TT LIN OA FL

U HP / ON TO

Front

AU

QU

E

TE CW

TA

PH C

RO

Link Tilt Clamps Inspect for position and tightness

CW

T

ILT TIL

KT

1

LIN ILL

DR

Rotate E RS VE

Driller’s Control Console

I NC

CY GEN ER OP EM ST

EUP

S

QUE TOR I NC

L DRIL

BX

OR N VAT OPE ELE I NC

BX ED

A SE RE

ARM CE LAN UMP

GEN

R LE D ND CLAMP HOL HA TWH AND PUS PIPE

VFD LT

AR

MS OR

MP L MOT DRIL RTE OVE

TILT LINK AT FLO

MA

TD KEU

PM SR

Monthly

P

E DECR EAS

RBA NDJ NTESTA COUL / DRIL

FAU

AL

A SE RE

ECREASE

D

BLE ENA

L ERA

A SE RE

E DE CR EAS

SET MAK

TD

DR

ILL

OR VAT ELESED BX CLO

Elevator Link Eyes Inspect for wear (see table)

HPU/ ON O AUT

SS PRE OIL S LOS

QUE

DE

WER BLO S LOS

TD

ATE CW

TOR PH

S MO

ROT

CCW

SPIN

TILT TILT

/

LINK

NCE SILECK RM CHE ALA P LAM

L DRIL

L DRIL

BR

AK

E

N

IO

E ERS REV

CT

RE

O AUT

TD

OP

IB

SED

S DI

OFF

D

CLO

WAR FOR

KE BRAOFF / ON

SE CLO IBOP N OPE

Figure B-3. PH-50: Elevator Link Inspection

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SM00856 Revision D Page B-7 of 28

PH-50 Pipe Handler

B

Link Tilt Disassembly/Assembly 1. Shut down the power and bleed the system (turn the valve on the bottom of the gearcase to the SHUT DOWN position). 2. Disconnect the hydraulic lines from the link tilt cylinders and cap all connections. 3. Unpin and remove the link tilt cylinders. 4. Unpin and remove the link tilt crank.

Use the recommended spanner wrench to remove the rod gland seal.

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B

SM00856 Revision D Page B-8 of 28

PH-50 Pipe Handler

Link Tilt Inspection

Pins Inspect for wear replace as needed Monthly

Monthly Bushings Inspect for wear replace as needed

Monthly Link Tilt Actuator Cylinders Inspect the hydraulic connections for leaks

Link Tilt

Monthly Bushings Inspect for wear replace as needed

Component

Replace when

Pins

Wear exceeds .06 in. on diameter

Bushings

Metal backing is visible through the lining End cap of the metal backing exceeds .04 in. wear

i

Bushings should be pressed in using the mating pin as an installation mandrel.

Figure B-4. PH-50: Link Tilt Inspection

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SM00856 Revision D Page B-9 of 28

PH-50 Pipe Handler

B

Torque Wrench Assembly Clamp Cylinder Body Disassembly/Assembly Procedure 1. Shutdown power and bleed the system (turn the valve on the bottom of the gearcase to the SHUT DOWN position). 2. Disconnect the hydraulic lines on the clamp cylinder body and cap all connections. 3. Support the clamp cylinder body. 4. Remove the two hex-head capscrews and lockwashers that hold the end cap in place. 5. Remove the end cap, spring spacer, spring sleeve, and spring. 6. Slowly lower the clamp cylinder body off the torque wrench frame and move it to a suitable work area. 7. Remove the 16 hex-head screws and lockwashers that hold the wear bushings on the clamp cylinder body. 8. Remove the four wear bushings, and replace the wear bushings as necessary. 9. Remove the two hinge pin retainer hex-head screws. 10. Swing out the two hinge pin retainers. 11. Remove the two hinge pins. 12. Remove the gate, front jaw, front stabilizer, and front stabbing guide. 13. Remove the two socket-head capscrews and hi-collar washers from the front jaw. 14. Remove the front jaw from the gate. 15. Repeat steps 11 and 12 for the rear jaw. 16. Push the cylinder head in enough to relieve the load on the cylinder head ring. Remove the cylinder head ring. Use care in this operation. 17. Slowly pull out the cylinder head using the threaded holes. Remove and discard the piston seal. 18. Carefully push the piston out of the body. Remove and discard the piston seal. 19. Remove the wiper rod and rod seal from the body. Discard the seals. 20. Clean the piston, cylinder head, and the body. Clean and lightly lubricate the new seals and seal surfaces prior to reassembly.

Use recommended spanner wrench to remove the rod gland seal.

Assembly is performed in reverse order of disassembly.

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SM00856 Revision D Page B-10 of 28

PH-50 Pipe Handler

Torque Wrench Assembly Clamp Cylinder Body Disassembly/Assembly Removing the Clamp Cylinder Body

Hydraulic Manifold

RIG-UP

SHUTDOWN

RUN

COUNTERBALANCE MODE

Rig-up/Run/ Shutdown Valve Shown in SHUTDOWN position (Shown with link tilt removed)

Torque Arrestor

Spring

Spring Spacer Spring Shims Adjust to ensure the torque wrench clamps fully onto the saver sub

Support clamp cylinder body before removing end cap.

End Cap

Clamp Cylinder Body

Figure B-5. PH-50: Removing the Clamp Cylinder Body

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SM00856 Revision D Page B-11 of 28

B

PH-50 Pipe Handler

Torque Wrench Assembly Clamp Cylinder Body Disassembly/Assembly Disassembling the Clamp Cylinder Body

Manifold

Rear Stabilizer Front Stabilizer Hinge Pin Retainer

Spring Hex Head Screws

Cylinder Head Ring

Clamp Cylinder Body

Cylinder Head

Body Seals

Piston Seals

Jaw Assembly

Piston

Tong Dies Gate

Wear Bushing

Socket Head Cap Screws Hinge Pin Front Stabbing Guide

Rear Stabbing Guide

Flippers

Spring

Retaining Plate

Figure B-6. PH-50: Disassembling the Clamp Cylinder Body

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SM00856 Revision D Page B-12 of 28

PH-50 Pipe Handler

Torque Wrench Assembly Inspecting the Clamp Cylinder Body Component

Replace when

Stabilizer

Wear exceeds 1/8 in.

Flippers

Wear exceeds 1/8 in.

Tugger Line

V A R C O P H 5

0

Front and Rear Stabilizers Inspect for wear

Wear Bushings Check for wear, replace as necessary

Weekly

Monthly

Tong Dies Inspect for excessive wear

CO

R VA

Daily

Daily Clamp Cylinder Check for leaks, replace seals as necessary

Swing Clear

Weekly Clamp Cylinder Gate Shown open

Stabbing Guide Inspect for damage

Weekly Weekly Flippers Inspect for damage and excessive wear

Clamp Cylinder Gate Hinge Pin Check for pin wear, replace as necessary

Figure B-7. PH-50: Inspecting the Clamp Cylinder Body

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SM00856 Revision D Page B-13 of 28

PH-50 Pipe Handler

B

Torque Wrench Assembly Inspecting the Stabilizers Remove the two bolts (with slotted nuts and cotter pins) that hold the front stabilizer. Check the springs for damage and replace if needed. Pack spring cavities with grease and reassemble. Be sure all safety wire, cotter pins, and capscrews are tight, and tighten or replace as necessary.

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B

PH-50 Pipe Handler

SM00856 Revision D Page B-14 of 28

Torque Wrench Assembly Inspecting the Stabilizers

Stabilizer Springs Check for damage, replace as necessary

Monthly

Monthly Stabilizers Inspect for wear, replace if wear exceeds 1/8 in.

Cotter Pin

Figure B-8. PH-50: Inspecting the Stabilizer

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SM00856 Revision D Page B-15 of 28

B

PH-50 Pipe Handler

Torque Wrench Assembly Disassembling the IBOP Actuator Cylinder and Yoke 1. Shutdown the power and bleed the system (turn the valve on the bottom of the gearcase to the SHUT DOWN position). 2. Remove one gate hinge pin, open the gate, and pull back the torque wrench assembly. 3. Disconnect the hydraulic lines from the IBOP actuator cylinder and cap all connections. 4. Unpin and remove the IBOP actuator cylinder and yoke. 5. Replace the hydraulic lines as necessary. 6. Check for cylinder leaks.

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SM00856 Revision D Page B-16 of 28

PH-50 Pipe Handler

Torque Wrench Assembly Inspecting the IBOP Actuator Cylinder and Yoke

Weekly IBOP Actuator Cylinder Check for leaks, tighten fittings

Daily

Monthly

Hoses Replace if worn or damaged

Pins and Bushings Check for wear or excessive play

Monthly IBOP Actuator Yoke Check pins and bushings for wear or excessive play

Component

Replace when

Pins

Wear exceeds .03 in. on diameter

Bushings

Metal backing is visible through the lining

Weekly IBOP Actuator Yoke Check cam followers for wear or excessive play

End cap of the metal backing exceeds .04 in. wear

i

Bushings should be pressed in using the mating pin as an installation mandrel Figure B-9. PH-50: Inspecting the IBOP Actuator Cylinder and Yoke

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SM00856 Revision D Page B-17 of 28

PH-50 Pipe Handler

B

IBOP Stack Tool Joint Locks Disassembly/Assembly

! Do not reuse locking screws.

1. Lubricate the locking screw threads, screw head bearing area, and the tapers of the inner rings with molybdenum disulfide grease, such as Molykote Gn paste. 2. Make sure the save sub, IBOPs, and main shaft are free of “high spots”, such as tong marks. If high spots exist, remove with file or light grinding. 3. Slide the tool joint lock over the main shaft, IBOP valves, and saver sub. 4. Clean the IBOP valves, main shaft, and saver sub surfaces thoroughly. Make sure these surfaces are smooth and free of grease, oil, and pipe dope. 5. Locate the tool joint lock symmetrically at each joint.

! Never tighten locking screws before the tool joint lock is at the correct location, otherwise it will not slide freely.

6. Take any three or four locking screws equally spaced and tighten them to establish parallel or perpendicular position of the tool joint lock collars relative to the main shaft, IBOP valves, and saver sub respectively. This properly seats the collars on the taper of the inner ring and aligns the collars. 7. Using a torque wrench, tighten all locking screws gradually in either a clockwise or counterclockwise sequence (not in a diametrically opposite sequence). Continue tightening all of the screws until they reach 185±5 ft lb. 8. Make sure no screw turns any more. The gap between the tool joint collars should be as equal as possible all the way around. 9. Safety wire all screws.

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SM00856 Revision D Page B-18 of 28

PH-50 Pipe Handler

IBOP Stack Inspecting the Tool Joint Locks Tool Joint Lock to be Equally Spaced on Upper IBOP and Main Stem Joint Connection

1.4"

Tool Joint Shoulder

1.4"

Remove O-Ring and Look through this Space and Split on Inner Ring

Tapered Inner Ring Tool Joint Lock to be Offset on Upper and Lower IBOP Joint Connection Tool Joint 1.0" Shoulder

I.D. Groove First Line Up this Point with the Tool Joint Shoulder. Then Move Inner Ring Down 3/8" with the Outer Assembly. Replace O-Ring

Daily

1.4"

Tool Joint Shoulder

1.4"

Tool Joint Locks Inspect for loose bolts. Repair or replace if necessary. Torque to 1855 ft lb.

Tool Joint Lock to be Equally Spaced on Lower IBOP and Saver Sub Joint Connection

Removing the Tool Joint Locks  Gradually release the locking screws all the way around. Initially release each screw about a quarter of a turn, avoid tilting and jamming the collars. Do not remove the screws completely at this time, otherwise the collars may spring off.  Remove any rust formed or dirt collected adjacent to the tool joint lock. Once the screws are loose, remove the tool joint lock from the saver sub, IBOP valves, and main shaft.

Figure B-10. PH-50: Inspecting the Tool Joint Locks

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PH-50 Pipe Handler

B

IBOP Stack Inspecting IBOP Valves and Saver Subs

Close

Component

Replace when

Saver Sub

Threads have been recut to a minimum shoulder-to-shoulder length of 5 in.

Weekly

Daily

Upper IBOP (Remote) Inspect for damage

Valve Check for proper operation and pressure test for leaks

Weekly Open

IBOP Crank (Remote) Inspect for damage

Weekly

Daily

Lower IBOP (Manual) (Optional) Inspect for damage

Valve Check for proper operation and pressure test for leaks

5 Years Upper and Lower IBOP

Figure B-11. PH-50: Inspecting IBOP Valves and Saver Subs

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PH-50 Pipe Handler

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Shot Pin Assembly Disassembly/Assembly 1. Disconnect the hydraulic and electrical lines. 2. Remove the capscrews that attach the shot pin assembly to the main body. 3. Remove the capscrew and lockwasher holding the shot pin cover in place. 4. Remove the shot pin components as shown in Figure B-12 (end cap, o-rings, rod seal assembly, shot pin). 5. Inspect the shot pin bearing and press the bearing out of the shot pin mounting bracket if the bearing is scored or damaged. 6. Remove the capscrew and lockwasher that hold the pinion gear in place, and remove the gear. 7. Remove the capscrews and lockwashers that hold the hydraulic motor in place and remove the motor. Inspect the disassemble parts and replace any worn or damaged parts. Assemble the shot pin in the reverse order of disassembly.

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B

PH-50 Pipe Handler

Shot Pin Assembly Inspection

Weekly Shot Pin Assembly Check for leaks, tighten fittings

Shot Pin Base Dowel Pin Rod Seal Assembly

Monthly Shot Pin Check for wear, remove buurrs

Dual Port Manifold

Rod Seal Assembly Monthly Shot Pin Sleeve Check for wear Hydraulic Motor

O-ring Monthly Shot Pin Bushing Check for wear

Shot Pin Cap

Pinion Gear

Component

Replace when

Shot Pin

Outer diameter is less than 1.375 in.

Shot Pin Sleeve

Inner diameter is greater than 1.510 in.

Shot Pin Bushing

Inner diameter is greater than 1.475 in.

Shot Pin Cover

Figure B-12. PH-50: Inspecting the Shot Pin Assembly

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PH-50 Pipe Handler

Rotating Link Adapter/Load Stem Removing the Rotating Link Adapter (while the top drive is in the mast) 1. Drain the oil from the gearbox. 2. Disconnect and cap all tubing, remove the shot pin assembly and the landing collar. 3. Build a support over well center to support the weight of the link adapter. 4. Lower the top drive to the support built in Step 3. 5. Remove the bolts that attach the load stem to the main body. 6. Raise the top drive slowly to separate the link adapter from the main body. 7. Move the link adapter assembly to a clean, safe work area. 8. Orient the assembly with the stem flange up and block the entire assembly so that it is secure in this position.

Disassembling the Link Tilt Assembly 1. Attach a three-point sling to the stem and pull the stem out of the link adapter. 2. Turn the stem over and place it on its flange.

! Protect the internal surfaces of the rotating link adapter and the surfaces of the drive stem when separating the two components. When removing the rotating link adapter from the stem, carefully tap with a mallet. There can be misalignment between the two bores when raising the drive stem and gear assembly.

The piston ring is assembled with a light press fit. Provide a support under the gear so that it does not drop when it breaks loose.

3. Remove and discard all rotary seals, O-rings, thrust ring, and the wear bushings from inside the rotating link adapter and gear inside dimension. 4. Remove and discard the stem flange O-rings and stem bore shaft seals.

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B

PH-50 Pipe Handler

Rotating Link Adapter/Load Stem Inspecting the Rotating Link Adapter Eye Bolts

Rotary GLYD Ring (10 Places) Remove, discard and replace Yearly

Rotary GLYD Ring Remove, discard and replace Yearly Rotary Link Adaptor O-Ring Remove, discard and replace Yearly

Thrust Ring Remove, discard and replace

Retainer Ring

Yearly

Turcite Bushing Remove, discard and replace

O-Ring

Yearly

Rotary GLYD Ring Wiper Seal Yearly Piston Ring Inspect for pitting and chipped plating

Rotating Link Adapter Gear

Wear Allowances Component

Replace when

Thrust Ring

Thickness is less than 0.105 in.

Turcite Bushing

Thickness is less than 0.112 in.

Yearly Stem Inspect for pitting, grooves and chipped plating

Stem O-Ring Remove, discard and replace

Index Mark Indicates front of stem

Yearly

Level Work Surface

Figure B-13. PH-50: Inspecting the Rotating Link Adapter

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PH-50 Pipe Handler

Rotating Link Adapter/Load Stem Assembling the Link Adapter 1. Orient the stem so the drive stem flange is down on a suitably protected surface. 2. Install the gear with its rotating seal and wiper in place. 3. Install the O-ring for the piston ring. 4. Install the piston ring by tapping on it lightly with a mallet to press it into place (Heat to 220-250°). 5. Install the retainer ring. 6. Install all of the rotary seals on the rotating link adapter, and an O-ring on the top surface. 7. Install the two wear bushings and the thrust ring in the rotating link adapter. 8. Rest the rotating link adapter on its bottom surface. 9. Clean and then lubricate (with hydraulic oil) the sealing surface of the stem and the inside diameter of the rotating link adapter. 10. Attach three lifting slings symmetrically through the holes on the top of the stem flange and slowly lower the assembly into the rotating link adapter body. Hammering with a large plastic mallet is an aid when assembling the stem to the link adapter.

! Make sure the seals do not twist in the grooves.

11. Install the gear onto the link adapter and install the bolts. 12. Pressure test each port at 1,000 psi and inspect for leaks at the adjacent ports. 13. Grease all lubrication points on the assembly. 14. Inspect the lower gearbox seal (located inside the stem flange), and replace as necessary.

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PH-50 Pipe Handler

B

Rotating Link Adapter/Load Stem Installing the Rotating Link Adapter (while the top drive is in the mast) 1. Check the condition of the main shaft wear ring and replace if there is any evidence of grooving. 2. Place the rotating link adapter assembly back on the support built over well center, orienting the assembly so that the stem flange is up, and so that the index mark faces forward. 3. Carefully lower the top drive to engage the main shaft in the stem bore and then the stem flange pilot diameter is in the main body bore. 4. Install the flange bolts. 5. Install the link tilt cylinders, pin, and secure in place. 6. Install the link tilt crank and pin, and secure in place. 7. Install all hose assemblies. 8. Install tubing. 9. Install the shot pin assembly. 10. Fill the gearcase with gear oil (see Lubrication). 11. Check and fill the hydraulic oil as necessary. 12. Turn on the top drive and perform all pipe handler functions several times, checking for proper function and any leaks. 13. Re-check the hydraulic oil level and fill as necessary.

! Always install a new main shaft seal and use care not to damage the seal or the case.

A light coating of grease applied to the O-ring helps in installing the rotating link adapter assembly into the main body.

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PH-50 Pipe Handler

Wireline Adapter Inspection

i Inspect the condition of the sheaves before and after each use

Each Use Sheaves Replace or repair damaged parts as necessary

Figure B-14. PH-50: Inspecting the Wireline Adapter

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PH-50 Pipe Handler

Nondestructive Examination Yearly (or after approximately 3,000 operating hours), perform a Nondestructive Examination (NDE) of all critical load path items. NDE inspection includes visual examination, dye penetrant examination, magnetic particle inspection, ultrasonic inspection, x-ray examination, and other methods of nondestructive testing for metallurgical integrity.

Making Visual Inspections Use calipers on a regular basis to measure the amount of wear on the elevator link eyes. Compare the measurements with the information provided in the Links User Manual (D635000870) to determine the current strength of the elevator links. The capacity of the links equals the capacity of the weakest link.

Magnetic Particle Inspection (MPI) Every five years, NOV recommends that customers inspect all top drive hoisting equipment using the wet fluorescent method of Magnetic Particle Inspection (MPI). Refer to the documentation listed in the following section before beginning the MPI for any equipment component. Refer to the following standards that define the use of the wet fluorescent method of MPI when examining machined surfaces for any equipment component. 

ASTM A-275, Standard Method for Magnetic Particle Inspection of Steel Forgings



ASTM-E-709, Standard Recommended Practice for Magnetic Particle Inspection



I.A.D.C., Drilling Manual



API RP 8B, Recommended Practice for Procedures for Inspection, Maintenance, Repair and Remanufacture of Hoisting Equipment



API 8C, Specification for Drilling and Product Hoisting Equipment (provides MPI inspection acceptance criteria)

Any indications found are a potential cause for replacing one or more of the following: 

Main shaft (lower portion)



Bail



Split Load Collar



Upper and lower IBOP



Link adapter



Saver, crossover, and spacer subs



Power subs



Power swivels



Elevator links

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SM00856 Revision D Page B-28 of 28

Nondestructive Examination Magnetic Particle Inspection (MPI) The drilling operator may determine that the MPI schedule should occur more frequently, based on one or more of the following factors: 

environment



load cycles



regulatory requirements



operating time



testing



repairs

Please contact your NOV Service Center if you have any questions.

Ultrasonic Inspection In addition to the MPI, NOV also recommends performing an ultrasonic Inspection of the previously listed components to detect any erosion of the inside diameter. Any erosion reduces the load carrying capability of the part. Any subsurface irregularity can also compromise a component’s integrity. Details on Ultrasonic Inspection procedures are in the publication: ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy Steel Forgings

IBOP Inspection Upper and lower IBOP valves, because of their internal grooves and shoulders, are particularly susceptible to corrosion fatigue cracking. These internal diameter changes act as stress risers for bending and tensile loads. It is especially important to properly inspect the IBOP valves on a frequent basis.

Lubrication Refer to the section titled "Lubrication Schedules" on page 5-58 for pipe handler component lubrication schedules. Refer to Figure 5-36 on page 5-63 for general pipe handler lubrication procedures.

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FINAL DOCUMENTATION TDS-11SA - Top Drive Drilling System

Chapter 2.0 Service Manual, Washpipe Assembly

www.nov.com

WASHPIPE ASSEMBLY

Service Manual

SM01053 Revision A

© Copyright 2004 Varco® LP. All rights reserved. Varco® is a registred trademark of Varco I/P Reg. U.S. Patent & Trademark Office. This publication is the property of, and contains information proprietary to, Varco International, Inc. No part of this publication may be reproduced or copied in any form, or by any means, including electronic, mechanical, photocopying, recording, or otherwise without the prior written permission of Varco International, Inc. All product, brand, or trade names used in this publication are the trademarks or registered trademarks of their respective owners. Information in this manual is subject to change without notice.

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Intended Audience and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Washpipe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Washpipe Assembly Pressure Ratings . . . . . . . . . . . . . . . . . . . . . 10 General Maintenance Practices . . . . . . . . . . . . . . . . . . . . 11 Equipment Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . . 11 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Standard Washpipe Assembly . . . . . . . . . . . . . . . . . . . . . . 12 Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Hammerless Washpipe Assembly . . . . . . . . . . . . . . . . . . 36 Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Removing the Washpipe Assembly . . . . . . . . . . . . . . . . . . . . . . . 49 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Washpipe

3

4

Varco

General Information Intended Audience and Use This manual is intended for use by field engineering, installation, operation, and repair personnel. Every effort has been made to ensure the accuracy of the information contained herein. Varco International, Inc., will not be held liable for errors in this material, or for consequences arising from misuse of this material. This manual is intended as a supplement to the service manuals supplied with the Varco Top Drive System (TDS) and/or the Varco Integrated Drilling System (IDS).

Conventions Notes, Cautions, and Warnings Notes, cautions, and warnings are used throughout this manual to provide readers with additional information, and to advise the reader to take specific action to protect personnel from potential injury or lethal conditions. They may also inform the reader of actions necessary to prevent equipment damage. Please pay close attention to these advisories. Note:

i The note symbol indicates that additional information is provided about the current topics.

Caution:

! The caution symbol indicates that potential damage to equipment or injury to personnel exists. Follow instructions explicitly. Extreme care should be taken when performing operations or procedures preceded by this caution symbol.

Warning:

The warning symbol indicates a definite risk of equipment damage or danger to personnel. Failure to observe and follow proper procedures could result in serious or fatal injury to personnel, significant property loss, or significant equipment damage.

Illustrations Figures provide a graphical representation of equipment components or screen snapshots for use in identifying parts or establishing nomenclature, and may or may not be drawn to scale. For more specific component information pertinent to your rig configuration, see the technical drawings included with your Varco documentation.

Washpipe

5

Safety Requirements Varco equipment is installed and operated in a controlled drilling rig environment involving hazardous operations and situations. Proper service and repair is important for safe and reliable operation. Operation and service procedures provided by Varco manuals are the recommended methods of performing those operations.

! To avoid injury to personnel or equipment damage, carefully observe the following safety requirements.

Personnel Training All personnel performing installation, operations, repair, or maintenance procedures on the equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool operation, and maintenance to ensure their safety.

! During installation, maintenance, or repair of equipment, personnel should wear protective gear. Protective gear must be worn during certain operation.

Contact the Varco training department for more information about equipment operation and maintenance training.

Recommended Tools Service operations may require the use of tools designed specifically for the purpose being described. Varco recommends that only those tools specified be used when stated. Ensure that personnel and equipment safety are not jeopardized when using service procedures or tools not specifically recommended by Varco.

6

Varco

Safety Requirements General System Safety Practices The equipment discussed in this manual may require or contain one or more utilities, such as electrical, hydraulic, pneumatic, or cooling water.

! Before installing or performing maintenance or repairs on equipment, read the following instructions to avoid endangering exposed persons or damaging equipment.

‰

Isolate all energy sources before beginning work.

‰

Avoid performing maintenance or repairs while the equipment is in operation.

‰

Wear proper protective equipment during equipment installation, maintenance, or repair.

Replacing Components ‰

Verify that all components (such as cables, hoses, etc.) are tagged and labeled during disassembly and reassembly of equipment to ensure correct installment.

‰

Replace failed or damaged components with Varco certified parts. Failure to do so could result in equipment damage, or personal injury.

Routine Maintenance Equipment must be maintained on a regular and routine basis. See the service manual for maintenance recommendations.

! Failure to conduct routine maintenance could result in equipment damage or injury to personnel.

Proper Use of Equipment Varco equipment is designed for specific functions and applications, and should be used only for their intended purpose.

Washpipe

7

General Description Washpipe Assembly The washpipe assembly is located between the main shaft and the gooseneck (S-pipe) on the TDS/IDS, supported by a bonnet. The washpipe assembly allows for the rotation of the TSD/IDS drilling string. Two types of washpipe assemblies are available: standard and hammerless.

8

Varco

General Description Special Tools The standard washpipe assembly has hammer nuts on its washpipe nut and packing box. The hammer nuts are provided so that a special wrench and a hammer can be used to tighten to washpipe nut and packing box during installation. The hammerless washpipe assembly uses gear nuts which are tightened more precisely without a hammer but with a special torque wrench kit. This feature makes the unit easier to install by allowing the unit to swing in and out of its support bonnet before being torqued and does not require the use of a hammer.

Standard Washpipe

Standard Washpipe Wrench

Strike here

Hammerless Washpipe Torque Wrench 30-250 ft lb Hammerless Washpipe Torque Multiplier 3200 ft lb Removable extension not shown

Socket Adapter

Washpipe

9

Specifications Washpipe Assembly Pressure Ratings

i Assembly descriptions are repeated for similar units. Use the assembly part number when referencing pressure ratings.

Standard Washpipe Assembly Description

Part No.

Pressure Rating (psi)

Small Bore (3-inch)

30123290

7,500

Large Bore (4-inch)

30123440

7,500

Large-to-Small Bore

30153491-50

7,500

Hammerless Washpipe Assembly

10

Description

Part No.

Pressure Rating (psi)

Large Bore (4-inch)

30156883

7,500

Large-to-Small Bore

30173058-50

7,500

Varco

General Maintenance Practices Equipment Maintenance Records Keep a record book of all maintenance procedures performed. Date each procedure, followed by a description and the technician who performed it. This data is valuable for fault finding and problem solving, should technical problems arise.

i Procedures in this chapter relate to Varco only components. See the vendor manuals for maintenance procedures and schedules for the vendor equipment.

Maintenance Schedules Maintenance schedules list preventive maintenance tasks. Inspection schedules assume normal operating conditions. Some conditions (excessive loading, dusty or corrosive atmosphere, temperature extremes, etc.) may warrant more frequent inspection intervals. Perform the procedures indicated, as warranted by the inspection.

Safety Precautions Avoid equipment damage or injury to personnel by paying close attention to the important safety notes highlighted as Notes, Cautions, and Warnings used throughout this manual. To avoid serious injury or death, read and understand the following Warnings before performing maintenance or troubleshooting procedures:

Unless instructed otherwise, properly lock out the main power source before performing any maintenance procedure. Wear protective glasses to prevent eye injuries. Do not attempt any adjustments while the machine is moving. Read and understand all safety precautions and warnings before performing maintenance procedures.

Washpipe

11

Standard Washpipe Assembly Initial Installation Procedure 1. Install the washpipe assembly on the TDS/IDS and hand-tighten the washpipe nut and packing box, then back off the packing box and washpipe nut by 1/4 turn.

the packing box.

securely tighten.)

i

Nut

12

Varco

Standard Washpipe Assembly Initial Installation

Washpipe

13

Standard Washpipe Assembly Initial Installation Procedure 11. Check washpipe alignment. Install dial indicator base on packing box. Adjust dial indicator to contact the washpipe approximately one inch above the packing box. 12. Rotate main shaft through one revolution, noting the minimum and maximum readings on the dial indicator. Subtract the minimum reading from the maximum reading to obtain the Total Indicated Runout (TIR). Maximum allowable TIR is 0.007 inch.

Washpipe

Dial Indicator Packing Box

14

Varco

Standard Washpipe Assembly Maintenance Schedules Inspection Schedule Item

Inspect for

Interval

Mating surface of stem liner(s) while it is installed in the TDS/IDS main shaft or gooseneck

• Surface should be

TDS/IDS main shaft bearing endplay

Endplay is within specification (refer to TDS/IDS Service Manual)

Once every six months and immediately after jarring

Washpipe Assembly grease fitting

Proper operation

Replace every six months

Washpipe pilot on the gooseneck and the washpipe pilot on the TDS/ IDS main shaft

Proper alignment between pilots

After TDS/IDS main shaft bearing endplay has been checked and is within specification

All parts

Refer to Disassembly Procedure

Upon disassembly of washpipe assembly

smooth and free of flaws or burrs • ID of stem liners

When washpipe assembly is to be removed from TDS/ IDS

Cleaning Schedule Item TDS/IDS bonnet (inside)

Procedure Remove residual mud

Interval Weekly

Lubrication Schedule Item Washpipe Assembly grease fitting

Washpipe

Procedure Apply 3 to 4 pumps of grease (refer to Lubrication Procedure)

Interval Twice daily or every 10 rotating hours

15

Standard Washpipe Assembly Inspection Procedures When Washpipe is to be Removed from TDS/IDS

Service Limit (inches) 3.090 3.840 3.120

16

Varco

Standard Washpipe Assembly Inspection Procedures Every Six Months Procedure 1. Remove the washpipe assembly and replace the grease fitting. 2. Check the main shaft axial movement by applying an upward force to the main shaft and measuring the amount of axial movement with a dial indicator. 3. If axial shaft movement is not .001 in. to .003 in., remove the bearing retainer and adjust the number of shims under the bearing retainer as required to allow .001 in. to .003 in. of axial shaft movement (end play) with the bearing retainer capscrews tightened to the required torque depending on the size of the capscrew (refer to the Initial Installation Procedure for proper torque requirements).

Washpipe Grease Fitting Replace

Dial Indicator

Washpipe

17

Standard Washpipe Assembly Inspection Procedures Every Six Months

Gooseneck Pilot

Dial Indicator

0.002 TIR between these two surfaces

Bonnet removed for clarity.

Main Shaft Pilot

18

Varco

Standard Washpipe Assembly Lubrication Procedures Daily Lubrication

Description grease fitting.

Cyprina 2.

Washpipe

19

Standard Washpipe Assembly Troubleshooting

i The troubleshooting table does not necessarily cover all possible symptoms. The table provides an insight to typical symptoms, their possible causes, and what components to check.

Symptom Leakage at threads between packing box and TDS/IDS main shaft

Leakage at grease fitting access hole

20

Probable cause

Remedy

Poly Pak seal failure in main shaft stem liner

Replace seal by removing the stem liner and installing the new seal. Be sure to deburr the edges of the main shaft as sharp edges will cut the seal on installation. Reinstall the stem liner.

Lower O-ring failure

1. Remove washpipe assembly. 2. Inspect the main shaft and stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly.

Stem liner not smooth and does not allow O-ring to seal properly

Follow instructions outlined in the Inspection Procedures, When Washpipe Is To Be Removed From TDS/IDS.

Stem liner not flat and does not allow O-ring to seal properly

Follow instructions outlined in the Inspection Procedures, When Washpipe Is To Be Removed From TDS/IDS.

Spacers not flat and prevents packing seals from sealing between spacers proper

Follow inspection procedures as outlined in step 8 of the Disassembly Procedure.

Poly Pak seal failure in main shaft stem liner

Replace seal by removing the stem liner and installing the new seal. Be sure to deburr the edges of the main shaft as sharp edges will cut the seal on installation. Reinstall the stem liner.

Lower O-ring failure

1. Remove washpipe assembly. 2. Inspect the main shaft and stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly.

Varco

Standard Washpipe Assembly Troubleshooting Symptom

Remedy

Leakage through grease fitting access hole (cont)

Spacers not flat and prevents packing seals from sealing between spacers proper

Follow inspection procedures as outlined the Inspection Procedure.

Leakage at grease fitting

Grease fitting failure

Follow inspection procedures as outlined in step 12 of the Disassembly Procedure.

Leakage between the washpipe and the packing box

Packing failure

Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe.

Leakage between the washpipe and the washpipe nut

Packing failure or packing is improperly seated

Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe.

Upper O-ring failure

1. Remove washpipe assembly. and replace O-ring. 2. Inspect the gooseneck and, for big bore units with lined goosenecks, the stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly.

Upper O-ring failure Leakage at threads between washpipe nut and gooseneck

1. Remove washpipe assembly. and replace O-ring. 2. Inspect the gooseneck and, for big bore units with lined goosenecks, the stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly.

Premature failure after greasing

Washpipe

Probable cause

Packing failure or packing is improperly seated

Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe.

Improper greasing procedure

Greasing can cause the seal to unseat from the washpipe and cause premature failure of the assembly. Running the TDS/ IDS without standpipe pressure allows the seals to reseat. Follow greasing procedure as outlined in the Lubrication Procedures.

21

Standard Washpipe Assembly Troubleshooting Symptom

Probable cause

Remedy

Premature failure accompanied by occasional spurts of mud from packing box

Washpipe alignment caused by improper installation, or misalignment of the gooseneck, or excessive bearing endplay

If necessary, reinstall washpipe or realign the gooseneck. Check washpipe alignment as follows (see illustration on following page): 1. Install dial indicator base on packing box. Adjust dial indicator to contact the washpipe approximately one inch above the packing box. 2. Rotate main shaft through one revolution, noting the minimum and maximum readings on the dial indicator. Subtract the minimum reading from the maximum reading to obtain the Total Indicated Runout (TIR). Maximum allowable TIR is 0.007 inch. 3. If out of specification, check gooseneck alignment.

Premature failure accompanied by occasional spurts of mud from packing box

Misalignment of gooseneckto-washpipe pilot

Inspect main shaft and mainshaft-togooseneck alignment as described in the Every Six Months Inspection procedure.

Installation problems

The proper installation sequence allows the packing and washpipe to align to each other, and ensures that both the washpipe nut and the packing box engage their pilots. Follow proper installation procedures (refer to the Initial Installation Procedure).

Nut not torqued

Improper torque prevents metal-to-metal contact between the flat surfaces of the spacers. When pressure is applied, it will extrude the packing between the spacers. Follow proper torquing procedures as described in the Initial Installation Procedure.

Too mush grease during assembly of the unit

Too much grease prevents metal-to-metal contact between the flat surfaces of the spacers during operation. The grease can sustain a hydrostatic pressure that resists torque during the installation.

Premature failure due to flanged packing

During operation the grease gradually leaks out resulting in loosening of the packing box. Follow proper greasing procedure during reassembly and check for proper spacer contact during installation (refer to the Initial Installation Procedure).

22

Varco

Standard Washpipe Assembly Troubleshooting

Washpipe

Dial Indicator Packing Box

Washpipe

23

Standard Washpipe Assembly Troubleshooting Symptom Packing is worn out

Probable cause

Remedy

Poor greasing schedule or improper grease.

Follow proper lubrication procedures.

RPM, pressure and mud temperature too high

Friction between the seals and the washpipe create heat. TDS/IDS rpm and standpipe pressure contribute equally to the amount of heat generated. If pressure of rpm is increased, so is the amount of heat generated. Heat generation goes up with the square of the bore size. Mud is what cools the system. The hotter the mud, the less cooling it provides. The greater the amount of heat generated is relative to the amount of cooling the mud will provide, the hotter the seals run. As the seals run hotter, the wear resistance of the rubber drops. If using a large-bore washpipe, convert to a small-bore washpipe.

Spacers too flat

If the spaces are not flat, then metal-tometal contact cannot be maintained even when they are bottomed out against each other. The resulting small gaps will allow the packing to extrude into these areas. Follow instructions outlined in the Inspection Procedures.

Nut not torqued

Improper torque prevents metal-to-metal contact between the flat surfaces of the spacers. When pressure is applied, it will extrude the packing between the spacers. Follow proper torquing procedures as described in the Initial Installation Procedure.

Blue spacers

Improper torque or grease on the OD of the spacers

Improper torque on the nut can lead to situations where the lower and middle spacers spin the packing box. The resulting heat achieves temperatures high enough to turn the spacers blue.

Unable to maintain torque on packing box

Improper assembly or installation

1. Remove washpipe assembly from TDS/IDS. 2. Disassemble the washpipe assembly, setting aside the packing seals for the lower, middle, and upper spacers. 3. Reassemble the washpipe assembly without the packing seals for the lower, middle, and upper spacers.

Packing extruding between spacers

24

Varco

Standard Washpipe Assembly Troubleshooting Symptom Unable to maintain torque on packing box (cont)

Probable cause

Remedy 4. Reinstall the washpipe assembly on the TDS/IDS as follows: a. Install the packing box onto the TDS/ IDS main shaft. Tighten until spacers are firmly held. b. Install the holding ring into the washpipe nut and install washpipe nut onto the TDS/IDS goosneck until the holding ring is firmly in place. c. Using a dial indicator, measure and record the distance between the flat surfaces on the washpipe nut and the packing box. Also for future use, mark the location where the measurement is taken. NOTE To ensure that the washpipe assembly has been sufficient tightened, measure the distance with each subsequent installation of the washpipe assembly.

Washpipe

25

Standard Washpipe Assembly Disassembly Procedure

Snap Ring

1. Remove washpipe assembly from the TDS/IDS. 2. Completely disassemble the washpipe assembly. Take care to prevent damage to the sharp edge of the upper and middle spacers. 3. Dispose of packing, washpipe and O-rings. These parts are not serviceable and must be replaced.

Holding Ring

Washpipe Nut

O-Ring

Packing Box Grease Fitting

i Washpipe

Discard and replace these non-serviceable parts from the washpipe assembly. Upper Spacer

Packing Set (5 per Set)

Socket Head Dog Nose Screw

Middle Spacer

Middle Spacer

O-Ring

26

Varco

Standard Washpipe Assembly Disassembly Procedure 4. Thoroughly clean and inspect remainder of parts. 5. Check that the ID of each spacer is within specification. 6. Check that the flat portions of each spacer are free of burrs that could prevent the spacers from seating properly. Burrs should be lightly filed flush. If surfaces are out-of-flat, replace spacer. 7. The edge that directly backs up the packing should be free of cuts, nicks, and burrs. If edge is damaged replace spacer. This surface to be smooth and flat

ID This surface to be smooth and flat

This edge to be sharp

Spacer

Varco Part No.

Proper ID (inches)

Service Limit ID (inches)

Small Bore

Upper Middle Lower

123585 30123286 123287

3.635 to 3.640 3.635 to 3.640 3.635 to 3.640

3.645 3.645 3.645

Large Bore

Upper Middle Lower

30123434 30123435 30123436

4.895 to 4.900 4.895 to 4.900 4.895 to 4.900

4.905 4.905 4.905

Middle Spacer

Upper Middle Lower

123585 30123286 123287

3.635 to 3.640 3.635 to 3.640 3.635 to 3.640

3.645 3.645 3.645

Middle Spacer

Washpipe Assembly

Large to Small Bore

Washpipe

Upper Spacer

27

Standard Washpipe Assembly Disassembly Procedure 8. Check that the ID of the washpipe nut where the washpipe passes through. 9. Check that the ID of the packing box where the washpipe passes through.

Washpipe Nut

ID Packing Box

Washpipe Assembly

Washpipe Nut Part No.

Proper ID (inches)

Service Limit ID (inches)

Small Bore

123284

3.655 to 3.660

3.665

Large Bore

30123431

4.905 to 4.910

4.915

Large to Small Bore

30153493

3.655 to 3.660

3.665

Washpipe Assembly

Packing Box Part No.

Proper ID (inches)

Service Limit ID (inches)

Small Bore

30123563

3.637 to 3.644

Large Bore

30123626

4.900 to 4.905

Large to Small Bore

30153494

3.637 to 3.644

28

Varco

Standard Washpipe Assembly Disassembly Procedure 10. Inspect the holding ring drive dogs. Each dog has a slight undercut. If the undercut is no longer visible, replace the holding ring.

Holding Ring

This surface to be smooth and flat Undercut rease i

This surface to be smooth and flat 11. Check that the flat portions of the holding ring are free of burrs that could prevent the ring from seating properly. Burrs should be lightly filed flush. 12. Inspect the spring tension in the ball of the grease fitting. If the ball is not properly tensioned, replace the grease fitting. If in doubt, replace the grease fitting. Replace the grease fitting every six months or every other rebuild of the washpipe assembly, whichever period is longer, even if the grease fitting is working properly. 13. Reassemble the washpipe assembly as described in the Reassembly Procedure.

Washpipe

29

Standard Washpipe Assembly Reassembly Procedure 1. Apply a light grease film to the outside of each packing seal and fill the plunge with grease, flush with the packing. Packing Seal Fill with grease to level shown Spacer

2. Install one packing seal into each of the four spacers (one upper, two middle, one lower) that go into the packing box. Wipe all excess grease from the top edge of the packing and all excess grease from the spacers. Take care to prevent damage to the sharp edges of the spacers. Upper Spacer

Sharp edge of spacer Sharp edge of spacer Sharp edge of spacer

30

Wipe grease from area shown, all the way around on each spacer.

Middle Spacer

Middle Spacer

Varco

Standard Washpipe Assembly Reassembly Procedure 3. Install each spacer (with packing seals) in the proper sequence in the packing box. Handle each spacer from the ID to ensure that no grease gets between the metal portions of the spacer, or on the outside diameter of the spacer. When installing the upper spacer, line up the slot in the upper spacer with the dowel pin in the packing box. Dowel Pin

Grease Fitting

Socket Head Dog Nose Screw Packing Box

Ensure that the nose of the socket head dog nose screw is fully engaged in the groove of the lower spacer (screw should not push spacer off center) .010" Min

i In the following step, an Arbor press may be required to compress the packing enough to in stall the screws. 4. Install the socket head cap screws. The heads of the screws should bottom out in the nut casing. The dog head should not bottom out on the space er. The screw prevents the spacers from not otherwise constrain them. 5. packing box. 6. NOT OVER GREASE.

Washpipe

31

Standard Washpipe Assembly Reassembly Procedure 7. Lightly grease the washpipe, then install the washpipe into the packing box, with the slotted end of the washpipe up and the nonslotted end flush with the bottom edge of the packing box. 8. Install the washpipe nut onto the washpipe.

Washpipe Nut

Washpipe

Packing Box

32

Varco

Standard Washpipe Assembly Reassembly Procedure 9. Lightly grease the packing seal, fill the plunge with grease, and install in the holding ring, taking care to not damage the seal on the splines of the washpipe. Wipe all excess grease from the top edge of the packing and wipe all grease from the holding ring.

Holding Ring Wipe grease from area shown, all the way around the holding ring.

Packing Seal

Fill with grease to level shown.

Holding Ring

10. Insert the holding ring and packing, seal side down, over the slotted end of the washpipe. 11. Install the snap ring. 12. Install the upper and lower O-rings. Apply a light coat of grease to the O-rings.

Packing Seal

Snap Ring O-ring

13. approximately the length of the washpip pe. 14. Initial Installation Procedure.

Washpipe

33

Standard Washpipe Assembly Illustrated Parts List O-Ring Snap Ring

Holding Ring Upper Spacer Packing Set 5 per set

Washpipe Nut Middle Spacer

Middle Spacer Washpipe

Lower Spacer

Packing Box O-Ring

Grease Fitting Socket Head Dog Nose Screw

Long-Arm Allen Wrench

34

Varco

Standard Washpipe Assembly Illustrated Parts List

Washpipe

Description

Small Bore (3-inch)

Large Bore (4-inch)

Large-to-Small Bore

Washpipe Assembly

30123290

30123440

30153491

O-Ring

51300-348-F

51300-359-F

51300-348-F

Snap Ring

30123562

123634

30123562

Holding Ring

30123288

30123437

30123288

Washpipe Nut

123284

30123431

30153493

Washpipe

30123289 (7,500 psi)

30123438 (7,500 psi)

30123289 (7,500 psi)

Packing Box

30123563

30123626

30153494

Grease Fitting

53219-1

53219-1

53219-1

Socket Head Screw

30123564

30123564

30123564

Upper Spacer

123585

30123434

123585

Middle Spacer

30123286

30123435

30123286

Lower Spacer

123287

30123436

123287

Pressure Seal Kit (Packing Set)

30123290-PK

30123440-PK

30123290-PK

Stem Liners

98290

112871

30153492

Poly Pak Seal

98291

112895

112895

Grease

56005-1

56005-1

56005-1

35

Hammerless Washpipe Assembly Initial Installation Procedure

i During installation the washpipe assembly is brought into place as one unit and handled by a tugger line. Ensure that the washpipe assembly is strapped together securely before lifting.

1. Unlock the TDS/IDS handling yoke from its stored position and swing it out to accept the washpipe assembly.

Makes the washpipe assembly easier to install by allowing it to swing in and out of the motorsupport bonnet.

i

Nut

Yoke

36

2 places

Varco

Hammerless Washpipe Assembly Initial Installation Procedure

the TDS/IDS main shaft. 4. it until it makes contact with the top of the main shaft. 5. packing box and the washpipe nuts. 6. Apply pipe dope to the threads and hand-tighten the washpipe nut and packing box. 7. align the pipe in the packing box. 8. Set the TDS/IDS brake.

Torque Multiplier Ratio – 18.5 to 1 Removable extension

Torque Wrench

9. Loosen the thumb screw on the pinion gear and raise the pinion gear from its stored position and lock the thumb screw in place when it aligns with the gear on the packing box. It may be necessary to rotate the square drive shaft to engage the gears. 10. Install the torque kit assembly over the square shaft. Set the torque wrench to 100 ft-lb and begin applying torque to the packing box gradually until the torque wrench clicks. Torque Wrench Setting-ft.-lbf. 75 100 125 150

Applied Torque to Nut-ft.-lbf. 4,500 6,000 7,500 9,000

11. Disengage the pinion gear from the packing box gear and engage it with the washpipe nut gear and secure it in place. Similarly, apply torque to the washpipe nut, completing the installation of the washpipe assembly. 12. Apply 6 to 8 pumps of grease to the grease fittings. 13. Return the pinion gear to its stored position and secure it with the thumb screw. Secure the handling yoke to its stored position by pinning it with the two pins. 14. Release the TDS/IDS brake and rotate the TDS/IDS at approximately 50 rpm for one minute.

Washpipe

37

Hammerless Washpipe Assembly Maintenance Schedules Inspection Schedule Inspect for

Item

Interval

Mating surface of stem liner(s) while it is installed in the TDS/IDS main shaft or gooseneck

• Surface should be

TDS/IDS main shaft bearing endplay

Endplay is within specification (refer to TDS/IDS Service Manual)

Once every six months and immediately after jarring

Washpipe Assembly grease fitting

Proper operation

Replace every six months

Washpipe pilot on the gooseneck and the washpipe pilot on the TDS/ IDS main shaft

Proper alignment between pilots

After TDS/IDS main shaft bearing endplay has been checked and is within specification

All parts

Refer to Disassembly Procedure

Upon disassembly of washpipe assembly

smooth and free of flaws or burrs • ID of stem liners

When washpipe assembly is to be removed from TDS/ IDS

Cleaning Schedule Procedure

Item TDS bonnet (inside)

Remove residual mud

Interval Weekly

Lubrication Schedule Procedure

Item Washpipe Assembly grease fitting

Apply 3 to 4 pumps of grease

Interval Twice daily or every 10 rotating hours

! To prevent rust from damaging parts, properly clean and grease the following parts before storage: 1. Jacking nut and shaft threads 2. Square shaft from top to bottom 3. Gear teeth on all three gears

38

Varco

Hammerless Washpipe Assembly Inspection Procedures Every Six Months Washpipe Assembly Alignment Satisfactory packing life depends on good washpipe alignment. Use the following procedure to check sleeve-to-gooseneck support alignment: 1. Attach an indicator base to the gooseneck support and place the indicator at the top of the sleeve. 2. Raise and lower the sleeve and record the total indicator reading. 3. Attach a magnetic indicator base or an improvised holding fixture to the sleeve or packing box. 4. Rotate the sleeve 360° and record the TIR. Washpipe Assembly Tolerances Use the following procedure to check washpipe assembly tolerances: 1. Shim the gooseneck support to obtain a required bearing clearance of 0.001 to 0.003 inch. 2. Check the clearance by raising and lowering the sleeve. The maximum allowable misalignment at the gooseneck support bore is 0.008 inch TIR. The maximum allowable misalignment at the gooseneck pilot is 0.010 inch TIR. The maximum allowable misalignment after complete assembly of the washpipe assembly is 0.010 inch TIR.

i Inspection may indicate misalignment exceeding recommended limits. The packing box assemblies are designed to accommodate misalignment of the sleeve to the gooseneck and can operate with some excessive misalignment. However, to achieve maximum packing life, maintain the misalignment at the washpipe within the recommended limits.

Washpipe

39

Hammerless Washpipe Assembly Inspection Procedures Every Six Months Procedure 1. Remove the washpipe assembly and replace the grease fitting. 2. Check the mainshaft axial movement by applying an upward force to the mainshaft and measuring the amount of axial movement with a dial indicator. 3. If axial shaft movement is not .001 in. to .003 in., remove the bearing retainer and adjust the number of shims under the bearing retainer as required to allow .001 in. to .003 in. of axial shaft movement (end play) with the bearing retainer capscrews tightened to the required torque depending on the size of the capscrew (refer to the Initial Installation Procedure for proper torque requirements).

Washpipe Grease Fitting Replace

Dial Indicator

40

Varco

Hammerless Washpipe Assembly Inspection Procedures Every Six Months

Gooseneck Pilot

Dial Indicator

0.002 TIR between these two surfaces

Bonnet removed for clarity.

Main Shaft Pilot

Washpipe

41

Hammerless Washpipe Assembly Lubrication Procedures Daily Lubrication Recommended Grease

42

Manufacturer

Description

Shell

Cyprina

Procedure 1. Twice daily or once every 10 hours of rotation, apply 3 to 4 pumps of grease to the washpipe grease fitting. 2. Rotate the TDS/IDS at 50 rpm for one minute with 0 psi standpipe pressure. 3. Turn on the mud pumps and check for leaks.

Varco

Hammerless Washpipe Assembly Troubleshooting

i The troubleshooting table does not necessarily cover all possible symptoms. The table provides an insight to typical symptoms, their possible causes, and what components to check.

Symptom Leakage at threads between packing box and TDS/IDS main shaft

Leakage at grease fitting access hole

Washpipe

Probable cause

Remedy

Poly Pak seal failure in main shaft stem liner

Replace seal by removing the stem liner and installing the new seal. Be sure to deburr the edges of the main shaft as sharp edges will cut the seal on installation. Reinstall the stem liner.

Lower O-ring failure

1. Remove washpipe assembly. 2. Inspect the main shaft and stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly.

Stem liner not smooth and does not allow O-ring to seal properly

Follow instructions outlined in the Inspection Procedures, When Washpipe Is To Be Removed From TDS/IDS.

Stem liner not flat and does not allow O-ring to seal properly

Follow instructions outlined in the Inspection Procedures, When Washpipe Is To Be Removed From TDS/IDS.

Spacers not flat and prevents packing seals from sealing between spacers proper

Follow inspection procedures as outlined in step 8 of the Disassembly Procedure.

Poly Pak seal failure in main shaft stem liner

Replace seal by removing the stem liner and installing the new seal. Be sure to deburr the edges of the main shaft as sharp edges will cut the seal on installation. Reinstall the stem liner.

Lower O-ring failure

1. Remove washpipe assembly. 2. Inspect the main shaft and stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly.

43

Hammerless Washpipe Assembly Troubleshooting Symptom

Probable cause

Remedy

Leakage through grease fitting access hole (cont)

Spacers not flat and prevents packing seals from sealing between spacers proper

Follow inspection procedures as outlined the Inspection Procedure.

Leakage at grease fitting

Grease fitting failure

Follow inspection procedures as outlined in step 12 of the Disassembly Procedure.

Leakage between the washpipe and the packing box

Packing failure

Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe.

Leakage between the washpipe and the washpipe nut

Packing failure or packing is improperly seated

Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe.

Upper O-ring failure

1. Remove washpipe assembly. and replace O-ring. 2. Inspect the gooseneck and, for big bore units with lined goosenecks, the stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly.

Upper O-ring failure Leakage at threads between washpipe nut and gooseneck

1. Remove washpipe assembly. and replace O-ring. 2. Inspect the gooseneck and, for big bore units with lined goosenecks, the stem liner for any burrs that can damage the O-ring and deburr as required. The surface of the stem liner should be smooth and flat. If it is not, replace stem liner. 3. Replace the O-ring and reinstall the washpipe assembly.

Premature failure after greasing

44

Packing failure or packing is improperly seated

Disassemble and inspect components. Replace worn or damaged components on reassembly of the washpipe.

Improper greasing procedure

Greasing can cause the seal to unseat from the washpipe and cause premature failure of the assembly. Running the TDS/ IDS without standpipe pressure allows the seals to reseat. Follow greasing procedure as outlined in the Lubrication Procedures.

Varco

Hammerless Washpipe Assembly Troubleshooting Symptom

Probable cause

Remedy

Premature failure accompanied by occasional spurts of mud from packing box

Washpipe alignment caused by improper installation, or misalignment of the gooseneck, or excessive bearing endplay

If necessary, reinstall washpipe or realign the gooseneck. Check washpipe alignment as follows (see illustration on following page): 1. Install dial indicator base on packing box. Adjust dial indicator to contact the washpipe approximately one inch above the packing box. 2. Rotate main shaft through one revolution, noting the minimum and maximum readings on the dial indicator. Subtract the minimum reading from the maximum reading to obtain the Total Indicated Runout (TIR). Maximum allowable TIR is 0.007 inch. 3. If out of specification, check gooseneck alignment.

Premature failure accompanied by occasional spurts of mud from packing box

Misalignment of gooseneckto-washpipe pilot

Inspect main shaft and mainshaft-togooseneck alignment as described in the Every Six Months Inspection procedure.

Installation problems

The proper installation sequence allows the packing and washpipe to align to each other, and ensures that both the washpipe nut and the packing box engage their pilots. Follow proper installation procedures (refer to the Initial Installation Procedure).

Nut not torqued

Improper torque prevents metal-to-metal contact between the flat surfaces of the spacers. When pressure is applied, it will extrude the packing between the spacers. Follow proper torquing procedures as described in the Initial Installation Procedure.

Too mush grease during assembly of the unit

Too much grease prevents metal-to-metal contact between the flat surfaces of the spacers during operation. The grease can sustain a hydrostatic pressure that resists torque during the installation.

Premature failure due to flanged packing

During operation the grease gradually leaks out resulting in loosening of the packing box. Follow proper greasing procedure during reassembly and check for proper spacer contact during installation (refer to the Initial Installation Procedure).

Washpipe

45

Hammerless Washpipe Assembly Troubleshooting

Washpipe

Dial Indicator Packing Box

46

Varco

Hammerless Washpipe Assembly Troubleshooting Symptom Packing is worn out

Remedy

Poor greasing schedule or improper grease.

Follow proper lubrication procedures.

RPM, pressure and mud temperature too high

Friction between the seals and the washpipe create heat. TDS/IDS rpm and standpipe pressure contribute equally to the amount of heat generated. If pressure of rpm is increased, so is the amount of heat generated. Heat generation goes up with the square of the bore size. Mud is what cools the system. The hotter the mud, the less cooling it provides. The greater the amount of heat generated is relative to the amount of cooling the mud will provide, the hotter the seals run. As the seals run hotter, the wear resistance of the rubber drops. If using a large-bore washpipe, convert to a small-bore washpipe.

Spacers too flat

If the spaces are not flat, then metal-tometal contact cannot be maintained even when they are bottomed out against each other. The resulting small gaps will allow the packing to extrude into these areas. Follow instructions outlined in the Inspection Procedures.

Nut not torqued

Improper torque prevents metal-to-metal contact between the flat surfaces of the spacers. When pressure is applied, it will extrude the packing between the spacers. Follow proper torquing procedures as described in the Initial Installation Procedure.

Blue spacers

Improper torque or grease on the OD of the spacers

Improper torque on the nut can lead to situations where the lower and middle spacers spin the packing box. The resulting heat achieves temperatures high enough to turn the spacers blue.

Unable to maintain torque on packing box

Improper assembly or installation

1. Remove washpipe assembly from TDS/IDS. 2. Disassemble the washpipe assembly, setting aside the packing seals for the lower, middle, and upper spacers. 3. Reassemble the washpipe assembly without the packing seals for the lower, middle, and upper spacers.

Packing extruding between spacers

Washpipe

Probable cause

47

Hammerless Washpipe Assembly Troubleshooting Symptom Unable to maintain torque on packing box (cont)

Probable cause

Remedy 4. Reinstall the washpipe assembly on the TDS/IDS as follows: a. Install the packing box onto the TDS/ IDS main shaft. Tighten until spacers are firmly held. b. Install the holding ring into the washpipe nut and install washpipe nut onto the TDS/IDS goosneck until the holding ring is firmly in place. c. Using a dial indicator, measure and record the distance between the flat surfaces on the washpipe nut and the packing box. Also for future use, mark the location where the measurement is taken. NOTE To ensure that the washpipe assembly has been sufficient tightened, measure the distance with each subsequent installation of the washpipe assembly.

48

Varco

Hammerless Washpipe Assembly Removing the Washpipe Assembly Remove the washpipe assembly by reversing the Installation Procedure.

! Once the packing box and washpipe nuts are unscrewed, the assembly must be strapped together as one unit before it is picked up by the handling yoke.

i The hammerless washpipe assembly must always be handled as one unit. Avoid disassembly unless you suspect faulty parts (refer to Troubleshooting).

Washpipe

49

Hammerless Washpipe Assembly Disassembly Procedure

Snap Ring

1. Remove washpipe assembly from the TDS/IDS. 2. Completely disassemble the washpipe assembly. Take care to prevent damage to the sharp edge of the upper and middle spacers. 3. Dispose of packing, washpipe and O-rings. These parts are not serviceable and must be replaced.

Holding Ring

Washpipe Nut

O-Ring

Packing Box

i Washpipe

Discard and replace these non-serviceable parts from the washpipe assembly.

Grease Fitting Socket Head Dog Nose Screw Upper Spacer

Packing Set (5 per Set)

Middle Spacer

Middle Spacer

O-Ring

50

Varco

Hammerless Washpipe Assembly Disassembly Procedure 4. Thoroughly clean and inspect remainder of parts. 5. Check that the ID of each spacer is within specification. 6. Check that the flat portions of each spacer are free of burrs that could prevent the spacers from seating properly. Burrs should be lightly filed flush. If surfaces are out-of-flat, replace spacer. 7. The edge that directly backs up the packing should be free of cuts, nicks, and burrs. If edge is damaged replace spacer. This surface to be smooth and flat

ID This surface to be smooth and flat

This edge to be sharp

Spacer

Varco Part No.

Proper ID (inches)

Service Limit ID (inches)

Large Bore

Upper Middle Lower

30123434 30123435 30123436

4.895 to 4.900 4.895 to 4.900 4.895 to 4.900

4.905 4.905 4.905

Large to Small Bore

Upper Middle Lower

123585 30123286 123287

3.635 to 3.640 3.635 to 3.640 3.635 to 3.640

3.645 3.645 3.645

Washpipe Assembly

Washpipe

Upper Spacer

Middle Spacer

51

Hammerless Washpipe Assembly Disassembly Procedure 8. Check that the ID of the washpipe nut where the washpipe passes through. 9. Check that the ID of the packing box where the washpipe passes through. hpipe ut

ID Packing Box

Washpipe Assembly

Washpipe Nut Part No.

Proper ID (inches)

Service Limit ID (inches)

Large Bore

30123431

4.905 to 4.910

4.915

Large to Small Bore

30153493

3.655 to 3.660

3.665

Washpipe Assembly

Packing Box Part No.

Proper ID (inches)

Service Limit ID (inches)

Large Bore

30123626

4.900 to 4.905

Large to Small Bore

30153494

3.637 to 3.644

52

3 650

Varco

Hammerless Washpipe Assembly Disassembly Procedure 10. Inspect the holding ring drive dogs. Each dog has a slight undercut. If the undercut is no longer visible, replace the holding ring.

Holding Ring

This surface to be smooth and flat Undercut Grea Fitti

This surface to be smooth and flat 11. Check that the flat portions of the holding ring are free of burrs that could prevent the ring from seating properly. Burrs should be lightly filed flush. 12. Inspect the spring tension in the ball of the grease fitting. If the ball is not properly tensioned, replace the grease fitting. If in doubt, replace the grease fitting. Replace the grease fitting every six months or every other rebuild of the washpipe assembly, whichever period is longer, even if the grease fitting is working properly. 13. Reassemble the washpipe assembly as described in the Reassembly Procedure.

Washpipe

53

Hammerless Washpipe Assembly Reassembly Procedure 1. Apply a light grease film to the outside of each packing seal and fill the plunge with grease, flush with the packing. Packing Seal Fill with grease to level shown Spacer

2. Install one packing seal into each of the four spacers (one upper, two middle, one lower) that go into the packing box. Wipe all excess grease from the top edge of the packing and all excess grease from the spacers. Take care to prevent damage to the sharp edges of the spacers. Upper Spacer

Sharp edge of spacer Sharp edge of spacer

Wipe grease from area shown, all the way around on each spacer.

Middle Spacer

Sharp edge of spacer

54

Varco

Hammerless Washpipe Assembly Reassembly Procedure 3. Install each spacer (with packing seals) in the proper sequence in the packing box. Handle each spacer from the ID to ensure that no grease gets between the metal portions of the spacer, or on the outside diameter of the spacer. When installing the upper spacer, line up the slot in the upper spacer with the dowel pin in the packing box. Dowel Pin

Grease Fitting

Socket Head Dog Nose Screw

Packing Box

Ensure that the nose of the socket head dog nose screw is fully engaged in the groove of the lower spacer (screw should not push spacer off center) .010" Min

i In the following step, an Arbor press may be required to compress the packing enough to in stall the screws. 4. Install the socket head cap screws. The heads of the screws should bottom out in the nut casing. The dog head should not bottom out on the space er. The screw prevents the spacers from not otherwise constrain them. 5. packing box. 6. NOT OVER GREASE.

Washpipe

55

Hammerless Washpipe Assembly Reassembly Procedure 7. Lightly grease the washpipe, then install the washpipe into the packing box, with the slotted end of the washpipe up and the nonslotted end flush with the bottom edge of the packing box. 8. Install the washpipe nut onto the washpipe. Washpipe Nut

Washpipe

Packing Box

56

Varco

Hammerless Washpipe Assembly Reassembly Procedure 9. Lightly grease the packing seal, fill the plunge with grease, and install in the holding ring, taking care to not damage the seal on the splines of the washpipe. Wipe all excess grease from the top edge of the packing and wipe all grease from the holding ring.

Holding Ring Wipe grease from area shown, all the way around the holding ring.

Packing Seal

Fill with grease to level shown.

Holding Ring

10. Insert the holding ring and packing, seal side down, over the slotted end of the washpipe. 11. Install the snap ring. 12. Install the upper and lower O-rings. Apply a light coat of grease to the O-rings.

Packing Seal

Snap Ring O-ring

13. approximately the length of the washpip pe. 14. Initial Installation Procedure.

Washpipe

57

Hammerless Washpipe Assembly Illustrated Parts List O-Ring Snap Ring

Holding Ring Upper Spacer Packing Set 5 per set

Washpipe Nut Middle Spacer

Middle Spacer

Washpipe

Lower Spacer

Packing Box O-Ring

Grease Fitting

Socket Head Dog Nose Screw Long-Arm Allen Wrench

58

Varco

Hammerless Washpipe Assembly Illustrated Parts List Description

Washpipe

Large Bore (4-inch)

Large-to-Small Bore

Washpipe Assembly

30156883 & 30156883-750

30173058-50 & 30173058-100

O-Ring

51300-359-F

51300-348-F

Snap Ring

123634

30123562

Holding Ring

30123437

30123288

Washpipe Nut

30152547

30173057

Washpipe - Low Pressure

30123438 (7,500 psi)

30123289 (7,500 psi)

Washpipe - High Pressure

30123438-TC (7,500 psi)

30123289-TC (10,000 psi)

Packing Box

30156884

30173056

Grease Fitting

53219-1

53219-1

Socket Head Screw

30123564

30123564

Upper Spacer

30123434

123585

Middle Spacer

30123435

30123286

Lower Spacer

30123436

30123287

Pressure Seal Kit (Packing Set)

30123584-2 (7,500 psi)

123292-2 (7,500 psi)

Stem Liner

112871

30153492

Poly Pak Seal

112895

112895

Grease

56005-1

56005-1

59

Glossary ID - Inner Diameter IDS - Integrated Drilling System OD - Outer Diamaeter TDS - Top Drive System TIR - Total Indicator Reading

60

Varco

FINAL DOCUMENTATION TDS-11SA - Top Drive Drilling System

Chapter 3.0 Links User Manual

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LINKS USER’S MANUAL

Weldless Links Perfection Links

Original Instructions REFERENCE Links

REFERENCE DESCRIPTION Weldless Links and Perfection Links

This document contains proprietary and confidential information which is the property of National Oilwell Varco, L.p, its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use of this design or distribution of this information to others is not permitted without the express written consent of NOV. This document is to be returned to NOV upon request or upon completion of the use for which it was loaned. This document and the information contained and represented herein is the copyrighted property of NOV. DOCUMENT NUMBER

50000870-MAN-001

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VarcoBJ BV Nijverheidsweg 45 4879 AP Etten-Leur P.O. Box 17 4870 AA Etten-Leur The Netherlands Tel + 31-76-5083000 Fax + 31-76-5046000 www.nov.com REV

E Nov 2011

User’s Manual Weldless Links Perfection Links

REFERENCE Link

REFERENCE DESCRIPTION Links

This document contains proprietary and confidential information which is the property of National Oilwell Varco, L.p., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use of this design or distribution of this information to others is not permitted without the express written consent of NOV. This document is to be returned to NOV upon request or upon completion of the use for which it was loaned. This document and the information contained and represented herein is the copyrighted property of NOV.

DOCUMENT NUMBER

50000870-MAN-001

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VarcoBJ B.V. Nijverheidsweg 45 4879AP Etten-Leur Tel: +31-76-5083000 Fax: +31-76-5046000 REV

E

Document number Revision Page

50000870-MAN-001 E 2 of 20

Revision History Revision

Change Description

-

First Issue

A

New style

B

Corrections

C

Corrections

D

Info added

E

Corrections

This document is PDM-link controlled

Change Description E

21.11.2011

Corrected link compatibility

E

21.11.2011

Added information about allowable twist & wear data

D

01.06.2009

Added Link connectors info

C

18.05.2009

Added wear size Perfection links

B

28.10.2008

Added Link connector info

B

30.06.2008

Page 14: The SLX 5.1/2” - 24.1/2” link DOES fit in 500 tons 3.1/2” links, pn 25469

A

26.03.2007

Data updated; part numbers, inspection,handle

-

12.03.2007

Issued for Implementation

Rev

Date

Reason for issue

© Copyright 2011 NOV®. All rights reserved. Varco is a registered trademark of Varco I/P reg. U.S. Patent & Trademark Office. This publication is the property of, and contains information proprietary to NOV. No part of this publication may be reproduced or copied in any form, or by any means, including electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of NOV®. All product, brand, or trade names used in this publication are the trademarks or registered trademarks of their respective owners. Information in this manual is subject to change without notice. Patents Pending US & Worldwide (D) Varco I/P, Inc. No US. D533,432.

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Table of Contents General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Link restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Design safety factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Safe Working Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Limited warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Identification numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Weldless Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Perfection Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Intended usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Reference Numbers* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Perfection links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Link handle kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Elevator link compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Link connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Inspection & wear data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Wear chart shaft (shank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Wear chart forged links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Wear data Perfection links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 MPI and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Qualifications and certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Evaluation of indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Acceptance criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Equipment covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Table of Contents

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1: General Information

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50000870-MAN-001 E 5 of 20

General Information This manual contains installation, operation, maintenance and parts information. Information in this manual should enable qualified personnel to install, operate and troubleshoot this system. Every effort has been made to ensure the accuracy of the information contained herein. National Oilwell Varco (NOV) will not be held liable for errors in this material, or for consequences arising from misuse of this material.

Conventions Notes, Cautions, and Warnings Notes, cautions, and warnings provide readers with additional information and advise the reader to take specific action to protect personnel from potential injury or lethal conditions. They may also inform the reader of actions necessary to prevent equipment damage. Please pay close attention to these advisories Note:

The note symbol indicates that additional information is provided about the current topics.

Caution:

The caution symbol indicates that potential damage to equipment or injury to personnel exists. Follow instructions explicitly. Extreme care should be taken when performing operations or procedures preceded by this caution symbol.

Warning:

The warning symbol indicates a definite risk of equipment damage or danger to personnel. Failure to observe and follow proper procedures could result in serious or fatal injury to personnel, significant property loss, or significant equipment damage.

Illustrations Illustrations (figures) provide a graphical representation of equipment components or screen snapshots for use in identifying parts or establishing nomenclature, and may or may not be drawn to scale. For component information specific to your application, see the technical drawings included with your NOV documentation.

Safety Requirements NOV equipment is installed and operated in a controlled drilling rig environment involving hazardous situations. Proper maintenance is important for safe and reliable operation. Procedures outlined in NOV manuals are the recommended methods of performing operations and maintenance. Caution: To avoid injury to personnel or equipment damage, carefully observe requirements outlined in this section.

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1: General Information

Personnel Training All personnel performing installation, operations, repair, or maintenance procedures on the equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool operation, and maintenance to ensure their safety. Caution: Personnel should wear protective gear during installation, maintenance, and certain operations.

Recommended Tools Service operations may require the use of tools designed specifically for the purpose described. NOV recommends that only those tools specified be used when stated. Ensure that personnel and equipment safety are not jeopardized when following service procedures or using tools not specifically recommended by NOV.

General System Safety Practices The equipment discussed in this manual may require or contain one or more utilities, such as electrical, hydraulic, pneumatic, or cooling water. Caution: Read and follow the guidelines below before installing equipment or performing maintenance to avoid endangering exposed persons or damaging equipment. 

Isolate energy sources before beginning work.



Avoid performing maintenance or repairs while the equipment is in operation.



Wear proper protective equipment during equipment installation, maintenance, or repair.

Replacing Components 

Verify that all components (such as cables, hoses, etc.) are tagged and labeled during assembly and disassembly of equipment to ensure correct installment.



Replace failed or damaged components with genuine NOV parts. Failure to do so could result in equipment damage or injury to personnel.

Routine Maintenance Equipment must be maintained on a routine basis. See the service manual for maintenance recommendations. Caution: Failure to conduct routine maintenance could result in equipment damage or injury to personnel.

Proper Use of Equipment NOV equipment is designed for specific functions and applications, and should be used only for its intended purpose.

Lifting The lifting procedures should carefully be observed and carried out according to the manual.

Link restrictions The Link is designed to be used as an connecting element between Top Drive Systems and elevators, or between Hooks and elevators, and must not be used for any other purpose.

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1: General Information

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50000870-MAN-001 E 7 of 20

Design safety factor The design-safety factor and design verification of the links is in accordance with requirements of API specification 8A, 8C PSL 1 or 8C PSL2. During manufacturing the link is proof load tested to 1.5 times the rated load.

Safe Working Load Per API Specification 8C – The operator of the equipment shall be responsible for determination of the safe working load for any hoisting operation. The Safe working load is equal to the design load minus the dynamic load.

Limited warranty The warranty will be void if the Link were either: 

unauthorized modified, repaired or serviced



replacement parts not manufactured by NOV were utilized



not properly stored or maintained



any welding is carried out

Identification numbers You will find the serial number of the tool stamped into the shank near the small eye.

CE marking The link complies with the Machinery Directive 98/37/EC and 2006/42/EC The marking is as follows:

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1: General Information

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2: Specifications

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General specifications Description Weldless Links Weldless links are forged from a single billet of high strength alloy steal and heat treated to provide maximum strength and toughness. Additional material is added in critical wear areas for extended life. NOV Weldless Links are available in 250, 350, 500, 750, and 1000 ton ratings.

Perfection Links Dependable, efficient perfection links are designed for light loads. They are made by forging, bending and electric welding of high quality steel bar stock, which is then heat-treated and magnafluxed. For loads which exceed capacity ratings of perfection links Varco BJ Weldless links are recommended.

Intended usage The links are designed to hang elevators from Top Drive Systems, Hooks, Beckets and Link Adapters.

Fig. 1

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2: Specifications

Part No.

Nominal link Size, in (mm) size (inch)

Rated Capacity /Set, Weight/Set, tons (tonnes) lb (Kg)

16363-1060 16363-1072 16363-1084 16363-1096 16363-1108 16363-1132 16363-1168 26940-1060 26940-1072 26940-1084 26940-1096 26940-1108 26940-1120 26940-1132 26940-1144 26940-1150 26940-1168 26940-1180 26940-1192 26940-1200 26940-1216 26940-1240 26940-1264 26940-1290 26940-1350 26940-1360 26940-1480 26940-1540 26940-1600 25469-1072 25469-1096 25469-1108 25469-1120 25469-1132 25469-1144 25469-1160 25469-1168 25469-1180 25469-1190 25469-1192 25469-1216 25469-1226 25469-1264 25469-1360 25469-1480 25469-1540

2.1/4 x 60 2.1/4 x 72 2.1/4 x 84 2.1/4 x 96 2.1/4 x 108 2.1/4 x 132 2.1/4 x 168 2.3/4 x 60 2.3/4 x 72 2.3/4 x 84 2.3/4 x 96 2.3/4 x 108 2.3/4 x 120 2.3/4 x 132 2.3/4 x 144 2.3/4 x 150 2.3/4 x 168 2.3/4 x 180 2.3/4 x 192 2.3/4 x 200 2.3/4 x 216 2.3/4 x 240 2.3/4 x 264 2.3/4 x 290 2.3/4 x 350 2.3/4 x 360 2.3/4 x 480 2.3/4 x 540 2.3/4 x 600 3.1/2 x 72 3.1/2 x 96 3.1/2 x 108 3.1/2 x 120 3.1/2 x 132 3.1/2 x 144 3.1/2 x 160 3.1/2 x 168 3.1/2 x 180 3.1/2 x 190 3.1/2 x 192 3.1/2 x 216 3.1/2 x 226 3.1/2 x 264 3.1/2 x 360 3.1/2 x 480 3.1/2 x 540

250 (226.8) 250 (226.8) 250 (226.8) 250 (226.8) 250 (226.8) 250 (226.8) 250 (226.8) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 350 (317.5) 500 (453.6) 500 (453.6) 500 (453.6) 500 (453.6) 500 (453.6) 500 (453.6) 500 (453.6) 500 (453.6) 500 (453.6) 500 (453.6) 500 (453.6) 500 (453.6) 500 (453.6) 500 (453.6) 500 (453.6) 500 (453.6) 500 (453.6)

60” (1524) 72” (1828.8) 84” (2133.6) 96” (2438.4) 108” (2743.2) 132” (3353) 168” (4267) 60” (1524) 72” (1828.8) 84” (2133.6) 96” (2438.4) 108” (2743.2) 120” (3048) 132” (3353) 144” (3657) 150” (3810) 168” (4267.2) 180” (4572) 192” (4876.8) 200” (5080) 216” (5486.4) 240” (6096) 264” (6705) 290” (7366) 350” (8890) 360” (9144) 480” (12192) 540” (13716) 600” (15240) 72” (1829) 96” (2438) 108” (2743.2) 120” (3048) 132” (3353) 144” (3688) 160” (4064) 168” (4267.2) 180” (4572) 190” (4826) 192” (4826) 216” (5486) 226” (5740) 264” (6705.6) 360” (9144) 480” (12192) 540” (13716)

480 (218) 530 (241) 580 (264) 630 (286) 680 (309) 780 (355) 880 (399) 620 (282) 685 (311) 740 (336) 805 (366) 870 (395) 935 (425) 1,000 (454) 1,064 (483) 1,095 (498) 1,190 (541) 1,255 (571) 1,320 (600) 1,363 (618) 1,450 (659) 1,580 (718) 1,770 (800) 1,944 (882) 2,180 (988) 2,235 (1014) 2,885 (1306) 3,187 (1446) 3,408 (1546) 705 (320) 1058 (480) 1,450 (659) 1,622 (736) 1,670 (759) 1,780 (809) 1,927 (876) 2,000 (909) 2,110 (959) 2,202 (998) 2,220 (1007) 2,422 (1098) 2,596 (1177) 2,882 (1307) 3,174 (1440) 3,968 (1800) 4,519 (2050)

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2: Specifications

50000870-MAN-001 E 11 of 20

Part No.

Nominal link Size, in (mm) Rated Capacity /Set, Appr. weight/ size (inch) tons (tonnes) Set, lb (Kg)

16143-1132 16143-1144 16143-1160 16143-1180 16143-1200 16143-1216 16143-1240 16143-1264 16143-1300 70101-1200* M614000320Y1180 M614000320Y1200 M614000320Y1240 For TDS-4 and TDS-5 15386-1108

4.3/4 x 132 4.3/4 x 144 4.3/4 x 160 4.3/4 x 180 4.3/4 x 200 4.3/4 x 216 4.3/4 x 240 4.3/4 x 264 4.3/4 x 300 5.1/2 x 200 5.1/2 x 180 5.1/2 x 200 5.1/2 x 240

132” (3352) 144” (3688) 160” (3688) 180” (4572) 200” (5080) 216” (5486) 240” (6096) 264” (6705) 300” (7620) 200” (5080) 200” (5080) 200” (5080) 200” (5080)

750 (680.4) 750 (680.4) 750 (680.4) 750 (680.4) 750 (680.4) 750 (680.4) 750 (680.4) 750 (680.4) 750 (680.4) 1000 (907.2) 1,250 (1133) 1,250 (1133) 1,250 (1133)

1,741 (790) 2,312 (1051) 3,178 (1445) 3,900 (1769) 4,550 (2063) 5,200 (2364) 5,864 (2660) 7,275 (3300) 8,800 (3991) 5,100 (2315) 4,550 (2063) 5,100 (2315) 7,275 (3300)

2.3/4 x 108

108” (2743.2)

350 (317.5)

920 (418)

* other lengths on request

Reference Numbers* Link P/N 250 Ton 16363 “ 350 Ton 26940 " 500 Ton 25469 " 750 Ton 16143 " 1000 Ton 70101 " 1250 Ton M614000320 "

Nominal Dim.

A

B

C

D

E

F

G

H

2.1/4” “

in (mm)

2.5/16" 58.7

5.1/2" 139.7

7.1/2" 190.5

2.7/8" 73

9.1/2" 241.3

12" 304.8

5" 127

15" 381

2.3/4 “

in (mm)

2.13/16" 5.5/8" 71.4 142.9

8.3/8" 212.7

3.1/2" 88.9

9.1/2" 241.3

12" 304.8

5" 127

15" 381

3.1/2 “

in (mm)

3.5/8" 92.1

6.1/2" 165.1

10.1/8" 257.2

4.1/2" 114.3

9.1/2" 241.3

12" 304.8

6" 152.4

17" 431.8

4.3/4 “

in (mm)

7.1/2" 190.5

10" 254

14.5/8" 371.5

6" 152.4

10" 254

14.5/8" 371.5

7.1/2" 190.5

23" 584.2

5.1/2 “

in (mm)

8.1/4" 209.6

12.3/4" 323.9

17.1/2" 444.5

6" 152.4

12.3/4" 17.1/2" 323.9 444.5

8.1/4" 209.6

29.1/4" 743

5.1/2 “

in (mm)

8.1/4" 209.6

12.3/4" 323.9

17.1/2" 444.5

6" 152.4

12.3/4" 17.1/2" 323.9 444.5

8.1/4" 209.6

29.1/4" 743

* The dimensions are nominal and actual dimensions will vary slightly due to manufacturing tolerances. All API contact radius dimensions are manufactured to API specifications, see Fig. 1

www.nov.com

Document number Revision Page

50000870-MAN-001 E 12 of 20

2: Specifications

Perfection links 9.00 5.00

X

Fig. 2 2.00 3.12

Part No.

Size, in (mm)

Rated Cap/Set, Weight/Set, lb Dimension X inch tons (tonnes) (Kg) (mm))

200450-130 200450-136 200450-142 200450-148 200450-160

2” x 30” (50.8 x 762) 2” x 36” (50.8 x 914) 2” x 42” (50.8 x 1,067) 2” x 48” (50.8 x 1,219) 2” x 60” (50.8 x 1,524)

100 (89.3) 100 (89.3) 100 (89.3) 100 (89.3) 100 (89.3)

49 (108) 58 (128) 67 (148) 76 (168) 95 (208)

30 (762) 36 (914) 42 (1,067) 48 (1,219) 60 (1,524)

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2: Specifications

Document number Revision Page

50000870-MAN-001 E 13 of 20

Link handle kit The Link handle kit can be used in combination with any Manual Operated Elevator. It is developed for easier handling of links and functions as a safe gripping point when closing and opening elevators. It suitable for 250 (2.1/4”) and 350 (2.3/4”)ton links. Part number 50006435.

Fitting The handle(s) must be mounted to the eye of the link, and not to the shank. Ensure no interference occurs between handle and elevator when rotating the elevator.

Fitted handle

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Document number Revision Page

50000870-MAN-001 E 14 of 20

2: Specifications

Elevator link compatibility WARNING: Never use links which have a capacity too low for carrying the load intended (dynamic + static), even if the links may fit on the elevator. Elevator links

Top Drive Solid Body Elevator Rating 250T 400T 500T 650T 250 Ton 2.1/4" pn 16363 yes no no no 350 Ton 2.3/4" pn 26940 yes yes yes yes 500 Ton 3.1/2" pn 25469 no yes yes yes 750 Ton 4.3/4" pn 16143 no no no yes 1000 Ton 5.1/2" pn 70101 no no no no 1250 Ton 5.1/2" pn M14000320Y no no no no Elevator links

Elevator Y series

250 Ton 2.1/4" pn 16363 350 Ton 2.3/4" pn 26940 500 Ton 3.1/2" pn 25469 750 Ton 4.3/4" pn 16143 1000 Ton 5.1/2" pn 70101

YC yes yes no no no

1250 Ton 5.1/2" pn M14000320Y no

750T no yes yes yes no no

MYC yes yes no no no

HYC yes yes yes no no

YT yes yes no no no

HYT yes yes yes no no

LYT* no no no no no

MYT yes yes no no no

no

no

no

no

no

no

*Requires link 7/8” - 1.3/4 Elevator links

Elevator T(M)A series TA 1.050 - 2.7/8 TMA 2.3/8 - 5

250 Ton 2.1/4" pn 16363 350 Ton 2.3/4" pn 26940 500 Ton 3.1/2" pn 25469 750 Ton 4.3/4" pn 16143 1000 Ton 5.1/2" pn 70101 1250 Ton 5.1/2" pn M14000320Y

no no no no no no

yes yes no no no no

Elevator links

Elevator G series

250 Ton 2.1/4" pn 16363 350 Ton 2.3/4" pn 26940 500 Ton 3.1/2" pn 25469 750 Ton 4.3/4" pn 16143 1000 Ton 5.1/2" pn 70101 1250 Ton 5.1/2" pn M14000320Y

MG yes yes no no no no

RGG yes yes no no no no

MGG yes yes yes no no no

GG yes yes yes no no no

HGG no yes yes yes no no

TA 4.3/4 - 8.5/8 up to 100 ton yes yes no no no no

RGA yes yes no no no no

GA yes yes yes no no no

TA 4.3/4 - 11.1/4 150 ton only yes yes yes no no no

GGA yes yes yes no no no

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Document number Revision Page

2: Specifications

Elevator links

50000870-MAN-001 E 15 of 20

Elevator X series

SSD SLX SLX SSD 8.5/8-10.3/4 1.66-5.1/2 5.1/2-24.1/2 1.66-7.5/8 + 11.3/4-14 250 Ton 2.1/4" pn 16363 yes yes yes yes 350 Ton 2.3/4" pn 26940 yes yes yes yes 500 Ton 3.1/2" pn 25469 no yes no yes 750 Ton 4.3/4" pn 16143 no no no no 1000 Ton 5.1/2" pn 70101 no no no no 1250 Ton 5.1/2" no no no no pn M14000320Y

SX except 350 ton no yes yes no no

SX 350 ton yes yes yes no no

no

no

Elevator links

*250 and 350 ton SMX

Elevator X series SMX SMX 150 Ton 250 + 350 Ton 250 Ton 2.1/4" pn 16363 yes yes 350 Ton 2.3/4" pn 26940 yes yes 500 Ton 3.1/2" pn 25469 no yes* (rotation limited) 750 Ton 4.3/4" pn 16143 no no 1000 Ton 5.1/2" pn 70101 no no 1250 Ton 5.1/2" no no pn M14000320Y

Casing Elevators / Spiders Varco Type 750T 200T 350T 500T 14” 250 Ton 2.1/4" pn 16363 yes yes no no 350 Ton 2.3/4" pn 26940 yes yes yes no 500 Ton 3.1/2" pn 25469 yes yes yes yes 750 Ton 4.3/4" pn 16143 no no no yes 1000 Ton 5.1/2" pn 70101 no no no no 1250 Ton 5.1/2" no no no no pn M14000320Y

yes yes yes no no no

elevators in combination with 500 ton links gives reduced rotation possibility. Be advised to use 350 ton links.

Casing Elevators / Spiders BJ Type

Elevator links

750T 24.1/2” no no yes yes no

1000T 24.1/2” no no no yes yes

no

yes

250T 350T 500T 1000T yes yes yes no no

no yes yes yes no

no no yes yes no

no no yes yes no

no

no

no

no

Elevator links

Riser handling solid body elevator rating 250 T 400 T 500 T 650T 750 T 250 Ton 2.1/4" pn 16363 yes no no no no 350 Ton 2.3/4" pn 26940 yes yes yes yes yes 500 Ton 3.1/2" pn 25469 no yes yes yes yes 750 Ton 4.3/4" pn 16143 no no no yes yes 1000 Ton 5.1/2" pn 70101 no no no no yes 1250 Ton 5.1/2" no no no no yes pn M14000320Y

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SLX SD

1000T no no no yes yes yes

Document number Revision Page

50000870-MAN-001 E 16 of 20

Elevator links

2: Specifications

BX1 450 T 250 Ton 2.1/4" pn 16363 yes 350 Ton 2.3/4" pn 26940 yes 500 Ton 3.1/2" pn 25469 yes 750 Ton 4.3/4" pn 16143 no 1000 Ton 5.1/2" pn 70101 no 1250 Ton 5.1/2" no pn M14000320Y

BX2 500 T no yes yes no no

BX3 350 T no yes yes yes no

BX4-35 350 T no yes yes yes no

no

no

no

Elevator links

BX4-75 750 T no no yes yes no

BX5 1000 T no no no yes yes

BX7 1250 T no no no no yes

BXS, Slip type 350 T yes yes yes no no

no

yes

yes

no

BX4-50 500 T 250 Ton 2.1/4" pn 16363 yes 350 Ton 2.3/4" pn 26940 yes 500 Ton 3.1/2" pn 25469 yes 750 Ton 4.3/4" pn 16143 no 1000 Ton 5.1/2" pn 70101 no 1250 Ton 5.1/2" no pn M14000320Y NOTES:

1. Compatibility is based on API 8C radii unless specific link part No's are listed. 2. If a link part No. is not listed, suitable fit with the SBE is to be confirmed 3. In some cases special links are required for use on Top Drive SBE's to permit proper operation of link tilt. 4. In general, an elevator will fit one size larger and one size smaller noted link. However, fit should always be confirmed when combining sizes of links and elevators.

Link connectors The link connector can be used to make a link assembly up to 50/60 Feet long. Part number 350 ton: 250167. Part number 500 ton: not available yet. Partnumber 750: 250341

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Document number Revision Page

3: Inspection and wear data

50000870-MAN-001 E 17 of 20

Inspection & wear data Safety WARNING: NOV does not allow welding of links and bails. Links and bails cannot be repaired or reconditioned by welding. WARNING: Ensure daily if the secondary retention (wire, cotter pins) is in good condition. Replace or repair if needed. NOTE: Capacity of set is that of the weakest link.

Wear chart shaft (shank) Wear/damage may result in a reduced section of the material, hence this will lead to a derating of the link according to below table. 250 Ton Link 350 Ton Link 500 ton link

750 Ton Link 1000 Ton Link

1250 Ton Link

Diameter Rating Diameter Rating Diameter Rating Diameter Rating

Diameter

Rating

Diameter

Rating

2.75" 2.688" 2.625" 2.5"

5.25" 5.125" 5" 4.875"

1000 962 915 870

5.25" 5.125" 5" 4.875"

1250 1202 1143 1087

250 215 200 185

3.25" 3.188" 3.125" 3"

350 325 312 288

3.688" 3.625" 3.5" 3.375"

500 480 450 415

4.55" 4.438" 4.375" 4.25"

750 725 700 662

Wear chart forged links

Fig. 3

Upper eye

Lower eye

NOTE: In general, an allowable twist between the upper and lower eye is 2 degrees

Link 1.3/4" - 150 TON

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Upper Eye (A)

Lower Eye (B)

Rating

(greater or equal to) 3.38" 3.25" 3.13" Height less than 3.13

(greater or equal to) 1.625" 1.50" 1.44" Height less than 1.44

(Short Ton) 150 125 112.5 Scrap

Document number Revision Page

50000870-MAN-001 E 18 of 20

Link

Upper Eye (A)

Lower Eye (B)

Rating

(greater or equal to) 4.75" 4.63" 4.5" Height less than 4.5"

(greater or equal to) 2.06" 1.88" 1.75" Height less than 1.75"

(Short Ton) 250 200 180 Scrap

Upper Eye (A)

Lower Eye (B)

Rating

(greater or equal to) 4.75" 4.63" 4.5" Height less than 4.50"

(greater or equal to) 2.56" 2.38" 2.25" Height less than 2.25"

(Short Ton) 350 290 260 Scrap

Upper Eye (A)

Lower Eye (B)

Rating

(greater or equal to) 5.625" 5.25" 5." Height less than 5"

(greater or equal to) 3.25" 3" 2.75" Height less than 2.75"

(Short Ton) 500 440 375 Scrap

Upper Eye (A)

Lower Eye (B)

Rating

(greater or equal to) 7" 6.75" 6.5" Height less than 6.5"

(greater or equal to) 7" 6.75" 6.5" Height less than 6.5"

(Short Ton) 750 700 600 Scrap

Upper Eye (A)

Lower Eye (B)

Rating

(greater or equal to) 7.875" 7.5" 7.125" Height less than 7.125"

(greater or equal to) 7.875" 7.5" 7.125" Height less than 7.125"

(Short Ton) 1000 900 800 Scrap

Upper Eye (A)

Lower Eye (B)

Rating

(greater or equal to) 7.875" 7.5" 7.125" Height less than 7.125"

(greater or equal to) 7.875" 7.5" 7.125" Height less than 7.125"

(Short Ton) 1250 1125 1000 Scrap

2.1/4" - 250 TON

Link 2.3/4" - 350 TON

Link 3.1/2" - 500 TON

Link 750 TON

Link 1000 TON

Link 1250 TON

3: Inspection and wear data

Wear data Perfection links. Standard diameter of a Perfection link is 2.00”. Minimum allowable diameter is 1.75”

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3: Inspection and wear data

Document number Revision Page

50000870-MAN-001 E 19 of 20

MPI and inspection References 1. ASTM E 709 (latest edition) Standard Practice for Magnetic Particle Examination 2. ASTM A 275 (latest edition) Standard Test Method for Magnetic Particle Examination of Steel Forgings. 3. API Specification 8A & 8C (latest edition) 4. API Recommended Practice RP 8B (latest edition)

Qualifications and certification All personnel performing and interpreting examinations shall be qualified in accordance with the guidelines of ASNT-TC-1A (latest edition) or an equivalent standard recognized by ASNT. All personnel performing NDE shall also be trained in the NDE of forgings as well as trained in the interpretation of the MPI with regard to the acceptance criteria.

Evaluation of indications Relevant indications: Only those indications with major dimensions greater than 1/16 inch (1.6mm) and associated with a surface rupture shall be considered relevant. Relevant indications are indications that results from discontinuities within the test part. Non relevant indications are indications that results from excessive magnetizing current, structural design or permeability variances within the test parts. Any indication believed to be non relevant shall be regarded as relevant and shall be re-examined to determine whether an actual defect exists. Linear indications shall be considered as those having a length of more than three times the width. Rounded indications shall be considered as those having a length less than three times the width. Aligned indication should be considered as a group of three or more indications which touch an imaginary straight line connecting any two of the group.

Acceptance criteria The link is considered critical in all area’s.

Equipment covered Wrought material: In all cases as specified in the following table. Relevant Indications No relevant indications with a major dimension equal to or greater than 3/16 inch (4.8 mm) No more than ten indications of 1/16 inch (1.6 mm) long or greater in any continuous 6-square-inch (40 cm2) area No more than three 1/16 inch (1.6 mm) long or greater indications in a line separated by less than 1/16 inch (1.6 mm) edge to edge

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Document number Revision Page

50000870-MAN-001 E 20 of 20

3: Inspection and wear data

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FINAL DOCUMENTATION TDS-11SA - Top Drive Drilling System

Chapter 4.0 Technical Drawing Package

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Technical Drawing Package TDS-11SA NOV Galena Park AC Ideal Rig 135

RIG/PLANT REFERENCE ADDITIONAL CODE

SDRL CODE

TOTAL PGS

REMARKS MAIN TAG NUMBER

DISCIPLINE

CLIENT PO NUMBER CLIENT DOCUMENT NUMBER

Client Document Number

M611005667-GEN-001

REFERENCE DESCRIPTION

Customer Configuration

This document contains proprietary and confidential information which is the property of National Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use of this design or distribution of this information to others is not permitted without the express written consent of NOV. This document is to be returned to NOV upon request or upon completion of the use for which it was loaned. This document and the information contained and represented herein is the copyrighted property of NOV. © National Oilwell Varco DOCUMENT NUMBER

D811002283-DOS-001

www.nov.com D811000461-GEN-001/04

National Oilwell Varco RIG SOLUTIONS 11000 Corporate Centre Drive Houston, TX 77041

REV

01

Document number Revision Page

D811002283-DOS-001 01 2

REVISION HISTORY

01

13/01/2012

Rev

Date (dd.mm.yyyy)

First Issue Reason for issue

T. Harmon

H. Lim

H. Lim

Prepared

Checked

Approved

CHANGE DESCRIPTION

Revision 01

Change Description First Issue

www.nov.com D811000461-GEN-001/04

Document number Revision Page

D811002283-DOS-001 01 3

TECHNICAL DRAWING PACKAGE This document provides a list of drawings for the TDS-11SA. The actual drawings are arranged in the binder by assembly order.

Drawings by Assembly General Customer Configuration ................................................................................ M611005667-GEN-001 General Arrangement, TDS-11SA ......................................................................................30170471 Hydraulic Schematic, TDS-11SA...................................................................D614000075-GAD-001 Block Diagram…………….. ........................................................................................ 10620480-DIA Electrical Interconnect Diagram, TDS-11SA ............................................................. 10620482-DIA Cable Schedule, TDS-11SA ....................................................................................... 10620483-IDX Network Topology, TDS-11SA………………………… ............................................... 10620486-DIA I/O Map…………......................................................................................................... 10620484-IDX Hazardous Equipment Index………………….. ........................................................... 10620485-IDX Top Drive Assembly Motor Housing, TDS-11SA ............................................................................................... 120900-UL Drilling Motor Assembly .......................................................................... 118217-40R60 & 40L60 Lube Pump Assembly .................................................................................................... 117603-1 Rotating Link Adapter Assembly ...................................................................................30173277 Hydraulic Drive/Shot Pin Assembly ....................................................................... 30151875-504 Hydraulic Oil Reservoir Assembly ................................................................................. 110068-2 Electrical Package ................................................................................................... 30188268-A60R Motor/Pump Assembly................................................................................................... 114113-2 Manifold Assembly.............................................................................................................114174 Hydraulic Plumbing Package..................................................................................................121403 Carriage Package…………………………. .................................................................. 30124540-502 Carriage Assembly (Left)……… ................................................................................ 124538-502 Carriage Assembly (Right)…….. ........................................................................... 30124539-502 Counterbalance Package………………………… ........................................................... 112190-120 Cylinder Assembly………………………………..................................................................110703 Cylinder Assembly………………………………..................................................................110704 Motor Guard Package………….. ............................................................................................120917 S-Pipe Package……………….. .............................................................................. 30156835-R75-2 Washpipe Assembly.....................................................................................................30123290

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Document number Revision Page

D811002283-DOS-001 01 4

Bail Package………………. ............................................................................................ 121442-120 Shipping Package……………… ................................................................................. 30179070-501 Lubrication Kit…………………............................................................................................ 92643-15 Counterbalance Attachment Kit…………………. ..................................................... 118244-BLOCK BX Elevator Control Kit.. ............................................................................................ 30151452-CRT Manifold Assembly, BX Elevator ............................................................................ 30156900-UL Manifold Assembly, Rectifier ........................................................................................30116378

Pipe Handler and Adapter Kits Pipe Handler Package, PH-75…………………………………….. .............................. 30157366-35-B Hydraulic Cylinder Assembly………………. ..................................................................30119592 Torque Arrestor Assembly………………………. ...........................................................30157288 Cylinder Assembly, IBOP Actuator ............................................................................125594 Cylinder Assembly, Clamp…………………………………………………................30157287 Stabbing Guide Assembly……………….. ............................................................125158 Jaw Assembly……………………………. .........................................................30125052 Upper IBOP………………… ...................................................................................... 110103-500 Lower IBOP……………… .......................................................................................... 114706-500 IBOP (External) Crank Assembly…………………………. ...................................................98898 PH-75 Tool Kit………………………………………………. .................................. 30157616-NC50

Service Loops and Derrick Kits Service Loop Kit, Electrical ...................................................................................... 30183283-75-75 Derrick Leg Kit………………………….. .......................................................................... 124977-100 Derrick Termination Kit .......................................................................................................30183678

Rigging Guide Beam Kit………………………………………………………………………………..M614003021 Lower Tieback Kit………………………………………………………………………...………30178883

Accessories Tool Joint Adapter Kit, NC38…………………………………………………...……….30157622-NC38

www.nov.com D811000461-GEN-001/04

FINAL DOCUMENTATION TDS-11SA - Top Drive Drilling System

Section 4.1 General

www.nov.com

This document contains proprietary information, and such information may not be disclosed to others for any purpose, nor used for manufacturing purposes without written permission from Varco International, Inc.

LTR

01 02

REVISIONS PREPARED / DATE

DESCRIPTION

INITIAL RELEASE See ECN

H. Lim C. George

STANDARD ORDER INFORMATION SHIPMENT DATE: 27-Jan-12 PRE-SHIP DATA: N/A RIG TYPE: Land INSTALLATION LOC: US OPERATING LOC: US RELATED CONFIGS: N/A SALES ORDER #: 25957 PO #: GPK1000406 QUOTE #: 142603 SPARES QUOTE #: N/A TURNKEY QUOTE #: N/A UNIT #: TBD SERIAL (TDS)#: TBD

CHECKED/ DATE

7/5/11 M. Clark 03-May-12 H. Lim

Rev. 0

APVD / DATE

7/5/11 H. Lim 03-May-12 H. Lim

QUALITY REQUIREMENTS CERT AUTHORITY / RULES: NATIONAL REGULATIONS: INDEPENDENT BODY: DATA BOOK: 3rd PARTY SERVICES:

NONE NONE NONE NONE NONE

CONTACT NOTES CUSTOMER: Tel: Fax: E-mail: CONTRACTS: SALES: RESPONSIBLE ELEC. ENG.: RESPONSIBLE MECH. ENG.:

Joyce Guilford Michael Martin Michael Maslyar Hyoung Lim

7/5/11 03-May-12

APPLICATION NOTES: 1. Customer Configuration document to be inserted into the front of the Technical Drawing Package in the Owner’s Manual by the end user. The Customer Configuration lists the rig specific part numbers used to identify the drawings. 2. Configured with IDEAL Rig Guide Beam Design and PH-75 Pipehandler. 3. Unit is CRT-Ready. 4. Configured with four section guide beam kit.

Sheet 1 of 7

CUSTOMER CONFIGURATION FORM CC-11S (f:\eng\appe7000\tds\_tools\M611005667-GEN-001_REV_02): 1:18 PM 5/3/2012

REVISION

DOCUMENT NUMBER

M611005667-GEN-001

02

CUSTOMER / OWNER

Cust: Rig:

GALENA PARK AC IDEAL RIG 135 TDS-11SA

PART NUMBER

QTY -1* BSC

DESCRIPTION

*-1 IS AN INVENTORY ITEM. THE BALANCE OF ITEMS ARE NON-INVENTORY KITS, AND MUST BE MASTER SCHEDULED ACCORDINGLY.

QTE PO REF REF

INDICATES NEW OR SPECIAL DRAWING/DESIGN. CONSULT APPLICATIONS ENGINEERING PRIOR TO MANUFACTURE.

REFERENCE DRAWINGS / TEST SPECIFICATIONS 30170471 REF DRAWING, GENERAL ARRANGEMENT, TDS-11SA D614000075-GAD-001 REF SCHEMATIC, HYDRAULIC, TDS-9/11SA, AC IDEAL RIG M614003010-SPL-001 REF SPARES LIST, MECHANICAL, AC IDEAL RIG, TDS-11SA ASP00020 REF TDS-9SA/11SA Motor Housing Assembly Procedure 3ASP00073 REF TDS-9SA/11SA Motor Installation Procedure, Brake Hub & Pinion Gear 3ASP00030 REF TDS Inspection Form TS00259 REF Test Specification, Motor Housing Assembly, TDS-9SA/11SA TS00271 REF TDS-9SA/11SA Final Function Test Procedure TS00286 REF TDS-9SA/11SA Factory System Test TS00162 REF Test Specification, Hydrostatic Pressure & Post MPI Test (Gooseneck / S-Pipe) TS00168 REF Test Specification, Mag Particle Inspection TS00419 REF Post Function Test, Hydraulic Fluid Cleanliness TS00465 REF Hydrostatic Pressure Test, Rotating Link Adapter Assembly, PH-75 TS00167 REF Test Spec. Link Pull Test, All TS00465 REF Hydrostatic Pressure Test, Clamp Cylinder Body 10620480-DIA REF BLOCK DIAGRAM, TDS-11SA 10620482-DIA REF ELECTRICAL INTERCONNECT DIAGRAM, TDS-11SA 10620483-IDX REF CABLE SCHEDULE, TDS-11SA 10620484-IDX REF I/O MAP, TDS-11SA 10620485-IDX REF HAZARDOUS EQUIPMENT INDEX, TDS-11SA 10620486-DIA REF NETWORK DIAGRAM, TDS-11SA 10620488-SPL REF CONTROL SPARE LIST, TDS-11SA D744000275 REF TRACEABILITY WORK SHEEET, TDS-9/10/11

Sheet 2 of 7

CUSTOMER CONFIGURATION FORM CC-11S (f:\eng\appe7000\tds\_tools\M611005667-GEN-001_REV_02): 1:18 PM 5/3/2012

REVISION

DOCUMENT NUMBER

M611005667-GEN-001

02

CUSTOMER / OWNER

Cust: Rig:

GALENA PARK AC IDEAL RIG 135 TDS-11SA

PART NUMBER

QTY -1* BSC

DESCRIPTION

*-1 IS AN INVENTORY ITEM. THE BALANCE OF ITEMS ARE NON-INVENTORY KITS, AND MUST BE MASTER SCHEDULED ACCORDINGLY.

TOP DRIVE ASSEMBLY M611005667-1 1 OID(10388308-001) 120900-UL 1 30188268-A-60-R 1 30151452-CRT 121403

1 1

30124540-502 30157366-35-B

1 1

112190-120 120917

1 1

30156835-R75-2

1

121442-120 30179070-501 92643-15 30157616-NC50 118244-BLOCK

QTE PO REF REF

INDICATES NEW OR SPECIAL DRAWING/DESIGN. CONSULT APPLICATIONS ENGINEERING PRIOR TO MANUFACTURE.

MOTOR/CARRIAGE ASSY, TDS-11SA 5000-7500 psi

1

MOTOR HOUSING, TDS-11SA Pressure Rating: ELECTRIC PACKAGE, TDS-11SA System Electrical: UL Installation Type: Service Loop Location: Right BX ELEVATOR CONTROL KIT HYDRAULIC PLUMBING PACKAGE, TDS-11SA System Electrical: UL CARRIAGE PACKAGE, TDS-9/11SA Setback: PIPE HANDLER PACKAGE, PH-75, TDS-11SA Drill String Connection: NC50 IBOP Trim: Link Option: 350 Ton COUNTERBALANCE PACKAGE, TDS-9/11SA MOTOR GUARD PACKAGE, TDS-9/11SA System Electrical: UL S-PIPE PACKAGE, TDS-9/11SA Mud Hose Connection: 4", Female Fig. 1002 S-Pipe Location: Pressure Rating: 7500 psi BAIL PACKAGE, TDS-9/11SA Bail Length: SHIPPING PACKAGE, GUIDE BEAM: W/SKID Setback: LUBRICATION KIT, TDS-9/11SA Lubricant Temperature Class:

1 1

PIPE HANDLER KIT, PH-75 Drill String Connection: NC50 COUNTERBALANCE ATTACHMENT KIT Attachment: To Block

1 1

Sheet 3 of 7

CUSTOMER CONFIGURATION FORM CC-11S (f:\eng\appe7000\tds\_tools\M611005667-GEN-001_REV_02): 1:18 PM 5/3/2012

REVISION

DOCUMENT NUMBER

M611005667-GEN-001

02

Portable

39.5" Standard

Right 120" 39.5", PH-75 High

CUSTOMER / OWNER

Cust: Rig:

GALENA PARK AC IDEAL RIG 135 TDS-11SA

PART NUMBER

QTY -1* BSC

DESCRIPTION

*-1 IS AN INVENTORY ITEM. THE BALANCE OF ITEMS ARE NON-INVENTORY KITS, AND MUST BE MASTER SCHEDULED ACCORDINGLY.

RIGGING M614003021

1

30178883

1

QTE PO REF REF

INDICATES NEW OR SPECIAL DRAWING/DESIGN. CONSULT APPLICATIONS ENGINEERING PRIOR TO MANUFACTURE.

GUIDE BEAM KIT: IDEAL RIG: FOUR SECTION IDEAL RIG Mast Height: 142A ft Guide Beam Section Length: TBD KIT, TIEBACK LOWER

CONTROL SYSTEM (TDCS) MJOB-7127-00 REF AC DRIVE HOUSE, Supplied By NOV-Ross-Hill TDCS Connectors: Power & Control Cables VFD Option: Ross Hill TDCS Incoming Freq.: 60 Hz CABLE REQUIREMENTS 30183283-75-75 1 124977-100 120591-100 30183287-100 30183678 30178585-50-H 84514-96-0

1 1 1 1 1 5

SERVICE LOOP KIT, 777 MCM (TDS to mid Derrick) System Electrical: UL Installation Type: Portable Service Loop Length: 75 ft Aux. Loop Length: 75 ft DERRICK LEG KIT, 777 MCM, QD Installation Type: Portable CRT DERRICK LEG CABLE – 24/C CRT DERRICK LEG CABLE – 7 TSP DERRICK TERMINATION KIT, 646 MCM/777 MCM, QD Installation Type: Portable CABLE ASSEMBLY, 5 TSP HEAT SHRINK TUBING

Sheet 4 of 7

CUSTOMER CONFIGURATION FORM CC-11S (f:\eng\appe7000\tds\_tools\M611005667-GEN-001_REV_02): 1:18 PM 5/3/2012

REVISION

DOCUMENT NUMBER

M611005667-GEN-001

02

CUSTOMER / OWNER

Cust: Rig:

GALENA PARK AC IDEAL RIG 135 TDS-11SA

PART NUMBER

QTY -1* BSC

DESCRIPTION

*-1 IS AN INVENTORY ITEM. THE BALANCE OF ITEMS ARE NON-INVENTORY KITS, AND MUST BE MASTER SCHEDULED ACCORDINGLY.

QTE PO REF REF

INDICATES NEW OR SPECIAL DRAWING/DESIGN. CONSULT APPLICATIONS ENGINEERING PRIOR TO MANUFACTURE.

ACCESSORIES/SPECIAL ITEMS 30157622-NC38 1 TOOL JOINT ADAPTER KIT, NC38 26940Y1120 1 WELDLESS LINK, 350 TON X 120” LENGTH

Sheet 5 of 7

CUSTOMER CONFIGURATION FORM CC-11S (f:\eng\appe7000\tds\_tools\M611005667-GEN-001_REV_02): 1:18 PM 5/3/2012

REVISION

DOCUMENT NUMBER

M611005667-GEN-001

02

CUSTOMER / OWNER

Cust: Rig:

GALENA PARK AC IDEAL RIG 135 TDS-11SA

PART NUMBER

QTY -1* BSC

DESCRIPTION

*-1 IS AN INVENTORY ITEM. THE BALANCE OF ITEMS ARE NON-INVENTORY KITS, AND MUST BE MASTER SCHEDULED ACCORDINGLY.

QTE PO REF REF

INDICATES NEW OR SPECIAL DRAWING/DESIGN. CONSULT APPLICATIONS ENGINEERING PRIOR TO MANUFACTURE.

SPARES

SERVICE MANUALS AND SUPPLEMENTS 10482378-001 4 OWNER’S MANUAL: TDS-11SA D811002283-DOS-001 REF TECHNICAL DRAWING PACKAGE M611005667-GEN-001 4 CUSTOMER CONFIG DOCUMENT: See Note 1 on sheet 1.

LEGACY D811002283-MAN-001

CLASSIFICATION SOCIETY/STATUTORY/INDUSTRIAL STD Designed, Built & Tested to API-8C, PSL-1 REF REF CRITICAL LOAD PATH ITEMS - See later page(s) of this configuration

TDS SUMMARY (W/ACCESSORIES) TDS Motor Type (2) Elect. Type: Space Htr per motor Solenoids Blower motor: HydSystemMotor:

X X 1 9 5 10

AC UL QTY QTY HP HP

Encoder EEx 115 VAC 24 VDC 575 VOLTS 575 VOLTS X

60

Div 2 Hz

60 60

Hz Hz

Sheet 6 of 7

CUSTOMER CONFIGURATION FORM CC-11S (f:\eng\appe7000\tds\_tools\M611005667-GEN-001_REV_02): 1:18 PM 5/3/2012

250 WATTS 3 3

REVISION

DOCUMENT NUMBER

M611005667-GEN-001

02

PHASE PHASE

2 1

QTY QTY

CUSTOMER / OWNER

Cust: Rig:

GALENA PARK AC IDEAL RIG 135 TDS-11SA

CLP: Critical Load Path (CLP) Component Index ESS = ESSENTIAL COMPONENT

PRI = PRIMARY ESS PRI

Motor/Carriage Assy: TDS-11SA (M611005667-1) Motor Housing Assy (120900-UL) Main Body (121227) Main Shaft w/ Landing Collar (121131) Collar, Landing (Set) (118377) Retainer, Landing Collar (118378) Rotating Link Adapter, 500 ton (121341) Body, Rotating Link Adapter (121340) S-Pipe Package (30156835-R75-2) Weldment, S-Pipe (117063-7500) Supply Pipe, Bent (117062-7500) Sub, Female (81156) Male Sub (110038) Nut, 4” (81161) Sub, Female, 3” (91922) Casting, Adapter (110037) Blind Plug, 3” (91921) Nut, 3” Hammer Union (91924) Wing Nut, 4” (81158) Elbow, S-Pipe, 4” Female Fig. 1002 (84617) Bail Package, 500 Ton (121442-120) Bail (109505-3) Bail Pin (109506) Pipe Handler Package (30157366-35-B) Saver Sub, NC50 (76666-2) Upper IBOP (110103-500) Lower IBOP (114706-500)

X X X X X X X X

SEC = SECONDARY SEC

PPC

X X

X X X

X X X X X X X X X X X X

CONFIGURATION FORM CC-11S (f:\eng\appe7000\tds\_tools\M611005667-GEN-001_REV_02): 1:18 PM 5/3/2012

ESS

PRI

X X X X

X X X X

X X X X

Adapter Kit, PH-75, NC38 (30157622-NC38) Crossover Sub (110852) Saver Sub, NC50 (118954-1)

X X X

X X X

X

Weldless Link, 350 Ton X 120” (26940Y1120)

X X X X

REVISION

DOCUMENT NUMBER

M611005667-GEN-001

SEC PPC

Pipe Handler Kit, PH-75 (30157616-NC50B) Crossover Sub (79410-3) Saver Sub, NC50 (76666-2) Spacer Sub (80098)

X X X

Sheet 7 of 7

CUSTOMER

PPC = PRIMARY PRESSURE-RETAINING COMPONENT

02

CUSTOMER / OWNER

Cust: Rig:

GALENA PARK AC IDEAL RIG 135 TDS-11SA

MJOB-8375

TDS-11SA

NEXT ASSY

USED ON

APPLICATION

This document contains proprietary and confidential information which belongs to National-Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use of this design or distribution of this information to others is not permitted without the express written consent of NOV. This document is to be returned to NOV upon request and in any event upon completion of the use for which it was loaned. This document and the information contained and represented herein is the copyrighted property of NOV. © National Oilwell Varco

CURRENT

TITLE

CABLE SCHEDULE, TDS-11SA AC IDEAL RIG 135

INITIAL

DRAWN

B. BOEPPLE

CHECKED

R. MOENCH

SIZE

APPVD

R. MOENCH

B

DATE

11/1/2011

SCALE

DWG NO

REV

10620483-IDX 01 NONE

WT LBS

SHEET

1

OF

3

D74DCF0049-TPL-001 (REV B)

CABLE SCHEDULE, TDS-11SA AC IDEAL RIG 135

NATIONAL OILWELL VARCO

FROM

TO

CABLE ID

CABLE

NOV

GLAND

GLAND

CABLE

TAG NO.

CONSTRUCTION

PART NO.

SIZE

P/N

TYPE

TAG NO.

30175017-75-4-3-B -

-

-

POWER POWER POWER POWER POWER POWER POWER POWER POWER POWER POWER POWER PE POWER POWER POWER PE POWER POWER POWER PE N.I.S.

TD-MOT-01 TD-MOT-01 TD-MOT-01 TD-MOT-01 TD-MOT-02 TD-MOT-02 TD-MOT-02 TD-MOT-02 TD-P01 TD-P02 TD-P03 TD-P04 TD-ENC-01

DRILL MOTOR ASSEMBLY DRILL MOTOR ASSEMBLY DRILL MOTOR ASSEMBLY DRILL MOTOR ASSEMBLY DRILL MOTOR ASSEMBLY DRILL MOTOR ASSEMBLY DRILL MOTOR ASSEMBLY DRILL MOTOR ASSEMBLY TOP DRIVE PLUG PANEL MAST PLUG PANEL MAST PLUG PANEL MAST PLUG PANEL MAST PLUG PANEL GRASSHOPPER PLUG PANEL GRASSHOPPER PLUG PANEL GRASSHOPPER PLUG PANEL GRASSHOPPER PLUG PANEL AC DRIVE HOUSE PLUG PANEL AC DRIVE HOUSE PLUG PANEL AC DRIVE HOUSE PLUG PANEL AC DRIVE HOUSE PLUG PANEL DRILL MOTOR INCREMENTAL ENCODER

TD-P01-U TD-P01-V TD-P01-W TD-P01-G VFD VFD VFD VFD TD-PNJB01

TD-N03

2

7C x 1.5 mm

-

-

-

N.I.S.

TD-HTR-01

DRILL MOTOR HEATER #1

TD-N04

7C x 1.5 mm2

-

-

-

N.I.S.

TD-HTR-02

DRILL MOTOR HEATER #2

TD-P08

4C x 2.5 mm

2

-

-

-

POWER

TD-MOT-03

TD-P06

4C x 2.5 mm2

-

-

-

POWER

TD-P07 CAB-N03A CAB-N03 CAB-N03B TD-LOOP 2

4C x 2.5 mm2 3 TSP x 16 AWG 3 TSP x 16 AWG 3 TSP x 16 AWG

124457-75-4-4-B

-

-

POWER N.I.S. N.I.S. N.I.S. POWER

TD-P01C TD-P02C TD-P03C TD-P04C TD-P01D TD-P02D TD-P03D TD-P04D TD-LOOP 1 TD-P01A TD-P02A TD-P03A TD-P04A TD-P01 TD-P02 TD-P03 TD-P04 TD-P01-U TD-P02-V TD-P03-W TD-P04-G TD-N20

1C x 4/0 AWG 1C x 4/0 AWG 1C x 4/0 AWG 1C x 4/0 AWG 1C x 4/0 AWG 1C x 4/0 AWG 1C x 4/0 AWG 1C x 4/0 AWG 3C x 777MCM + 3C x 2/0 AWG 1C x 646MCM 1C x 646MCM 1C x 646MCM 1C x 444MCM 1C x 646MCM 1C x 646MCM 1C x 646MCM 1C x 4/0 AWG 1C x 646MCM 1C x 646MCM 1C x 646MCM 1C x 4/0 AWG 2

3 TSP x 1.0 mm

2

18C x 2.5 mm

TD-P05C

18C x 2.5 mm2

TD-P05A TD-P05 TD-P05B TD-LOOP 3 TD-N01 TD-N01A TD-N01B

18C x 2.5 mm2 20C x 12 AWG 20C x 12 AWG 4 TSP x 14 AWG + 30C x 12 AWG 4 TSP x 14 AWG + 30C x 12 AWG 4 TSP x 14 AWG + 30C x 12 AWG 4 TSP x 14 AWG + 30C x 12 AWG

TD-N05

DATE

LOCATION

TAG NO.

BLOCK DIAG.

REMARKS

CABLE

DWG. NO.

SHT.

DWG. NO.

SHT.

SUPPLIED BY

TOP DRIVE PLUG PANEL TOP DRIVE PLUG PANEL TOP DRIVE PLUG PANEL TOP DRIVE PLUG PANEL TOP DRIVE PLUG PANEL TOP DRIVE PLUG PANEL TOP DRIVE PLUG PANEL TOP DRIVE PLUG PANEL MAST PLUG PANEL GRASSHOPPER PLUG PANEL GRASSHOPPER PLUG PANEL GRASSHOPPER PLUG PANEL GRASSHOPPER PLUG PANEL AC DRIVE HOUSE PLUG PANEL AC DRIVE HOUSE PLUG PANEL AC DRIVE HOUSE PLUG PANEL AC DRIVE HOUSE PLUG PANEL TOP DRIVE VFD TOP DRIVE VFD TOP DRIVE VFD TOP DRIVE VFD INSTRUMENT J-BOX

10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 5

NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV

TD-PNJB01

INSTRUMENT J-BOX

10620480-DIA

2

10620482-DIA

3

NOV

TD-PNJB01

INSTRUMENT J-BOX

10620480-DIA

2

10620482-DIA

3

NOV

HYDRAULIC PUMP MOTOR

TD-PNJB01

INSTRUMENT J-BOX

10620480-DIA

2

10620482-DIA

3

NOV

TD-MOT-04

RT. BLOWER MOTOR

TD-PNJB01

INSTRUMENT J-BOX

10620480-DIA

2

10620482-DIA

3

NOV

TD-MOT-05 DFT-NJB100 CAB-N03 -

LT. BLOWER MOTOR DRILL FLOOR TOOL REMOTE I/O CABINET GRASSHOPPER PLUG PANEL AC DRIVE HOUSE PLUG PANEL TOP DRIVE PLUG PANEL

TD-PNJB01 CAB-N03B -

INSTRUMENT J-BOX GRASSHOPPER PLUG PANEL AC DRIVE HOUSE PLUG PANEL ASSIGNMENT CUBICLE TD/RT MAST PLUG PANEL

10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA

2 2 2 2 2

10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA

3 2,12 2 2 3

NOV NOV NOV NOV NOV

-

LOCATION

INTERCONNECT

11/1/2011 2:07:54 PM

124459-01-20

-

-

POWER

TD-PNJB01

INSTRUMENT J-BOX

124458-100-B 30183284-75-4-4-B 123985-100-B 122718-01-20

-

-

POWER POWER POWER N.I.S. N.I.S. N.I.S. N.I.S.

TD-P05 TD-N01 TD-LOOP 3

MAST PLUG PANEL GRASSHOPPER PLUG PANEL AC DRIVE HOUSE PLUG PANEL TOP DRIVE PLUG PANEL MAST PLUG PANEL DRILLER'S CABIN PLUG PANEL TOP DRIVE PLUG PANEL

TOP DRIVE PLUG PANEL

10620480-DIA

2

10620482-DIA

3

NOV

GRASSHOPPER PLUG PANEL AC DRIVE HOUSE PLUG PANEL 600VAC MCC MAST PLUG PANEL DRILLER'S CABIN PLUG PANEL DRILL FLOOR TOOL REMOTE I/O CABINET INSTRUMENT J-BOX

10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA 10620480-DIA

2 2 2 2 2 2 2

10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA 10620482-DIA

3 3 3 4 4,8 8 4

NOV NOV NOV NOV NOV NOV NOV

3C x 1.5 mm

2

10054266-001

M20 (O)

10054938-001

N.I.S.

TDS-PNJB01

INSTRUMENT J-BOX

TD-N06

3C x 1.5 mm2

10054266-001

M20 (O)

10054938-001

N.I.S.

TDS-PNJB01

INSTRUMENT J-BOX

PS-01

RT BLOWER DIFF. PRESSURE SWITCH

10620480-DIA

3

10620482-DIA

4

NOV

PS-02

LEFT BLOWER DIFF. PRESSURE SWITCH

10620480-DIA

3

10620482-DIA

4

TD-N07

3C x 1.5 mm2

10054266-001

M20 (O)

10054938-001

N.I.S.

TDS-PNJB01

INSTRUMENT J-BOX

NOV

PS-03

IBOP PRESSURE SWITCH

10620480-DIA

3

10620482-DIA

4

NOV

TD-N08

3C x 1.5 mm2

10054266-001

M20 (O)

10054938-001

N.I.S.

TDS-PNJB01

INSTRUMENT J-BOX

PS-04

LUBE OIL PRESSURE SWITCH

10620480-DIA

3

10620482-DIA

4

NOV

TD-N09

3C x 1.5 mm2

10054266-001

M20 (O)

10054938-001

N.I.S.

TDS-PNJB01

INSTRUMENT J-BOX

SOV-01

BRAKE ON SOLENOID

10620480-DIA

3

10620482-DIA

4

NOV

TD-N10

3C x 1.5 mm

2

10054266-001

M20 (O)

10054938-001

N.I.S.

TDS-PNJB01

INSTRUMENT J-BOX

SOV-02

ROTATE RIGHT SOLENOID

10620480-DIA

3

10620482-DIA

4

NOV

TD-N11

3C x 1.5 mm2

10054266-001

M20 (O)

10054938-001

N.I.S.

TDS-PNJB01

INSTRUMENT J-BOX

SOV-03

ROTATE LEFT SOLENOID

10620480-DIA

3

10620482-DIA

4

NOV

TD-N12

3C x 1.5 mm2

10054266-001

M20 (O)

10054938-001

N.I.S.

TDS-PNJB01

INSTRUMENT J-BOX

SOV-04

IBOP CLOSE SOLENOID

10620480-DIA

3

10620482-DIA

4

NOV

TD-N13

3C x 1.5 mm2

10054266-001

M20 (O)

10054938-001

N.I.S.

TDS-PNJB01

INSTRUMENT J-BOX

SOV-05

TORQUE WRENCH CLAMP SOLENOID

10620480-DIA

3

10620482-DIA

4

NOV

TD-N14

7C x 1.5 mm2

10054266-001

M20 (A)

10054938-001

N.I.S.

TDS-PNJB01

INSTRUMENT J-BOX

SOV-06

LINK TILT EXTEND SOLENOID

10620480-DIA

3

10620482-DIA

4

NOV

TD-N15

3C x 1.5 mm2

10054266-001

M20 (O)

10054938-001

N.I.S.

TDS-PNJB01

INSTRUMENT J-BOX

SOV-07

LINK TILT "DRILL" SOLENOID

10620480-DIA

3

10620482-DIA

4

NOV

TD-N16

3C x 1.5 mm2

10054266-001

M20 (O)

10054938-001

N.I.S.

TDS-PNJB01

INSTRUMENT J-BOX

SOV-08

LINK TILT "FLOAT" SOLENOID

10620480-DIA

3

10620482-DIA

4

NOV

TD-N17

3C x 1.5 mm2

10054266-001

M20 (O)

10054938-001

N.I.S.

TDS-PNJB01

INSTRUMENT J-BOX

SOV-09

STAND JUMP SOLENOID

10620480-DIA

3

10620482-DIA

5

NOV

TD-N18

3C x 1.5 mm2

10054266-001

M20 (O)

10054938-001

N.I.S.

TDS-PNJB01

INSTRUMENT J-BOX

SOV-10

Bx ELEVATOR OPEN SOLENOID

10620480-DIA

3

10620482-DIA

5

NOV

TD-N21

3C x 1.5 mm2

10054266-001

M20 (O)

10054938-001

N.I.S.

TDS-PNJB01

INSTRUMENT J-BOX

PS-05

Bx ELEVATOR PRESSURE SWITCH

10620480-DIA

3

10620482-DIA

4

NOV

TD-N30

1 TSP x 1.0 mm

2

10054266-001

M20 (O)

10054938-001

N.I.S.

-

CRT PLUG

PS-15

CRT SLIPS SET PRESSURE SWITCH

10620480-DIA

4

10620482-DIA

6

NOV

TD-N31

1 TSP x 1.0 mm2

10054266-001

M20 (O)

10054938-001

N.I.S.

-

CRT PLUG

PS-16

CRT SJ ELEVATOR CLOSED PRESSURE SWITCH

10620480-DIA

4

10620482-DIA

6

NOV

TD-N32

1 TSP x 1.0 mm2

10054266-001

M20 (O)

10054938-001

N.I.S.

-

CRT PLUG

PS-17

CRT STOP LOWERING PRESSURE SWITCH

10620480-DIA

4

10620482-DIA

6

NOV

TD-P05B MCC TD-N01A DFT-NJB100 TD-PNJB01

SHEET

2

OF

3

DWG NO

10620483-IDX

REV

01

CABLE SCHEDULE, TDS-11SA AC IDEAL RIG 135

NATIONAL OILWELL VARCO

DATE

FROM

CABLE ID

CABLE

NOV

GLAND

GLAND

CABLE

TAG NO.

CONSTRUCTION

PART NO.

SIZE

P/N

TYPE

TAG NO.

TO LOCATION

TAG NO.

BLOCK DIAG. LOCATION

INTERCONNECT

REMARKS

11/1/2011 2:07:54 PM

CABLE

DWG. NO.

SHT.

DWG. NO.

SHT.

SUPPLIED BY

TD-N25

3C x 1.5 mm

2

10054266-001

M20 (O)

10054938-001

N.I.S.

-

CRT PLUG

SOV-15

CRT SLIPS UP SOLENOID

10620480-DIA

4

10620482-DIA

6

NOV

TD-N26

3C x 1.5 mm2

10054266-001

M20 (O)

10054938-001

N.I.S.

-

CRT PLUG

SOV-16

CRT ELEVATOR OPEN SOLENOID

10620480-DIA

4

10620482-DIA

6

NOV

TD-N27

3C x 1.5 mm2

10054266-001

M20 (O)

10054938-001

N.I.S.

-

CRT PLUG

SOV-17

CRT LINK TILT EXTEND SOLENOID

10620480-DIA

4

10620482-DIA

6

NOV

TD-N28

3C x 1.5 mm2

10054266-001

M20 (O)

10054938-001

N.I.S.

-

CRT PLUG

SOV-18

CRT LINK TILT DRILL SOLENOID

10620480-DIA

4

10620482-DIA

6

NOV

TD-N29

3C x 1.5 mm2

10054266-001

M20 (O)

10054938-001

N.I.S.

-

CRT PLUG

SOV-19

CRT LINK TILT FLOAT SOLENOID

10620480-DIA

4

10620482-DIA

6

NOV

TD-LOOP 5

24C x 1.5 mm2

-

-

-

N.I.S.

TD-N34B

TD-N34

24C x 1.5 mm2

-

-

-

N.I.S.

TD-LOOP 5

TD-N34A

24C x 1.5 mm2

-

-

-

N.I.S.

TD-N34

TD-N34B

24C x 1.5 mm2

-

-

-

N.I.S.

TD-LOOP 5

TOP DRIVE PLUG PANEL

-

TD-LOOP 4

7 TSP x 1.0 mm2

-

-

-

N.I.S.

TD-N33B

TOP DRIVE PLUG PANEL

TD-N33

TD-N33

7 TSP x 1.0 mm2

-

-

-

N.I.S.

TD-LOOP 4

TD-N33A

7 TSP x 1.0 mm2

-

-

-

N.I.S.

TD-N33

TD-N33B

7 TSP x 1.0 mm2

-

-

-

N.I.S.

TD-LOOP 4

TOP DRIVE PLUG PANEL

TD-D1001 TD-P1001 TD-P1002

PROFIBUS 3C x 12 AWG 3C x 12 AWG

-

-

-

DATA POWER POWER

DFT-NJB100 DFT-NJB100 DFT-NJB100

DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET

MTC #1 MTC #1 MTC #1

ANT-D1001 TD-S33

LMR400, COAX 3C x 0.75 mm2

10077615-001 -

-

-

DATA I.S.

DFT-NJB100 LT-02

DRILL FLOOR TOOL REMOTE I/O CABINET LINK CYLINDER LINEAR TRANSDUCER

TDS-SJB01

TOP DRIVE PLUG PANEL

TD-N34

MAST PLUG PANEL

TD-N34A

DRILLER'S CABIN PLUG PANEL

DFT-NJB100

MAST PLUG PANEL

TD-N33A

DRILLER'S CABIN PLUG PANEL

DFT-NJB100 -

SHEET

3

OF

3

MAST PLUG PANEL

10620480-DIA

4

10620482-DIA

6

NOV

DRILLER'S CABIN PLUG PANEL

10620480-DIA

4

10620482-DIA

6,14

NOV

DRILL FLOOR TOOL REMOTE I/O CABINET

10620480-DIA

4

10620482-DIA

14

NOV

CRT PLUG

10620480-DIA

4

10620482-DIA

6

NOV

MAST PLUG PANEL

10620480-DIA

4

10620482-DIA

6

NOV

DRILLER'S CABIN PLUG PANEL

10620480-DIA

4

10620482-DIA

6,13

NOV

DRILL FLOOR TOOL REMOTE I/O CABINET

10620480-DIA

4

10620482-DIA

13

NOV

CRT PLUG

10620480-DIA

4

10620482-DIA

6

NOV

MULTI TOOL CONTROLLER CABINET #1 MULTI TOOL CONTROLLER CABINET #1 MULTI TOOL CONTROLLER CABINET #1

10620480-DIA 10620480-DIA 10620480-DIA

4 4 4

10620482-DIA 10620482-DIA 10620482-DIA

16 16 16

NOV NOV NOV

OMNI ANNTENA FLEX POWER NODE

10620480-DIA 10620480-DIA

4

10620482-DIA 10620482-DIA

15 7

NO BLOCK

DWG NO

NOV NOV

10620483-IDX

REV

01

MJOB-8375

TDS-11SA

NEXT ASSY

USED ON

APPLICATION

This document contains proprietary and confidential information which belongs to National-Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use of this design or distribution of this information to others is not permitted without the express written consent of NOV. This document is to be returned to NOV upon request and in any event upon completion of the use for which it was loaned. This document and the information contained and represented herein is the copyrighted property of NOV. © National Oilwell Varco

CURRENT

TITLE

I/O MAP, TDS-11SA AC IDEAL RIG 135

INITIAL

DRAWN

B. BOEPPLE

CHECKED

R. MOENCH

SIZE

APPVD

R. MOENCH

B

DATE

11/1/2011

SCALE

DWG NO

REV

10620484-IDX 01 NONE

WT LBS

SHEET

1

OF

3

D74DCF0051-TPL-001 (REV B)

I/O MAP, TDS-11SA AC IDEAL RIG 135

NATIONAL OILWELL VARCO

NETWORK NODE

I/O DESCRIPTION

I/O

1 FUNCTION

DATE

I/O

SIGNAL

ADDRESS

TYPE

ID

No.

0 FUNCTION

10DI0.0

NIS 24 vdc

DP1

10

TD-PS-01 STATUS

POS 1(1)

STATUS OK

PS FAILURE

10DI0.1

NIS 24 vdc

DP1

10

TD-PS-02 STATUS

10DI0.2

NIS 24 vdc

DP1

10

TD-CAT 0 E-STOP

POS 1(5) POS 1(4)

STATUS OK E-STOP NOT ENGAGED

PS FAILURE E-STOP ENGAGED

10DI0.3

NIS 24 vdc

DP1

10

TD-CAT 2 E-STOP

POS 1(8)

E-STOP NOT ENGAGED

E-STOP ENGAGED

10DI0.4

NIS 24 vdc

DP1

10

TD-DRILL MTR#1 (RIGHT) OVERTEMP SW

POS 3(1)

MOTOR TEMP OK

MOTOR TEMP HIGH

10DI0.5

NIS 24 vdc

DP1

10

TD-DRILL MTR#2 (LEFT) OVERTEMP SW

10DI0.6

NIS 24 vdc

DP1

10

TD-RIGHT BLOWER MOTOR PRESS SW

POS 3(5) POS 3(4)

MOTOR TEMP OK TD AIR FLOW OK

MOTOR TEMP HIGH TDS AIR FLOW LOW

10DI0.7 10DI1.0

NIS 24 vdc NIS 24 vdc

DP1 DP1

10 10

TD-LEFT BLOWER MOTOR PRESS SW

POS 3(8)

TD AIR FLOW OK

TDS AIR FLOW LOW

TD-IBOP PRESS SW

10DI1.1

NIS 24 vdc

DP1

10

TD-LUBE OIL PRESS SW

POS 4(1) POS 4(5)

IBOP CLOSED LUBE OIL PRESSURE OK

IBOP OPEN LUBE OIL PRESSURE LOW

10DI1.2

NIS 24 vdc

DP1

10

TD-Bx ELEVATOR CLOSED PRESS SW

POS 4(4)

Bx ELEVATOR CLOSED

Bx ELEVATOR ARMED OR OPEN

10DI1.3

NIS 24 vdc

DP1

10

SPARE

POS 4(8)

10DI1.4

NIS 24 vdc

DP1

10

SPARE

-

-

10DI1.5

NIS 24 vdc

DP1

10

SPARE

POS 5(1) POS 5(5)

-

-

10DI1.6

NIS 24 vdc

DP1

10

SPARE

POS 5(4)

-

-

10DI1.7

NIS 24 vdc

DP1

10

SPARE

POS 5(8)

-

-

10DI8.0

NIS 24 vdc

DP1

10

TD-CRT SLIPS SET PRESS SW

10DI8.1

NIS 24 vdc

DP1

10

TD-CRT SJ ELEVATOR CLOSED PRESS

POS 19(1) POS 19(5)

CRT SLIPS SET CRT ELEVATOR CLOSED

CRT SLIPS NOT SET CRT ELEVATOR ARMED OR OPEN

10DI8.2

NIS 24 vdc

DP1

10

TD-CRT STOP LOWERING PRESS SW

POS 19(4)

CRT LOWERING

10DI8.3

NIS 24 vdc

DP1

10

SPARE

POS 19(8)

CRT STOPPED LOWERING -

10DI8.4

NIS 24 vdc

DP1

10

SPARE

-

10DI8.5

NIS 24 vdc

DP1

10

SPARE

POS 20(1) POS 20(5)

-

-

10DI8.6

NIS 24 vdc

DP1

10

SPARE

POS 20(4)

-

-

10DI8.7

NIS 24 vdc

DP1

10

SPARE

POS 20(8)

-

-

10DQ0.0

NIS 24 vdc

DP1

10

TD-BRAKE ON SOLENOID

POS 7(1)

10DQ0.1

NIS 24 vdc

DP1

10

TD-ROTATE RIGHT SOLENOID

POS 7(5)

BRAKE APPLIED TD ROTATES RIGHT

BRAKE RELEASED TD STOPS

10DQ0.2

NIS 24 vdc

DP1

10

TD-ROTATE LEFT SOLENOID

TD ROTATES LEFT

TD STOPS

10DQ0.3

NIS 24 vdc

DP1

10

TD-IBOP CLOSE SOLENOID

10DQ0.4

NIS 24 vdc

DP1

10

TD-TORQUE WRENCH SOLENOID

POS 8(1) POS 8(5) POS 9(1)

IBOP CLOSED RLA JOGS, SHOT PIN ENGAGES, TORQUE WRENCH CLAMPS

LAST STATE TORQUE WRENCH RELEASE

10DQ0.5

NIS 24 vdc

DP1

10

TD-LINK TILT EXTEND SOLENOID

POS 9(5)

LINK TILT MOVES TO “EXTEND” POSITION OR FLOATS

LINK TILT STOPS

10DQ0.6

NIS 24 vdc

DP1

10

TD-LINK TILT DRILL SOLENOID

POS 11(1)

LINK TILT MOVES TO “DRILL” POSITION OR FLOATS

LINK TILT STOPS

10DQ0.7

NIS 24 vdc

DP1

10

TD-LINK TILT FLOAT SOLENOID

POS 11(5)

LINK TILT MOVES TO “FLOAT” POSITION OR FLOATS

LINK TILT STOPS

10DQ1.0

NIS 24 vdc

DP1

10

TD-STAND JUMP SOLENOID

10DQ1.1

NIS 24 vdc

DP1

10

TD-Bx ELEVATOR OPEN SOLENOID

POS 12(1) POS 12(5)

COUNTER BALANCE CYLINDERS RETRACT Bx ELEVATOR OPEN

COUNTER BALANCE CYLINDERS EXTENDS Bx ELEVATOR ARMED OR CLOSED

10DQ1.2

NIS 24 vdc

DP1

10

SPARE

POS 13(1)

-

-

10DQ1.3

NIS 24 vdc

DP1

10

SPARE

POS 13(5)

-

-

LOCATION

ENG. UNITS

SHEET

2

OF

3

11/1/2011 2:13:31 PM

MIN ENG. MAX ENG. SETPOINTS REMARKS UNITS

UNITS

-

DWG NO

10620484-IDX

REV

01

I/O MAP, TDS-11SA AC IDEAL RIG 135

NATIONAL OILWELL VARCO

I/O

SIGNAL

ADDRESS 10DQ1.4

TYPE NIS 24 vdc

ID DP1

No. 10

SPARE

POS 15(1)

-

10DQ1.5

NIS 24 vdc

DP1

10

SPARE

POS 15(5)

-

-

10DQ1.6

NIS 24 vdc

DP1

10

SPARE

POS 16(1)

-

-

10DQ1.7

NIS 24 vdc

DP1

10

SPARE

POS 16(5)

-

-

10DQ8.0

NIS 24 vdc

DP1

10

TD-CRT SLIPS UP SOLENOID

10DQ8.1

NIS 24 vdc

DP1

10

TD-CRT ELEVATOR OPEN SOLENOID

POS 22(1) POS 22(5)

SLIPS UP ELEVATOR OPEN

SLIPS DOWN ELEVATOR ARMED OR CLOSED

10DQ8.2

NIS 24 vdc

DP1

10

TD-CRT LINK TILT EXTEND SOLENOID

POS 23(1)

LINK TILT MOVES TO “EXTEND” POSITION OR FLOATS

LINK TILT STOPS

10DQ8.3

NIS 24 vdc

DP1

10

TD-CRT LINK TILT DRILL SOLENOID

POS 23(5)

LINK TILT MOVES TO “DRILL” POSITION OR FLOATS

LINK TILT STOPS

10DQ8.4

NIS 24 vdc

DP1

10

TD-CRT LINK TILT FLOAT SOLENOID

POS 24(1)

LINK TILT MOVES TO “FLOAT” POSITION OR FLOATS

10DQ8.5

NIS 24 vdc

DP1

10

SPARE

POS 24(5)

-

LINK TILT STOPS -

10DQ8.6

NIS 24 vdc

DP1

10

SPARE

POS 25(1)

-

-

10DQ8.7

NIS 24 vdc

DP1

10

SPARE

POS 25(5)

-

-

DATA

DP1

10

STATUS BYTE

POS 17

-

-

POS 17

-

-

10IB2

NETWORK NODE

I/O DESCRIPTION

I/O

1 FUNCTION

DATE

0 FUNCTION

LOCATION

ENG. UNITS

10IB3

DATA

DP1

10

STATUS BYTE

10IB4

DATA

DP1

10

VALUE BYTE

POS 17

-

10IB5

DATA

DP1

10

RESERVED BYTE

POS 17

-

-

10IB6

DATA

DP1

10

RESERVED BYTE

POS 17

-

-

10IB7

DATA

DP1

10

RESERVED BYTE

POS 17

-

-

POS 17

-

-

10QB2

DATA

DP1

10

CONTROL BYTE

10QB3

DATA

DP1

10

SETPOINT BYTE

POS 17

-

10QB4

DATA

DP1

10

SETPOINT BYTE

POS 17

-

-

10QB5

DATA

DP1

10

RESERVED BYTE

POS 17

-

-

10QB6

DATA

DP1

10

RESERVED BYTE

POS 17

-

-

10QB7

DATA

DP1

10

RESERVED BYTE

POS 17

-

-

SHEET

3

OF

3

11/1/2011 2:13:31 PM

MIN ENG. MAX ENG. SETPOINTS REMARKS UNITS

UNITS

DWG NO

10620484-IDX

REV

01

NOTES: UNLESS OTHERWISE SPECIFIED 1. THIS DOCUMENT BEST VIEWED THROUGH MS EXCEL. 2. THE STATUS COLUMN AND REVISION LETTER CORRESPONDS TO THE MOST CURRENT CHANGE TO RESPECTIVE LINE (ROW).

MJOB-8375

TDS-11SA

NEXT ASSY

USED ON

APPLICATION

This document contains proprietary and confidential information which belongs to National-Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use of this design or distribution of this information to others is not permitted without the express written consent of NOV. This document is to be returned to NOV upon request and in any event upon completion of the use for which it was loaned. This document and the information contained and represented herein is the copyrighted property of NOV. © National Oilwell Varco

CURRENT

INITIAL

TITLE

HAZARDOUS AREA INDEX, TDS-11SA AC IDEAL RIG 135

DRAWN

B. BOEPPLE

CHECKED

R. MOENCH

SIZE

APPVD

R. MOENCH

B

DATE

11/1/2011

SCALE

DWG NO

REV

10620485-IDX 01 NONE

WT LBS

SHEET

1

OF

3

D74DCF0050-TPL-001 (REV B)

HAZARDOUS AREA INDEX, TDS-11SA AC IDEAL RIG 135

NATIONAL OILWELL VARCO

NOV TAG NO.

NOV P/N:

DESCRIPTION

LOCATION

MANUFACTURER

MANUFACTURER P/N:

HAZARDOUS RATING

HAZARDOUS ZONE

CERTIFICATION AGENCY

DATE

CERTIFICATE No.

TEMP. RATING

IP RATING

MATERIAL

BLOCK DIAG. DWG. NO. SHT.

INTERCONNECT DWG. NO. SHT.

11/1/2011 2:16:16 PM

ASSOCIATED COMPONENT

REMARKS

TDS-11SA

TD-MOT-01

108235

DRILL MOTOR ASSEMBLY

TD-11SA

RELIANCE ELECTRIC

108235

EEx nC II T3

ZONE 2

EPSILON

04ATEX1284X

-20ºC TO +50ºC

IP40

CAST IRON

10620480-DIA

2

10620482-DIA

2

TD-MOT-02

108235

DRILL MOTOR ASSEMBLY

TD-11SA

RELIANCE ELECTRIC

108235

EEx nC II T3

ZONE 2

EPSILON

Ex95Y4141X

-20ºC TO +50ºC

IP40

CAST IRON

10620480-DIA

2

10620482-DIA

2

TD-MOT-03

109755-2

HYDRAULIC PUMP MOTOR

TD-11SA

RELIANCE ELECTRIC

109755-2

CLASS 1, DIV 1, GRP D

-

UL

E10822 (N)

-25ºC TO +40ºC

IP56

CAST IRON

10620480-DIA

2

10620482-DIA

3

TD-MOT-04

30172028-1

RT. BLOWER MOTOR

TD-11SA

RELIANCE ELECTRIC

6283074

CLASS 1, DIV 1, GRP D

-

UL

E10822 (N)

-25ºC TO +40ºC

IP56

CAST IRON

10620480-DIA

2

10620482-DIA

3

TD-MOT-05

30172028-1

LT. BLOWER MOTOR

TD-11SA

RELIANCE ELECTRIC

6283074

CLASS 1, DIV 1, GRP D

-

UL

E10822 (N)

-25ºC TO +40ºC

IP56

CAST IRON

10620480-DIA

2

10620482-DIA

3

TD-PNJB01

110139

INSTRUMENT J-BOX

TD-11SA

HOFFMAN

A-1412NFSS

-

-

UL

-

-

NEMA 4X

304SS

10620480-DIA

2

10620482-DIA

3

PS-01

76841

RT. BLOWER DIFF PRESSURE SWITCH

TD-11SA

UNITED ELEC CONTROLS

J120K-15642

CLASS 1, DIV 1 & 2, GRP B,CD

-

UL

E40857(N)

-40ºC TO +71ºC

IP66

-

10620480-DIA

3

10620482-DIA

4

PS-02

76841

LT. BLOWER DIFF PRESSURE SWITCH

TD-11SA

UNITED ELEC CONTROLS

J120K-15642

CLASS 1, DIV 1 & 2, GRP B,CD

-

UL

E40857(N)

-40ºC TO +71ºC

IP66

-

10620480-DIA

3

10620482-DIA

4

PS-03

83095-1

IBOP PRESSURE SWITCH

TD-11SA

UNITED ELEC CONTROLS

J120-15643

CLASS 1, DIV 1 & 2, GRP B,CD

-

UL

E40857(N)

-40ºC TO +71ºC

IP66

-

10620480-DIA

3

10620482-DIA

4

PS-04

87541-1

LUBE OIL PRESSURE SWITCH

TD-11SA

UNITED ELEC CONTROLS

J120-15646

CLASS 1, DIV 1 & 2, GRP B,CD

-

UL

E40857(N)

-40ºC TO +71ºC

IP66

-

10620480-DIA

3

10620482-DIA

4

PS-05

83095-2

B & V ELEVATOR PRESSURE SWITCH

TD-11SA

UNITED ELEC CONTROLS

J120-15644

CLASS 1, DIV 1 & 2, GRP B,CD

-

UL

E40857(N)

-40ºC TO +71ºC

IP66

-

10620480-DIA

3

10620482-DIA

4

S0V-01

127908-D2

BRAKES ON SOLENOID

TD-11SA

ATOS

DHA/UL-0631/2/NPT 240C/20

CLASS 1, DIV 1

-

UL

TBS

-

IP66

CAST IRON

10620480-DIA

3

10620482-DIA

4

S0V-02

127908J2

ROTATE RIGHT SOLENOID

TD-11SA

ATOS

DHA/UL-0713/NPT 24DC/20

CLASS 1, DIV 1

-

UL

TBS

-

IP66

CAST IRON

10620480-DIA

3

10620482-DIA

4

SOV-03

127908J2

ROTATE LEFT SOLENOID

TD-11SA

ATOS

DHA/UL-0713/NPT 24DC/20

CLASS 1, DIV 1

-

UL

TBS

-

IP66

CAST IRON

10620480-DIA

3

10620482-DIA

4

SOV-04

127908-D2

IBOP CLOSE SOLENOID

TD-11SA

ATOS

DHA/UL-0631/2/NPT 240C/20

CLASS 1, DIV 1

-

UL

TBS

-

IP66

CAST IRON

10620480-DIA

3

10620482-DIA

4

SHEET

2

OF

3

DWG NO

10620485-IDX

REV

01

HAZARDOUS AREA INDEX, TDS-11SA AC IDEAL RIG 135

NATIONAL OILWELL VARCO

NOV TAG NO.

NOV P/N:

SOV-05

DATE

BLOCK DIAG. DWG. NO. SHT.

INTERCONNECT DWG. NO. SHT.

DESCRIPTION

LOCATION

MANUFACTURER

MANUFACTURER P/N:

HAZARDOUS RATING

HAZARDOUS ZONE

CERTIFICATION AGENCY

CERTIFICATE No.

TEMP. RATING

IP RATING

MATERIAL

127908-D2

TORQUE WRENCH SOLENOID

TD-11SA

ATOS

DHA/UL-0631/2/NPT 240C/20

CLASS 1, DIV 1

-

UL

TBS

-

IP66

CAST IRON

10620480-DIA

3

10620482-DIA

4

SOV-06

127908J2

LINK TILT EXTEND SOLENOID

TD-11SA

ATOS

DHA/UL-0713/NPT 24DC/20

CLASS 1, DIV 1

-

UL

TBS

-

IP66

CAST IRON

10620480-DIA

3

10620482-DIA

4

SOV-07

127908J2

LINK TILT DRILL SOLENOID

TD-11SA

ATOS

DHA/UL-0713/NPT 24DC/20

CLASS 1, DIV 1

-

UL

TBS

-

IP66

CAST IRON

10620480-DIA

3

10620482-DIA

4

SOV-08

127908-D2

LINK TILT FLOAT SOLENOID

TD-11SA

ATOS

DHA/UL-0631/2/NPT 240C/20

CLASS 1, DIV 1

-

UL

TBS

-

IP66

CAST IRON

10620480-DIA

3

10620482-DIA

4

SOV-09

127908-D2

STAND JUMP SOLENOID

TD-11SA

ATOS

DHA/UL-0631/2/NPT 240C/20

CLASS 1, DIV 1

-

UL

TBS

-

IP66

CAST IRON

10620480-DIA

3

10620482-DIA

5

SOV-10

127908-D2

Bx ELEVATOR OPEN SOLENOID

TD-11SA

ATOS

DHA/UL-0631/2/NPT 240C/20

CLASS 1, DIV 1

-

UL

TBS

-

IP66

CAST IRON

10620480-DIA

3

10620482-DIA

5

SOV-15

TBD

CRT SLIPS UP SOLENOID

TD-11SA

-

-

-

-

-

-

-

-

-

10620480-DIA

4

10620482-DIA

6

SOV-16

TBD

CRT ELEVATOR OPEN SOLENOID

TD-11SA

-

-

-

-

-

-

-

-

-

10620480-DIA

4

10620482-DIA

6

SOV-17

TBD

CRT LINK TILT EXTEND SOLENOID

TD-11SA

-

-

-

-

-

-

-

-

-

10620480-DIA

4

10620482-DIA

6

SOV-18

TBD

CRT LINK TILT DRILL SOLENOID

TD-11SA

-

-

-

-

-

-

-

-

-

10620480-DIA

4

10620482-DIA

6

SOV-19

TBD

CRT LINK TILT FLOAT SOLENOID

TD-11SA

-

-

-

-

-

-

-

-

-

10620480-DIA

4

10620482-DIA

6

PS-15

30178379

CRT SLIPS SET PRESSURE SWITCH

TD-11SA

UNITED ELEC CONTROLS

-

CLASS 1, DIV 1 & 2, GRP A,B,CD

ZONE 1

DEMKO

03ATEX0252466X

-50ºC TO +80ºC

IP66

SS

10620480-DIA

4

10620482-DIA

6

PS-16

-

CRT SJ ELEVATOR CLOSED PRESSURE SWITCH

TD-11SA

-

-

-

-

-

-

-

-

-

10620480-DIA

4

10620482-DIA

6

PS-17

-

CRT STOP LOWERING PRESSURE SWITCH

TD-11SA

-

-

-

-

-

-

-

-

-

10620480-DIA

4

10620482-DIA

6

LT-02

10077587-001

LINK CYLINDER LINEAR TRANSDUER

TD-11SA

ROTA

LTSY02621.SHB1804

EXII 1G, Eex ia IIC T4

ZONE 1

ATEX

BASOATEX1322

-20ºC TO +85ºC

-

SS

10620480-DIA

4

10620482-DIA

7

TDS-SJB01

10509113-001

BANNER FLEX POWER NODE

TD-11SA

BANNER ENGINEERING

14428

Ex ia IIC T4

ZONE 0

LCIE

08ATEX6098X

-40ºC TO +70ºC

IP68

PLYCARBONATE

10620480-DIA

4

10620482-DIA

7

SHEET

3

OF

3

11/1/2011 2:16:16 PM

ASSOCIATED COMPONENT

DWG NO

REMARKS

10620485-IDX

REV

01

FINAL DOCUMENTATION TDS-11SA - Top Drive Drilling System

Section 4.2 Top Drive Assembly

www.nov.com

8 N O TES

7 -

U N LESS

O T H E R W IS E

S P E C IF IE D :

1. REF: SYSTEM

S C H E M A T IC

124222.

2 . L U B R IC A T E ALL B O LTS

D

6

3

(R P ) =

4

PRESSURE O IL A IR

5

REPLAC EM AN T S W IT C H

PRESURE

PRESSURE

PART, 1

YEAR

S W IT C H S W IT C H

-

18

SPARES.

PSI + 0, - 2

1000 4 "W C

PSI ± 100 ± .5 "W C

D E S IG N A T O R

VO LTAG E

A

P S I (F A L L IN G ).

AT

REV

2

1

VO LTAG E

FREQUENC Y

VARC O

P / N IT E M

D

NO.

114174

10

-

-

-

(F A L L IN G ). TA B LE

B L O W E R / H Y D R A U L IC D E S IG N A T O R V O L T A G E & Q T Y FREQUENC Y

A S S E M B L Y . M IN IM U M

575VAC 60 Hz (T E F C )

60

DELETED

&

3

1

C O IL

24VDC

B

P S I (R IS IN G ).

P O T A L L R E C E P T A C L E S W IT H P O T T IN G C O M P O U N D (IT E M 6 3 ) P E R IN S T R U C T IO N S (IN C L U D E D W IT H P O T T IN G C O M P O U N D ). AFTER

TA B LE

S O L E N O ID

S E T T IN G S :

S W IT C H

6. M EGGER ALL AC - M O TO R LEADS R E S IS T A N C E : 2 M E G O H M S . 7

4

A L L B O L T S W IT H A N T I- S E IZ E C O M P O U N D . T O R Q U E P E R V A R C O S P E C . D S 0 0 0 0 8 A N D L O C K W IR E .

PRESSURE

IB O P

5

G.

1

2

M O TO R

VARC O P/N: 114113- 2

VO LTAG E IT E M NO.

D E S C R IP T IO N P U M P / M O TO R

R EF 30172028- 1 B LO W ER

ASSY

M O TO R

30188268 - XXXX

1

8

B A S IC 8

C

9

B L O W E R M O T O R A S S E M B L E D A T M O T O R / H O U S IN G R E F E R E N C E D R A W IN G N O . 1 2 0 9 0 0 . REPLAC ES

E X IS T IN G

ASSEM B LY

LEVEL

S O L E N O ID

H ARDW ARE TA B LE

10

M OVED Q TY

TO

SU B - ASSY

SHOWN

ARE

FOR

S E R V IC E

30182634. REFERENCE

O N LY.

P/N

LO O P / P O W ER VARC O P/N:

B L O W E R / H Y D R A U L IC

3

C O N N EC TO R

B RAC KET IT E M NO.

D E S IG N A T O R

Q TY

R ( R IG H T H A N D )

1

3 0 1 8 3 2 7 2 - R B R K T , S E R V IC E

1

127652- 501

B R AC K ET, C O N N EC TO R

80

1

30183272- L

B R K T , S E R V IC E

57

1

127652- 502 B R AC K ET, C O N N EC TO R

L (LE F T

H AN D)

C O IL V O L T A G E (S E E T A B L E 1 )

D E S C R IP T IO N LO O P

POWER

56

LO O P

C

M OTOR VOLTAGE (S E E T A B L E 2 )

C ON N EC TOR, B RAC K ET (S E E T A B L E 3 )

81

B

B

A

U N LESS

30183077 NEXT

TD S - 1 1 S A/ C R T

ASSY

USED

O T H E R W IS E

M A C H IN E D MAX 250

DRAW N

8

7

6

5

4

S P E C IF IE D

TO RC H 1000

CURRENT

ON

A P P L IC A T IO N UNLESS

O T H E R W IS E

CUT MAX

S P E C IF IE D

IN IT IA L

A G LO C K N E R

C HEC KED

H LIM

APPVD

H LIM

DATE

5/16/07

3

A

T H IS D O C U M E N T C O N T A IN S P R O P R IE T A R Y A N D C O N F ID E N T IA L IN F O R M A T IO N W H IC H B E L O N G S T O

IN T E R P R E T D IM / T O L P E R A S M E Y 1 4 .5 MN A T IO N A L - O IL W E L L , L .P . IT IS L O A N E D F O R L IM IT E D P U R P O S E S O N L Y A N D R E M A IN S T H E P R O P E R T Y O F D IM E N S IO N S A R E IN IN C H E S N A T IO N A L - O IL W E L L , L .P . R E P R O D U C T IO N , IN W H O L E O R IN P A R T , O R U S E O F T H IS D E S IG N O R .X X ± .0 3 .X X X ± .0 1 0 .X ± .1 D IS T R IB U T IO N O F T H IS IN F O R M A T IO N T O O T H E R S IS N O T P E R M IT T E D W IT H O U T T H E E X P R E S S W R IT T E N A N G L E S ± .5 ° C O N S E N T O F N A T IO N A L - O IL W E L L , L .P . T H IS D O N O T S C A L E D R A W IN G D O C U M E N T IS T O B E R E T U R N E D T O N A T IO N A L O IL W E L L , L .P . U P O N R E Q U E S T A N D IN A N Y E V E N T U P O N C O M P L E T IO N O F T H E U S E F O R W H IC H IT W A S L O A N E D . T H IS D O C U M E N T A N D T H E IN F O R M A T IO N C O N T A IN E D A N D R E P R E S E N T E D H E R E IN IS T H E C O P Y R IG H T E D P R O P E R T Y O F N A T IO N A L - O IL W E L L , L .P .

R IG S O LU TIO N S 1 0 0 0 0 R IC H M O N D A V E . H O U S TO N , TE X A S 7 7 0 4 2 U .S .A . (7 1 3 ) 3 4 6 - 7 5 0 0

2

T IT L E :

E L E C T R IC A L P A C K A G E , TD S - 1 1 S A (C R T3 5 0 ) SC ALE:

WT

P R O J E C T IO N :

LB S:

1/8 D R A W IN G

900

S IZ E :

D

SH EET:

1 OF 4 R E V IS IO N :

NUMBER:

30188268

-

1

DC F0022

(R E V

D)

7

8

1

D

C

30182634

6

E L E C / M A N IF O L D

SU B - ASSY

5

4

119888- 100- 38 C AB LE

2

50810- R- C

W ASH ER, FLAT

145

4

51803- C

NUT

144

4

50003- 6- C5D

SC REW , C AP- H EX

9

50649- 61

SCREW

18

56609- 11

T E R M IN A L

2

56612- 01

S P IC E

1

56611- 8

E L B O W , 4 5 ° IN T

-

D ELETED

138

-

D ELETED

137

3

55008- 12- C5D

SCREW, HEX

12

50182- 8- 03

S C R EW , C AP - B U TTO N

D

146

TR AY

10

1

143

H EAD

142

W IR E

141

R IN G

140

NUT

139

ELEC T

H EAD

56531- 8- S

P L U G , O - R IN G

3

56609- 25

T E R M IN A L , W IR E - R IN G

-

D ELETED

28

51804- C

N U T, H EX- S ELF

20

50004- 8- C5

SCREW, HEX

LK G

H EAD

(U N C - 2 B )

4

94872- 4

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D ELETED

-

D ELETED

16

B

10

A

H EAD

COND) 95

(4 2

C O N N EC TO R

SCREW, HEX

H EAD

L O C K W A S H E R , IN T E R N A L

S TAR

48

86872- 25- S

L O C K W A S H E R , IN T E R N A L

S TAR

47

92

3

16

50908- C

W ASH ER, LO C K - REGU LAR

46

16

50904- C

W ASH ER, LO C K - REGU LAR

45

14

50906- C

W ASH ER, LO C K - REGU LAR

44

89

5

50910- C

W ASH ER, LO C K - REGU LAR

43

88

6

50912- C

W ASH ER, LO C K - REGU LAR

42

87

6

50012- 16- C5D

SC REW , C AP- H EX

H EAD

41

50606- 8- C

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H EAD

40

2

50010- 52- C5D

SC REW , C AP- H EX

H EAD

39

-

D ELETED 50005- 4- C5D

SC REW , C AP- H EX

H EAD

37

8

50004- 8- C5D

SC REW , C AP- H EX

H EAD

36

12

50006- 8- C5D

SC REW , C AP- H EX

H EAD

35

91

8

50004- 10- C5D

SC REW , C AP- H EX

90

1

115911

C AB LE

1

115910

B R A C K E T , M O U N T IN G , C A B L E

115909

87074- 8- B

W ASH ER, LO C K

D ELETED

131

4

50206- B

SEE

B R A C K E T , M O U N T IN G , C A B L E

118993

-

SEE

H EAD

TR AY

C A B L E , 7 0 m m2

132

3

126

C AP

86872- 20- S

1

W AS H ER , FLAT- R EG U LAR

50910- S

TR AY TR AY

Y E LLO W W / G R E E N TR A C E R -

S TAR

4

N U T, H EX

TA BLE

B RASS H AN D

B R A C K E T , C O N N E C T O R - R IG H T

3

78002

C L A M P , S E R V IC E

50008- 16- C5D

LOOP

SC REW , C AP- H EX

H AN D

B RAC KET

H EAD

SC REW , C AP- H EX

H EAD

34

80

2

50010- 10- C5D

SC REW , C AP- H EX

H EAD

33

79

4

50008- 10- C5D

SC REW , C AP- H EX

H EAD

32

78

1

50010- 44- C5D

SC REW , C AP- H EX

H EAD

31

50006- 10- C5D

SC REW , C AP- H EX

H EAD

30

50008- 8- C5D

SC REW , C AP- H EX

-

D ELETED

123

1

115720

LAB EL, C O N N EC TO R

-

D ELETED

122

-

D ELETED

121

-

D ELETED

120

-

D ELETED

119

-

D ELETED

118

-

D ELETED

117

-

D ELETED

116

1

53219- 3

F IT T IN G , G R E A S E - S T R A IG H T

-

D ELETED

115

2

116427

S T U D , G R O U N D IN G

-

D ELETED

114

-

D ELETED

-

D ELETED

113

A/R

Z 6 0 0 0 .8

L O C K W IR E

Ø .0 3 1

-

D ELETED

112

1

56541- 32

K IT , S P L IT

FLAN GE

-

D ELETED

111

10

50905- C

W ASH ER, LO C K - REGU LAR

64

-

D ELETED

110

5

3M

63

-

D ELETED

109

10

75

1

56525- 12- 12S

T E E , S W IV E L

1

56509- 12- S

N U T, S H O R T

4

56606- 8

3 -

D ELETED

END

IN T

3 7 °/ 3 7 °/ 3 7 °

P O T T IN G

( IN C L U D E S

SHOWN)

ELB O W , C APPED

S E A L IN G

26

S E A L IN G

25

72

18

86871- 20

W ASH ER, N YLO N

S E A L IN G

71

1

78317- 50

LO C K N U T

23

1

78317- 25

LO C K N U T

22

18

78317- 20

LO C K N U T

1

129991- 07

GLAN D, EExe

ARM OU RED

C AB LE, 50m m

20

1

83444- 05

GLAN D, EExe

ARM OU RED

C AB LE, 25m m

19

13

83444- 01

GLAN D, EExe

ARM OU RED

C AB LE, 20m m

18

30183272- 07

P LATE

56626- 03

C A B L E , S H IP B O A R D - T W IS T E D / S H IE L D E D

66

2

50912- C

W ASH ER, LO C K - REGU LAR

60

-

D ELETED

106

2

50012- 16- C5D

SC REW , C AP- H EX

59

4

50004- 14- C5D

SC REW , C AP- H EX

105

-

D ELETED

1

110022- 1R

C O N N E C T O R , S IN G L E

P IN , P O W E R , R E D

104

SEE

TA BLE

3

B R K T , S E R V IC E

LO O P - LEFT

1

110022- 1W

C O N N E C T O R , S IN G L E

P IN , P O W E R , W H T

103

SEE

TA BLE

3

B R K T , S E R V IC E

L O O P - R IG H T

1

110022- 1B

C O N N E C T O R , S IN G L E

P IN , P O W E R , B L K

102

A/R

Z6001

L O C K W IR E

Ø .0 5 1

(N O T

SHOWN)

55

5

83444- 03

GLAN D, C AB LE, ARM O RED, 20m m

101

A/R

Z 6 0 0 0 .9

L O C K W IR E

Ø .0 4 7

(N O T

SHOWN)

54

1

83444- 07

GLAN D, C AB LE, ARM O RED, 32m m

100

10

110078- L18

C AB LE, S AFETY

( Ø .0 3 2 )

(N O T

SHOWN)

53

1

78317- 32

LO C K N U T

99

10

110078- FL2

C AB LE, S AFETY

(F E R R U LE ) (N O T

SHOWN)

52

1

86872- 32- S

L O C K W A S H E R , IN T E R N A L

98

3

86625- 02

GLAN D, C AB LE

-

JAC K E TE D (U L)

51

1

86871- 32

W ASH ER, N YLO N

4

86625- 01

GLAN D, C AB LE

-

JAC K E TE D (U L)

50

1

124459- 01- 20

C A B L E , P IG T A IL

86872- 50- S

L O C K W A S H E R , IN T E R N A L

PART

NO.

COMP

(1 8

COND) 96

L IS T

Q TY REF

REQD

FOR

Q TY

O N LY

OF

BSC IT E M S

1

ITE M NO.

D E S C R IP T IO N

Q TY R E Q D

9

M A T E R IA L

PART

ARE

58

NO.

L IS T

Q TY IN

SUB - ASSY

30182634

S TAR

REF

REQD

FOR

Q TY

O N LY

OF

BSC IT E M S

1

1

25FT

1 0 1 5 9 F T 2 4 1 F T 5 6 6 2 5 - 1 .5 - 0 3

21

17

B RAC KET

5 6 6 2 5 - 2 .5 - 0 4

C A B L E , S H IP B O A R D - M U L T IC O R E

13

2

76841

PRESSURE

S W IT C H , A IR

12

4

1

87541- 1

PRESSURE

S W IT C H , O IL

11

4

1

83095- 1

PRESSURE

S W IT C H , IB O P

10

-

D ELETED

8

53301- 10- 6

-

D ELETED

10

1

10

1

10

1

9 S C R E W , D R IV E - T Y P E

5

8 7

P L A T E , M O U N T IN G - J - B O X / M A N IF O L D

6

4

112711

P LATE, M O TO R

5

1

115202

N AM EP LATE, C O N N EC TO R

124994

J- B O X

SEE

TA BLE

1

M A N IF O L D

SEE

TA BLE

2

P U M P / M O TO R

PART

NO.

W A R N IN G

2

ASSY ASSY

1 ITE M NO.

D E S C R IP T IO N

L IS T

Q TY R E Q D

OF

4 3

ASSEM B LY

A

M A T E R IA L

M A T E R IA L

Q TY

ASSY ARE

IN

SUB - ASSY

REF

30182634

REQD

FOR

Q TY

O N LY

BSC IT E M S

ASSY ARE

SC ALE

6

U

110143

D

7

14

H EAD

S IZ E

8

15

C A B L E , S H IP B O A R D - M U L T IC O R E

4

10 66FT

B

16

50008- 16- C 5D SC REW , C AP- H EX

56

49

24

3

3

57

ITE M NO.

D E S C R IP T IO N

Q TY R E Q D

ASSY

10

69

107

10

27

W ASH ER, N YLO N

D ELETED

H AN D

B U S H IN G , R E D U C IN G , E L E C T R IC A L W ASH ER, N YLO N

61

H AN D

28

56600- 12- 8 86871- 25

62

H EAD

B U S H IN G , R E D U C IN G , E L E C T R IC A L

86871- 50

H A R D W A R E )6 5

COMPOUND

56600- 16- 12

1

68

(N O T

3 1

70 EXTEN D ED

D ELETED

73

67

A/R 127386

108

(B LU E )

C

29

4

74 C O M P O U N D , L O C K IN G R ED U C ER , TU B E

2

76

-

ASSY

10

77

H EAD

38

50008- 20- C5D

4

56516- 12- 8- S

4

2

124

1

2

81

D ELETED

A/R 53200- 242

2

82

B R AC K ET, C O N N EC TO R - LEFT

3

TA BLE

-

-

97

10

83

125

S E A L IN G

10

84

W ASH ER, LO C K

D ELETED

S TAR

10

86

-

H EAD

10

85

(B R AS S )

127

50006- 12- C5D

18

93

94

50804- R- C

2

128

C AP

COMP

ASSY

LU G, C O PPER

129

SCREW, HEX

ASSY

B AR

16

133

130

C AP

E A R T H IN G

2

134

BOSS

C A B L E , P IG T A IL

118866

15FT

135

H EAD

122718- 01- 20 1

1

136

C AP

1

50008- 12- C5D

1

2

147

1

4

3

4

3

2

IN

DWG

SUB - ASSY

30182634

REV

NO

30188268 1/8

WT

LB S

2

SHEET

1

OF

4

DC F0022

(R E V

D)

7

8

6

5

4

3

1

2 51

134

28

2X

140

131 4X

141 6X

12 REF

142 3X

D 4X 4X

131

143

130

96

130 4X

63 A/R

5

13

144

131 4X

130 4X 5

1 0 2 (B L K )

131 4X

63 A/R 1 0 3 (W H T )

D

130 4X 5

63 A/R 1 0 4 (R E D )

95 8 0 (R IG H T

H AND

C O N F IG . O N L Y )

4 4X

C

C O N F IG . O N L Y )

4X

55 A/R

C O N F IG . O N L Y )

LEFT

H AND

6

C

65

32 4X 2PL

4

128

9

4

46

9

80

FOR

R IG H T

81

FOR

LEFT

46 32

H AND

AND

8

A/R 55

(L E F T

R IG H T

75

59 2X 60 2X

REF

B O TH

94

H AND 81

(L E F T

146

8

57

55

(O P P O S IT E

H AND H AND

C O N F IG . O N L Y C O N F IG . O N L Y

REF REF

S ID E )

4X A/R

33 43

2X

145

(R IG H T

A/R 55

B

17

56

3X 78 H AND

C O N F IG . O N L Y )

14

6X 41

68 3X

73

ONE

PER

M O TO R

46

B

6X 42 147 10

4X REF

37

20 19

64 10

101

10

5X REF

21

18

24

21

48

22 REF 25

11X

5 35

49

A 6

28

21

97

24

98

48

REF

10

56

FOR

57

F O R L E F T H A N D C O N F IG . O N L Y (O P P O S IT E S ID E )

41 8X A/R

42

R IG H T

H AND

C O N F IG . O N L Y

99

2X

34

1

HAND

S E R V IC E

LO O PS

140

2X

141

6X

142

3X

A

SHOWN S IZ E

D

SC ALE

7

6

REF

51

R IG H T

8

REF

46

13

REF

4X

44

18

10

A

10

55

100

4

REF

10

48

A

26

47

24

REF

69

23

5

4

3

2

DWG

REV

NO

30188268 1/8

WT

LB S

3

SHEET

1

OF

4

DC F0022

(R E V

D)

7

8

6

5

4

(B L O W E R

M O TO R

ASSEM B LED

AT

3

M O T O R / H O U S IN G

ASSEM B LY

P/N

1

2

120900)

D

D (R E F

12

ASSEM B LED

4X 36

2X

ENCODER

2X 50

115299

(C O N N E C T O R

M O T O R / H O U S IN G

ASSEM B LY

B

4X 45

AT

P/N P/N

PART

120900)

OF

P LU G -

D IG IT A L E N C O D E R )

15

A/R 55

B 16

8 1 (R E F

-

LEFT

H AND

C O N F IG . O N L Y ) (M O T O R

POWER

V IE W

C AB LES)

B-B

SC ALE: N ON E

C

C 68 SEE

D E T A IL

REF

C 82 2X

85

88 4X 135

93

2X

8X 91 86

4X

89

6

35

REF

84

10

TO

EARTH

B AR

(IT E M

94)

44 5 7 (R E F

-

LEFT

H AND

C O N F IG . O N L Y ) 17

B

3X

10

14 46

2X 40

87

10

REF

30

2X

B

44

REF

4X 135 8X 91

C

D E T A IL 6

66 131 45 105 11 A/R

REF

1/1

50

147

4X

SC ALE 2 PL

10 62 REF 27 2X

9X

50 139 50

15

10

137 4X

45

39

2X

43

31

A/R 55

43

36

A

A/R 66

V IE W

LEFT

HAND

A- A

S E R V IC E

3

A

A 8

LO O PS

10

15 9X REF

SHOWN

S IZ E

D

SC ALE

8

7

6

5

4

3

2

DWG

REV

NO

30188268 1/8

WT

LB S

4

SHEET

1

OF

4

DC F0022

(R E V

D)

8

7

N O TES: U N LESS 1.

AP P LY

O T H E R W IS E

A N T I- S E IZ E

2 GREASE P O IN T S .

6

5

4

3

2

1

S P E C IF IE D

AND

TO RQ UE

ALL B O LTS

PER

D S 0 0 0 0 8 , L O C K W IR E

ALL B O LTS.

A L L S E R V IC E

2

4X

D

D A 2

3

4

C O N F IG U R A T IO N

5 A

DASH

5

NO

SETB AC K

-BSC

A 5 A 3

15X

4

15X

6

AR

TAB LE

D E S C R IP T IO N

3 0 .0 0

-500

3 3 .7 5

-501

3 9 .5 0

-502

3 9 .5 0

S T A N D A R D V E R S IO N 3 9 .5 0 " S E T B A C K S

-503

4 1 .0 0

F IR S T U S E D O N T A L IS M A N C L A Y M O R E

C

T Y P IC A L A P P L IC A T IO N W H E N B L O C K IS N A R R O W S ID E T O G U ID E B E A M S P E C IA L U S E D O N L Y F O R T W O O R D E R S . SEE CC 128579 & 128952 FOR

A

C

1 7 12 2 1

-

-

-

-

124539-503

C A R R IA G E

A S S Y , R IG H T , 4 1 .0 0 " S E T B A C K

13

1

-

-

-

-

124538-503

C A R R IA G E

A S S Y , L E F T , 4 1 .0 0 " S E T B A C K

12

-

1

-

-

-

124539-502

C A R R IA G E

A S S Y , R IG H T , 3 9 .5 0 " S E T B A C K

11

-

1

-

-

-

124538-502

C A R R IA G E

A S S Y , L E F T , 3 9 .5 0 " S E T B A C K

10

-

-

2

-

-

141510

C A R R IA G E

S P A C E R , 3 9 .5 0 " S E T B A C K

9

-

-

-

1

-

124539-500

C A R R IA G E

A S S E M B L Y , R IG H T , 3 3 .7 5 " S E T B A C K

8

-

124538-500

C A R R IA G E

A S S E M B L Y , L E F T , 3 3 .7 5 " S E T B A C K

7

L O C K W IR E

Ø .0 5 1

6

8

B

13

5 4X

-

-

-

1

A/R

A/R

A/R

A/R

A/R Z6001

4

4

8

4

4

51222-12-16

P IN , S P IR A L

15

15

24

15

15

939390-10

W ASH ER , FLAT

15

15

24

15

15

50016- 20- C 5D SC REW , C AP- H EX

-

-

1

-

1

124539

-

-

1

-

1

124538

- 503

- 502

- 501

- 500

- BSC PART

Q TY

5

U N LESS

R IG H T S ID E V IE W

7

6

TD S - 9 S

ASSY

UNLESS

O T H E R W IS E

M A C H IN E D MAX 250

5

USED

4

TO RC H 1000

CUT MAX

O T H E R W IS E

CURRENT DRAW N

S P E C IF IE D

H EAD

3

A S S Y , R IG H T , 3 0 .0 0 " S E T B A C K

C A R R IA G E

A S S Y , L E F T , 3 0 .0 0 " S E T B A C K

NO.

2 1 IT E M

D E S C R IP T IO N

S P E C IF IE D

OF

NO.

IN IT IA L

M .C L A R K

J .M A R T IN E S

C HEC KED

B .B R A M A N

N .W E S T

APPVD

B .B R A M A N

N .W E S T

DATE

5/9/07

3

3/26/98

A

M A T E R IA L S

T H IS D O C U M E N T C O N T A IN S P R O P R IE T A R Y A N D C O N F ID E N T IA L IN F O R M A T IO N W H IC H B E L O N G S T O

IN T E R P R E T D IM / T O L P E R A S M E Y 1 4 .5 MN A T IO N A L - O IL W E L L , L .P . IT IS L O A N E D F O R L IM IT E D P U R P O S E S O N L Y A N D R E M A IN S T H E P R O P E R T Y O F D IM E N S IO N S A R E IN IN C H E S N A T IO N A L - O IL W E L L , L .P . R E P R O D U C T IO N , IN W H O L E O R IN P A R T , O R U S E O F T H IS D E S IG N O R .X X ± .0 3 .X X X ± .0 1 0 .X ± .1 D IS T R IB U T IO N O F T H IS IN F O R M A T IO N T O O T H E R S IS N O T P E R M IT T E D W IT H O U T T H E E X P R E S S W R IT T E N A N G L E S ± .5 ° C O N S E N T O F N A T IO N A L - O IL W E L L , L .P . T H IS D O N O T S C A L E D R A W IN G D O C U M E N T IS T O B E R E T U R N E D T O N A T IO N A L -

ON

A P P L IC A T IO N

OF

TD S - 9 S / 11S

8

TD S - 1 1 S

119953 NEXT

L E F T S ID E REAR

119954

4

C A R R IA G E

L IS T

A

H ARDENED

REQD

A

B

O IL W E L L , L .P . U P O N R E Q U E S T A N D IN A N Y E V E N T U P O N C O M P L E T IO N O F T H E U S E F O R W H IC H IT W A S L O A N E D . T H IS D O C U M E N T A N D T H E IN F O R M A T IO N C O N T A IN E D A N D R E P R E S E N T E D H E R E IN IS T H E C O P Y R IG H T E D P R O P E R T Y O F N A T IO N A L - O IL W E L L , L .P .

R IG S O LU TIO N S 1 0 0 0 0 R IC H M O N D A V E . H O U S TO N , TE X A S 7 7 0 4 2 U .S .A . (7 1 3 ) 3 4 6 - 7 5 0 0

2

T IT L E :

C A R R IA G E , SC ALE:

WT

LB S:

1/4 D R A W IN G

1300

P R O J E C T IO N :

PACKAGE S IZ E :

D

SH EET:

1 OF 5 R E V IS IO N :

NUMBER:

30124540

H

1

DC F0022

(R E V

D)

8

7

6

5

4

3

1

2

D

D

2 8

C

C

B

B

A

A V IE W A - A

-BSC

1

7 D

SHOWN S IZ E

D

SC ALE

8

7

6

5

4

3

2

DWG

REV

NO

30124540 1/4

WT

LB S

H

1300 SHEET

2

1

OF

5

DC F0022

(R E V

D)

8

7

6

5

4

3

1

2

D

D

9

2

C

C

B

B

3 9 .5 0 S ETB AC K

A

1

V IE W A - A

A 7

D

- 501 SHOWN (S P E C IA L )

S IZ E

D

SC ALE

8

7

6

5

4

3

2

DWG

REV

NO

30124540 1/4

WT

LB S

H

1300 SHEET

3

1

OF

5

DC F0022

(R E V

D)

8

7

6

5

4

3

1

2

D

D

11

C

C

B

B

3 9 .5 0 1 SETB AC K

A 1

V IE W A - A

- 502

A

7 D

SHOWN

S IZ E

D

SC ALE

8

7

6

5

4

3

2

DWG

REV

NO

30124540 1/4

WT

LB S

H

1300 SHEET

4

1

OF

5

DC F0022

(R E V

D)

8

7

6

5

4

3

1

2

D

D

11

C

C

B

B

4 1 .0 0 1 SETB AC K

A

A 1

V IE W A - A

- 503

7 D

SHOWN S IZ E

D

SC ALE

8

7

6

5

4

3

2

DWG

REV

NO

30124540 1/4

WT

LB S

H

1300 SHEET

5

1

OF

5

DC F0022

(R E V

D)

8

7

6

5

4

3

NOTES: UNLESS OTHERWISE SPECIFIED

CONFIGURATION TABLE DASH NO

1.

ADJUST TO ALLOW LIGHT CONTACT WITH ITEM 21.

2.

LUBRICATE ALL JAM NUTS (ITEM 13) & (ITEM 7) WITH GREASE, TORQUE JAM NUTS (ITEM 7: 300 LBS) (ITEM 13: 400 LBS)

20 2X 19

3. LUBRICATE ALL OTHER THREADS WITH ANTI-SEIZE COMPOUND,

D

1

A/R 2X

33 -503

5. PACK WITH GREASE PRIOR TO ASSY.

27

6. DRILL SHANKS Ø.141 ON ASSEMBLY FOR ITEM 31.

11 2X

24

2X

26

2X

2X

23

4X

25

4X

26

4X

12 3X 14 3X

7

4X 34 6

2

28 3X

4

31 3X 18 2X

8X

6

2

8X

7

7

8X

4

2

2X

13

2X

8

2X

5

5 13 8

2X 2X

2

2X

34 2X 22

B

9.2

-500

33.75

39.50

13.0

STD FOR 39.50" SETBACKS

D

18.7

41.00

20.2

16

2X

17

2X

(ITEM 27)

1

10

USED WITH ADDITIONAL SPACER

-502 -503

C

34 4X

30.00

REF DIM A

15

(20.8)

3

DESCRIPTION

FOR SPECIAL 39.50" SETBACK

30 -502

4. GREASE CAM FOLLOWERS AFTER ASSY.

SETBACK

-BSC

-BSC

29 -500

32 6X

AND TORQUE TO DS00008. DO NOT LOCKWIRE.

2X

1

2

10

10

10

10

FITTING, GREASE (1/8"-27 NPT)

34

1

-

-

-

124535-503

CARRIAGE, (LEFT), 41.00" SETBACK

33

6

6

6

6

51219-2

FERRULE, CABLE

32

3

3

3

3

51402-12-S

PIN, COTTER

31

-

1

-

-

124535-502

CARRIAGE, (LEFT), 39.50" SETBACK

30

-

-

1

-

124535-500

CARRIAGE, (LEFT), 33.75" SETBACK

29

3

3

3

3

50812-N-C

WASHER, FLAT

28

53201

1

1

1

1

113370

STRAP, ACCUMULATOR, Ø6"

27

6

6

6

6

50908-C

WASHER, LOCK-REGULAR

26

4

4

4

4

50008-10-C5D

SCREW, HEX HD. CAP, 1/2 UNC X 1.25

25

2

2

2

2

50108-10-CD

SCREW, CAP-SOCKET HD. 1/2 UNC X 1.25

24

2

2

2

2

88710

STRAP

23

1

1

1

1

125727-2

PLATE

22

2

2

2

2

125727-1

PLATE

21

2

2

2

2

30152845

PIN

20

CABLE RETAINING Ø.063

1

1

1

1

51220-2

2

2

2

2

125727-3

2

2

2

2

2

2

2

2

1

1

1

1

72" LONG

C

19

FERRULE BAR

18

50906-C

WASHER, LOCK-REGULAR

17

50006-5-C5D

SCREW, HEX HD. CAP

16

129375

BRACKET, ANGLE

15

3

3

3

3

30179918

BOLT, SHOULDER SOCKET HD (UNC-3A)

4

4

4

4

80569

NUT, JAM, 2"-12 UN-2B

(MODIFIED)

13

3

3

3

3

50512-C

NUT, HEX SLOTTED

12

2

2

2

2

30157306

PIN, LINCH Ø.188

11

4

4

4

4

109944

BUSHING, FLANGED, 2.75 ID

10

4

4

4

4

51132-C

WASHER, LOCK, HI-COLLAR, 2" DIA.

8

8

8

8

8

8

8

8

2

2

2

8

8

8

2

2

2

2

-

-

B

14

9

(A)

21 2X

(68.0)

A

CONFIG

TDS-9S

PRODUCT:

INSTALL CAM FOLLOWERS ON THE MILL SIDE OF BOGEY

2

30155438

CAM FOLLOWER 6" DIA

5

8

51024-C

WASHER, LOCK - 1.5"

4

2

2

124537

BOGEY

3

2

2

112875

PIN, BOGEY PIVOT

2

-

1

124535

CARRIAGE, (LEFT), 30.00" SETBACK

INSTALL LOCK WASHER AND NUT ON COUNTER BORE SIDE

PART

TOL < ±.06

250

4

ANGLES

X.XX

±.03

1/2 DEG ± 1/16

±

FRACTIONS

X.XXX ±.010

BREAK EDGES .02/.03

CURRENT

TOL > ±.06 1000

INITIAL

A. PHILLIPS

JOHN MARTINEZ

H. LIM

NEIL WEST

APPVD

H. LIM

NEIL WEST

1/26/10

3/17/98

3

1 ITEM NO.

DESCRIPTION

OF

MATERIAL

A

THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL

INFORMATION WHICH BELONGS TO NATIONAL OILWELL VARCO,

L.P., ITS AFFILIATES OR SUBSIDIARIES (ALL COLLECTIVELY REFERRED TO HEREINAFTER AS "NOV"). IT IS LOANED FOR

LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF

NOV. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF

TITLE:

THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NOV. THIS DOCUMENT IS TO BE RETURNED

CHECKED

DRAWN

DATE

5

±.1

650

UNLESS OTHERWISE SPECIFIED

ENSURE ALL CAM FOLLOWERS ROTATE AFTER THEY ARE INSTALLED AND TORQUED

X.X

NO.

LIST

DO NOT SCALE DRAWING

FINISH

6

BSC

TOLERANCES ARE:

SIMILAR TO: WT LBS:

7

6

UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES.

124540

NEXT ASSY:

8

7

BEARING, CAM FOLLOWER

55324-C

QTY REQD

SHOWN

END ITEM:

7

NUT, HEX-JAM (1.50-12 UNF-2B)

30158767-04

-503 -502 -500

BSC

8

TO NOV UPON REQUEST OR UPON COMPLETION OF THE

CARRIAGE ASSEMBLY, LEFT

USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED AND REPRESENTED HEREIN IS THE COPYRIGHTED PROPERTY OF NOV.

SCALE:

RIG SOLUTIONS DWG NO.

MECHANICAL ENGINEERING

2

1/4

PROJECTION:

SIZE:

D

SHT:

1

124538

1

REV:

OF

1

AA

DRAWN IN ACAD

RS-MECH_D-TPL-001

8

7

6

2

4

3

CONFIGURATION TABLE

INSTALL LOCK WASHER AND NUT ON COUNTER BORE SIDE

ADJUST TO ALLOW FREE MOTION OF ITEM 21.

DASH NO

ENSURE ALL CAM FOLLOWERS ROTATE AFTER THEY ARE INSTALLED AND TORQUED

LUBRICATE ALL JAM NUTS (ITEM 13) WITH GREASE,

SETBACK

-BSC

DESCRIPTION

30.00 & 39.50

3.

LUBRICATE ALL OTHER THREADS WITH ANTI-SEIZE COMPOUND,

-500

AND TORQUE TO DS00008. DO NOT LOCKWIRE.

2X

REF DIM A

USED WITH ADDITIONAL SPACER

9.2

FOR SPECIAL 39.50" SETBACK

TORQUE JAM NUTS 300 TO 400 ft-lbs.

D

1

2

INSTALL CAM FOLLOWERS ON THE MILL SIDE OF BOGEY

8

NOTES: UNLESS OTHERWISE SPECIFIED 1

5

4

GREASE CAM FOLLOWERS AFTER ASSY.

5

PACK WITH GREASE PRIOR TO ASSY.

6

DRILL SHANKS Ø.141 ON ASSEMBLY FOR ITEM 25.

7.

(OBSOLETE DWG 124539) CARRIES REVISION HISTORY FOR THIS DWG

1

33.75

-502

-BSC

39.50

-503

23 -500

D

13.0

STD FOR 39.50" SETBACKS

18.7

41.00

20.2

24 -502 27 -503

3 8

(20.5)

C

C

2X 11

4X 15

4X 10

6

4X 29

1

3X 14

4

3X 16 6X

17

8X

2

6

2

8X

7

8

8X

4

2

2X 19

2X

13

2X

8

2X

5

15

4X

29 4X

5

2X

13

2X

8

2X

28

2X

2

2X 20

B

3X 22 15 2X

3X 25 12

29 2X

2X 18

10

10

10

10

GREASE CAP

GREASE CAP

29

2

2

2

2

53000-2-C

PLUG EXT. PIPE CTSK/HEX

28

1

-

-

-

CARRIAGE, (RIGHT), 41.00" SETBACK

27

DELETED

26

124536-503

51402-12-S

PIN, COTTER

25

-

124536-502

CARRIAGE, (RIGHT), 39.50" SETBACK

24

1

-

124536-500

CARRIAGE, (RIGHT), 33.75" SETBACK

23

3

3

50812-N-C

WASHER, FLAT

22

3

3

3

3

-

1

-

-

-

3

3

2

2

2

2

125727-1

2

2

2

2

4

4

4

2

2

2

6

6

3

3

10

PLATE

21

30152845

PIN

20

4

51220-2

CABLE RETAINING Ø.063, 48" LONG

19

2

125727-3

FERRULE BAR

18

6

6

51219-2

FERRULE CABLE

17

3

3

50512-C

NUT, HEX-SLOTTED (UNF-2B)

16

10

10

10

53201

FITTING, GREASE (1/8"-27 NPT)

15

3

3

3

3

30179918

BOLT, SHOULDER SOCKET HD (UNC-3A) (MODIFIED)

14

4

4

4

4

80569

NUT, JAM, 2"-12 UN-2B

13

1

1

1

1

125727-2

PLATE

12

2

2

2

2

30157306

PIN, LINCH Ø.188

11

4

4

4

4

109944

BUSHING, FLANGED, 2.75 ID

10

4

4

4

4

51132-C

WASHER, LOCK, HI-COLLAR, 2" DIA.

8

8

8

8

55324-C

NUT, HEX-JAM (1.50-12 UNF-2B)

7

8

8

8

8

30158767-04

BEARING, CAM FOLLOWER

6

2

2

2

2

30155438

CAM FOLLOWER, 6"

5

8

8

8

8

51024-C

WASHER, LOCK - 1.5"

4

2

2

2

2

124537

BOGEY

3

2

2

2

2

112875

PIN, BOGEY PIVOT

2

-

-

-

1

124536

CARRIAGE, (RIGHT), 30.00" SETBACK

B

9

(A)

-503 -502 -500 BSC

PART NO.

QTY REQD

(68.0)

TDS-9S

UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES.

TOLERANCES ARE:

END ITEM:

124540

NEXT ASSY:

-BSC SHOWN

FINISH

5

4

ANGLES

±.03

1/2 DEG ± 1/16

±

FRACTIONS

BREAK EDGES .02/.03

CURRENT

TOL > ±.06 1000

INITIAL

A. PHILLIPS

JOHN MARTINEZ

H. LIM

NEIL WEST

APPVD

H. LIM

NEIL WEST

1/26/10

3/17/98

3

A

THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL

INFORMATION WHICH BELONGS TO NATIONAL OILWELL VARCO,

L.P., ITS AFFILIATES OR SUBSIDIARIES (ALL COLLECTIVELY REFERRED TO HEREINAFTER AS "NOV"). IT IS LOANED FOR

LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF

NOV. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF

TITLE:

CARRIAGE ASSEMBLY, RIGHT

THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NOV. THIS DOCUMENT IS TO BE RETURNED

CHECKED

DRAWN

DATE

6

X.XX

650

UNLESS OTHERWISE SPECIFIED

250

±.1

DO NOT SCALE DRAWING

WT LBS:

TOL < ±.06

X.X

X.XXX ±.010

SIMILAR TO:

7

NO.

LIST OF MATERIALS PRODUCT:

8

1 ITEM

DESCRIPTION

21 2X

A

8

TO NOV UPON REQUEST OR UPON COMPLETION OF THE USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED AND REPRESENTED HEREIN IS THE COPYRIGHTED PROPERTY OF NOV.

SCALE:

RIG SOLUTIONS DWG NO.

MECHANICAL ENGINEERING

2

1/4

PROJECTION:

SIZE:

D

SHT:

1

30124539

1

REV:

OF

1

U

DRAWN IN ACAD

RS-MECH_D-TPL-001

8

7

6

5

4

3

2

1

N O T E S U N L E S S O T H E R W IS E S P E C IF IE D 1.

L U B R IC A T E A L L O - R IN G W IT H G R E A S E O R H Y D R A U L IC O IL A T A S S E M B L Y .

2.

T H E S E P L A S T IC P L U G S A R E R E M O V E D A T T H IS L E V E L A N D R E P L A C E D W IT H IT E M 1 4 # 5 6 5 1 9 - 1 2 - 1 2 S

D

3. 4.

NO

TO RQ U E ALL B O LTS PER DS00008.

PO RTS

P O S IT IO N

D

#3

C L E A N C L E V IS A N D R O D T H R E A D S , A P P L Y B L U E . L O C T IT E , A N D T O R Q U E T O 3 0 0 - 3 5 0 L B - F T .

5.

T A G W IT H V A R C O P A R T N U M B E R A N D R E V IS IO N L E T T E R .

6.

R E P L A C E B O L T S IN C L U D E D IN IT E M 3 W IT H IT E M 1 0 .

7.

P E E N P R O T R U D IN G T H R E A D S T O P R E V E N T N U T S

2 .0 0

REF

F R O M B A C K IN G O F F .

12

1

6

1

PO RTS

P O S IT IO N

6

#4

C

C

2PL

7

2

4

7 4PL 4 6

3

8

9

10

1

11

{

1

12

4PL

Ø 1 .3 7 5

1

REF

6

5

B

B 2 .5 0

PO RTS

REF

2

P O S IT IO N

2 4 .1 8 0

FU LLY

#1

RETRAC TED

4 2

56519-12-12-S

ELB O W , O - R IN G B O SS/ 37°

14

Z6001

LO C K W IR E Ø .05 1

13

2

50516-C

N U T, H EX SLO TTED

12

4

50906-C

LO C K W ASH ER

11

4

50006-12-C5D

SC R EW

10

1

1 1 0 0 7 8 - FL2

C AB LE, SAFETY, FER R U LE Ø .032

9

1

1 1 0 0 7 8 - L3 6

C AB LE, SAFETY, Ø .032

8

2

51437-16-S

P IN , C O TTER

7

3

87196-12-S

P LU G , SAE- 1 2 H EX SO C K ET

6

1

30172176-502

P IN , C LEVIS, C YLIN D ER , C O U N TER B ALAN C E

5

1

30172176- BSC

P IN , C LEVIS, C YLIN D ER , C O U N TER B ALAN C E

4

1

94681-12

B LIN D FLAN G E K IT, C O D E 6 1

3

1

111935

C LEVIS, R O D EN D , C YLIN D ER , C O U N TER B ALAN C E

2

1

110687

C YLIN D ER , 4", C 'B AL

A/R

2

PART Q TY

NO.

P AR T FLAG S

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M A T E R IA L S

V A R C O IN T E R N A T IO N A L , IN C . A L L R IG H T S R E S E R V E D

A T IT L E

W A S H P IP E ASSEM B LY, 3" B O R E

IN IT IA L

M . S A Z O H .O L S T Y N S K I E. DEU TSC H B . B RAM AN 09/20/04

JPSJ JPSJ 11/97

S IZ E

D

SC ALE

4

SET)

P IP E

D O C U M E N T M A Y N O T B E C O P IE D O R R E P R O D U C E D IN A N Y W A Y W ITH O U T TH E W R ITTE N C O N S E N T O F V A R C O . V A R C O O W N S A L L R IG H TS TO TH IS W O R K A N D IN TE N D S TO E N F O R C E ITS R IG H TS U N D E R TH E C O P Y R IG H T L A W S A S A P U B L IS H E D W O R K .

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± .5 °

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S P E C IF IE D

TO RC H

IN

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11 9

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NO.

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EXT.

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1

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30123290 H WT

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8

7

6

5

4

3

2

1

NOTES: UNLESS OTHERWISE SPECIFIED 1. CLEAN OUT ALL HOSES PRIOR TO ASSEMBLY. 2. CYCLE CYLINDERS AFTER INSTALLATION OF HOSES AND PRIOR TO ATTACHING TO HOOK.

D

3. FOLLOW ADJUSTMENT PROCEDURES IN SERVICE MANUAL. 4

D

SEE DRAWING 112190 FOR ADDITIONAL COUNTERBALANCE COMPONENTS.

C

C

CONFIGURATION TABLE

4

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CONFIGURED FOR USE WITH HOOKS.

-BLOCK

CONFIGURED FOR USE WITH BLOCKS

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CONFIGURED FOR USE WITH BECKET

B

B

DRAWING, COUNTERBALANCE PACKAGE (BECKET) SHACKEL (13.5 TON)

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1

PART NO.

DESCRIPTION

QTY REQD

ITEM

MATERIAL

NO.

LIST OF MATERIALS

A

PART FLAGS TRACEABILITY CRITICAL LOAD PATH ITEM CERTIFICATION

REQUIRED

SPARE PART COMMISSIONING OPERATIONAL INSURANCE

DIMENSIONS UNLESS OTHERWISE SPECIFIED ARE IN

INTERPRET DIMENSIONS &

INCHES

TOLERANCES PER ANSI Y14.5 &

DO NOT SCALE DOCUMENT

6

5

4

3

.XX ±.030

*TORCH CUT 1000 MAX

-

-

TITLE

.XXX ±.010

ANGULAR TOLERANCE ±0° 30'

INFORMATION MAY NEITHER BE DISCLOSED TO OTHERS FOR ANY

-

-

KIT, TRAVELING

112190

TDS-9S

EQUIPMENT ATTACHMENT

NEXT ASSY

PRODUCT

PURPOSE NOR USED FOR MANUFACTURING PURPOSES WITHOUT

WRITTEN PERMISSION FROM VARCO INTERNATIONAL, INC.

B

LTR

7

A

FINISHES

ABBREVIATIONS PER ANSI Y1.1 .X ±.1 CAN BE *TORCH CUT

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION, AND SUCH

THIRD ANGLE PROJECTION

8

SURFACE MACHINED 250 MAX

A. PHILLIPS

B. KRUEGER

B. KRUEGER

5/5/09

JRM

B.SHUMSKI

B.SHUMSKI

7/96

PREPARED BY

CHECKED BY

APPROVED BY

DATE

2

SIZE

DOCUMENT NO.

REVISION

118244

D SCALE

WEIGHT LB

1/10

125

20020219.09070623

SHEET

1

1

B OF

2

DCF0022 (REV B)

8

7

6

5

4

3

2

1

BLOCK ASSEMBLY TYPICAL

D

D

BECKET ASSEMBLY

HOOK ASSEMBLY

TYPICAL

TYPICAL

C

C

4 2X

4

2

3

1 2X

4

4

2X

6

2X

7

2X

8

32.7 FULLY EXTENDED 31.5 AS SHOWN 24.2 FULLY RETRACTED

B

B

A

A

THIS

DOCUMENT

CONTAINS

PROPRIETARY

TITLE

SIZE

INFORMATION, AND SUCH INFORMATION MAY NEITHER PURPOSE PURPOSES

BE

DISCLOSED

NOR

USED

WITHOUT

TO

FOR

OTHERS

FOR

WRITTEN

PERMISSION

KIT, TRAVELING

ANY

MANUFACTURING FROM

EQUIPMENT ATTACHMENT

VARCO INTERNATIONAL, INC.

8

7

6

5

4

3

2

DOCUMENT NO.

REVISION

118244

D SCALE

SHEET

2

1/10 20020219.09070623

1

B

OF

2 DCF0022 (REV B)

FINAL DOCUMENTATION TDS-11SA - Top Drive Drilling System

Section 4.3 Pipe Handler and Adapter Kits

www.nov.com

8

7

6

5

4

3

2

1

NOTES: UNLESS OTHERWISE SPECIFIED 1.

2

D

DELETED

LOCTITE AND TORQUE CLEVIS PER NOV DESIGN SPECIFICATION

D

3DS00082 SECTION 5 3

IMPRESSION STAMP VARCO PART NUMBER APPROXIMATELY WHERE SHOWN.

4.

PAINT PER VARCO SPECIFICATION VPS00001, COLOR - YELLOW. MASK ALL THREADS AND BORES.

5.

(OBSOLETE DWG 119592) CARRIES REVISION HISTORY FOR THIS DWG.

6

PEEN CYLINDER TIE ROD THREADS AT TOP OF NUTS. 4 PLACES

SAE #12

SAE #12

1

3

3

1.55

C

C

2

5

2

5

4 4

B

B

3

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(4.500 SQ)

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2

51435-16

2

50512-C

2

30172154

1

103141-7

1

119416

PIN, COTTER

5

NUT,HEX SLOTTED

4

PIN, CYLINDER MOUNTING

3

CLEVIS

2 1

CYLINDER, HYDRAULIC

PART NO.

DESCRIPTION

QTY REQD

ITEM

MATERIAL

NO.

LIST OF MATERIALS

A

PRODUCT: END ITEM: NEXT ASSY:

TDS-9S/11SA PH-50/75 117820/30157366

UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES.

TOLERANCES ARE: X.X

±.1

X.XX

±.03

X.XXX ±.010

SIMILAR TO:

FINISH

TOL > ±.06 1000

7

6

5

4

LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF

NOV. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO

A. PHILLIPS

H. OLSTYNSKI

B. KRUEGER

JPSJ

APPVD

B. KRUEGER

JPSJ

10/1/09

12/2/96

3

L.P., ITS AFFILIATES OR SUBSIDIARIES (ALL COLLECTIVELY REFERRED TO HEREINAFTER AS "NOV"). IT IS LOANED FOR

CONSENT OF NOV. THIS DOCUMENT IS TO BE RETURNED

INITIAL

A

THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL

INFORMATION WHICH BELONGS TO NATIONAL OILWELL VARCO,

OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN

CHECKED

DRAWN

DATE

8

FRACTIONS

BREAK EDGES .02/.03

CURRENT

UNLESS OTHERWISE SPECIFIED

250

1/2 DEG ± 1/16

±

DO NOT SCALE DRAWING

WT LBS:

TOL < ±.06

ANGLES

TO NOV UPON REQUEST OR UPON COMPLETION OF THE

TITLE:

ASSEMBLY, HYDRAULIC CYLINDER

USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED AND REPRESENTED HEREIN IS THE COPYRIGHTED PROPERTY OF NOV.

SCALE:

RIG SOLUTIONS MECHANICAL ENGINEERING

2

DWG NO.

PROJECTION:

SIZE:

D

SHT:

1

30119592

1

REV:

OF

1

L

DRAWN IN ACAD

RS-MECH_D-TPL-001

8

7

N O T E S : (U N L E S S 1 . IT E M

O T H E R W IS E

4 , S P R IN G , T O

2. STO RE

AS

A

6

5

4

3

2

1

S P E C IF IE D ) BE

COMPRESSED

.3 5

AS

IN S T A L L E D

SET

D

D

1

2X

3

C

C

2X

3 017 2 17 8

11

B

B

7

4X 2

2

50508-C

NUT, H EX

2

30172178

P IN , G U ID E

A/R 2

5

2X

2X

4

8X

6

8

9

2X

12

2X

10

Z6001

W IR E , L O C K , .0 5 1

8

50908-C

4

50810-N-S

8

50008-13-C5D

W ASH ER , LO C K

C AP

SCREW, HEX

6

H EAD

R E T A IN E R

5 4

2

76442

G U ID E , A R M

3

1

125059

G U ID E , S T A B B IN G , G A T E

1

125057

G U ID E , S T A B B IN G , C L A M P

NO.

2 1

C YL

D E S C R IP T IO N

IT E M

M A T E R IA L

NO.

REQD

O P E R A T IO N A L IN S U R A N C E

OF

D IM E N S IO N S U N L E S S O TH E R W IS E S P E C IF IE D A R E IN

IN T E R P R E T D IM E N S IO N S & T O L E R A N C E S P E R A N S I Y 1 4 .5 & A B B R E V IA T IO N S P E R A N S I Y 1 .1

IN C H E S DO NOT

.X ± .1 C A N B E * T O R C H .X X ± .0 3 0 .X X X ± .0 1 0

SC ALE DOC UMENT T H IS

DOC UMENT

IN F O R M A T IO N PURPOSE

ANG ULAR C O N T A IN S

MAY

NOR

W R IT T E N

C

T H IR D A N G LE P R O JE C T IO N

N E IT H E R

USED

FO R

P E R M IS S IO N

TO LERANC E

P R O P R IE T A R Y BE

M A N U F A C T U R IN G FRO M

VARC O

H . SETH

PREPARED

BY

TO

OTHERS

PURPOSES

M A T E R IA L S

SURFACE M A C H IN E D 250 MAX

*TO RC H C UT 1000 MAX

T IT L E

FO R

SUC H ANY

W IT H O U T

IN T E R N A T IO N A L , IN C .

B . R IC E

30157287

PH-75

30122000

PH-100

NEXT

ASSY

PRODUC T

B . R IC E

08/06/04

D . S E N E V IR A T N E D . S E N E V IR A T N E 5 / 1 2 / 9 8 C HEC KED

2

A

F IN IS H E S

CUT

± 0° 30'

IN F O R M A T IO N , A N D

D IS C L O S E D

K. N G U YEN LTR

3

D R IL L E D

S P R IN G

C O M M IS S IO N IN G

4

8 7

76443

SPARE PART

5

S E R IE S

76445

C R IT IC A L L O A D P A T H IT E M C E R T IF IC A T IO N R E Q U IR E D

6

REG

2

T R A C E A B IL IT Y

7

9

2

P AR T FLAG S

8

10

D IA

W ASH ER , FLAT, N AR R O W

L IS T

A

11

ARM

P IN , C O T T E R

51402-8-S

PART Q TY

12

SLO TTED

BY

APPROVED

BY

DATE

R e le a s e d

S T A B B IN G

G U ID E

Ø 6 .2 5 - 7 .5 0 (N C S IZ E

NO.

R E V IS IO N

125158

D SC ALE

1/2 -

50

DOC UMENT

ASSY.

T O O L J O IN T 1 - 5 FH ) 2

W E IG H T

LB SH EET

75

08/09/2004

1

C OF

1

1 1 :1 7 :3 4 A

1

DC F0022

(R E V

B)

8

7

N O TES: U N LESS 1.

C LEAN

2.

C O N N E C T IO N P R IO R

3.

AN D TO

L U B R IC A T E TH READS

W AVE

100%

W IT H

S P R IN G 56003

THE

ALL P AR TS

C A V IT Y GREASE

&

B EFORE

C RAN K

A

5.

RECORD

M A T E R IA L T R A C E A B IL IT Y

S L ID IN G

F IT

VALVE

ASSEM B LY.

AN D

B ALL TO

B ETW EEN

TH E

IN F O R M A T IO N

TW O PER

6.

IN C L U D E D

W IT H

"R E P A IR

K IT - C O M P L E T E ".

7.

IN C L U D E D

W IT H

"R E P A IR

K IT -

8.

TEST

9.

M A X IM U M

W O R K IN G

T E M P E R A T U R E : 2 0 0 °F

10.

M A X IM U M

W O R K IN G

P R E S S U R E : 1 5 ,0 0 0 p s i (1 0 3 4

11.

O R IE N T A T IO N O F IN T E R N A L H E X A N D P O IN T E R O N C RAN K M U ST B E AS SH OW N . EN SU RE TH AT TH E "R IG H T H A N D " C R A N K , IT E M 4 O R 5 , IS IN S T A L L E D A D J A C E N T T O T H E L U B R IC A T IO N P O R T A S S H O W N . M IN IM U M

SOFT

PARTS. TS000205.

D IA M E T E R

3 .0 6

IN C H E S

B EST

ASSY.

N/A

KSI

VARC O

NO.

110103-500

1

IN F O R M A T IO N

- 501, NAM , 15 B EST

2

NO.

N/A

KSI

VARC O

NO.

110103-501

-502, H2S, 15 B EST

NO.

N/A

KSI

VARC O

NO.

110103-502

K IT -

C O M P LETE

N/A

114859

N/A

114859

N/A

114860-2

29

27

14

12

25

18

R E P A IR

K IT -

SOFT

N/A

114859-1

N/A

114859-1

N/A

114860-1

28

26

13

11

23 24

17

SEALS

65021520

77408

65021520

77408

65021520

77408

SEAT

65021523

79489-14

65021523

79489-14

65021523

79489-14

NUT

65060325

89141-18

65060325

89141-18

65060325

89141-18

C RANK

WRENC H-

(9 3 °C )

NO.

3

R E P A IR

P U LLER -

TS000205.

BORE

D E S C R IP T IO N

WRENC H-

S E A L S ".

22 33

3

D

21

4X

b a r)

30 C LSD

(R E F ).

UP

12.

- 500, STD , 15

ASSEM B LY.

PROTEC TED

B A L L C A V IT Y

D U R IN G

ENSURE

PER

4 REFERENC E

S H A L L R E M A IN

O P E R A T IN G

SM OOTH

5

S P E C IF IE D

IN S T A L L A T IO N .

PAC K

IN S P E C T

4.

D

O T H E R W IS E

6

OPEN

11

(2 2 .5 0 )

C

4

2 6

1

5 / 8 " A .P .I. R E G

RH

16 15

31

C

32

5

6

4

5 / 8 " A .P .I. R E G

RH

15

33 SEE

D E TA IL

"A "

10

3

16

8

4

9

5

D E T A IL 2 1 1 4 2

(7 .3 7 5 )

2 1

2 1

1 4

1 4

2

2

1

1

1 1

1 1

2

2

1

1

1

1

1

1

4

4

2 2

2 2

2

2

1

1

1

1

1 1 2

2

1 2

B

1 1 1 4

31 32

15 16

4

15

6

2

16

7

2 2

(1 0 .7 5 )

1 1 VARC O PART NO. 110103- XXX CW

6

5 / 8 " R E G . R .H .

1 5 ,0 0 0 S/N 6

P S I IB O P

1 -502

CW

-501 QTY

A

1 -500

11 110050 NEXT

PH-50

ASSY

USED

O T H E R W IS E

M A C H IN E D MAX 250

8

7

6

5

4

S P E C IF IE D

TO RC H 1000

CUT MAX

O T H E R W IS E

CURRENT DRAW N

A P P L IC A T IO N UNLESS

NO.

D E S C R IP T IO N

S P E C IF IE D

APPVD DATE

B .R IC E

IN IT IA L

-

B . B R A M A N D .S E N E V IR A TN E 11/21/06

3

77369-5 91137-10 89453-1 89141-1 91137-12 89453-17 90441-10 89453-16 90441-9 96439-1 96439 65060625 89453-13 89141-13 89453-3 89141-3 89453-9 89141-9

34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

89453-12 89141-12 89453-11 89141-11 89453-8 89141-8

BEST

PART

IT E M NO.

NUMBER

T H IS D O C U M E N T C O N T A IN S P R O P R IE T A R Y A N D C O N F ID E N T IA L IN F O R M A T IO N W H IC H B E L O N G S T O

D .H IR U LK A R Q U IG L E Y 2 / 1 / 9 5

C HEC KED

"A "

B O D Y , IB O P B O D Y , IB O P

PART

20

16

110102

IN T E R P R E T D IM / T O L P E R A S M E Y 1 4 .5 MN A T IO N A L - O IL W E L L , L .P . IT IS L O A N E D F O R L IM IT E D P U R P O S E S O N L Y A N D R E M A IN S T H E P R O P E R T Y O F D IM E N S IO N S A R E IN IN C H E S N A T IO N A L - O IL W E L L , L .P . R E P R O D U C T IO N , IN W H O L E O R IN P A R T , O R U S E O F T H IS D E S IG N O R .X X ± .0 3 .X X X ± .0 1 0 .X ± .1 D IS T R IB U T IO N O F T H IS IN F O R M A T IO N T O O T H E R S IS N O T P E R M IT T E D W IT H O U T T H E E X P R E S S W R IT T E N A N G L E S ± .5 ° C O N S E N T O F N A T IO N A L - O IL W E L L , L .P . T H IS D O N O T S C A L E D R A W IN G D O C U M E N T IS T O B E R E T U R N E D T O N A T IO N A L -

ON

3

TH R E A D P R O TE C TO R - 6 5 / 8 " (N O T S H O W N ) P LU G , P R ESSU R E 6 7 R E T A IN IN G R IN G (H 2 S ) R E T A IN IN G R IN G N YLO N P LU G 7 B A C K - U P R IN G B A C K - U P R IN G O - R IN G O - R IN G SEAL, U - C U P SEAL, U - C U P S T A B IL IZ E R , S E A L R IN G B A C K - U P R IN G B A C K - U P R IN G O - R IN G O - R IN G 7 S P R IN G , W A V E S P R IN G , W A V E 6 SET, SEAT/ B ALL SET, SEAT/ B ALL B A C K - U P R IN G 7 B A C K - U P R IN G 7 O - R IN G 7 O - R IN G 7 SLEEVE, C R AN K SEAL, C R O W N 7 SEAL, C R O W N C R A N K , O P E R - L .H . C R A N K , O P E R .- L .H . C R A N K , O P E R .- R .H . C R A N K , O P E R .- R .H . 6

REQD U N LESS

L O W S T R E S S S T A M P U S IN G 1 / 4 " H IG H L E T T E R S A S S H O W N . S E E R E F . IN F O . T A B L E A B O V E F O R P A R T N O . S T A M P "C W " IN C IR C L E AS SHOW N

19

15

65020193 650210B0 65060192 65060191 65060492 65060199 65060197 65060198 65060196 65060696 65060695 96438 65021193 65021191 65021192 65021190 65021491 65021490 30177893 30177204 65060794 65060792 65060793 65060791 98895 65060691 65060690 114901 110128 30114902 110118

1

XXXXXX

5 / 8 " R E G . R .H .

4

2/6/95

O IL W E L L , L .P . U P O N R E Q U E S T A N D IN A N Y E V E N T U P O N C O M P L E T IO N O F T H E U S E F O R W H IC H IT W A S L O A N E D . T H IS D O C U M E N T A N D T H E IN F O R M A T IO N C O N T A IN E D A N D R E P R E S E N T E D H E R E IN IS T H E C O P Y R IG H T E D P R O P E R T Y O F N A T IO N A L - O IL W E L L , L .P .

R IG S O LU TIO N S 1 0 0 0 0 R IC H M O N D A V E . H O U S TO N , TE X A S 7 7 0 4 2 U .S .A . (7 1 3 ) 3 4 6 - 7 5 0 0

2

B

A

T IT L E :

6

A S S E M B L Y , U P P E R IB O P 5/ 5" X 6 5/ 8", PH- 50

SC ALE:

WT

P R O J E C T IO N :

LB S:

2/3 D R A W IN G

260

S IZ E :

D

SH EET:

1

OF

1

R E V IS IO N :

NUMBER:

110103

F

1

DC F0022

(R E V

D)

4

N O TES: U N LESS 1.

PRESS

O T H E R W IS E

RO LLER

H O U S IN G , IT E M

D

2.

ASSEM B LE IT E M

3.

C AM

2 , U S IN G

STAM P

2

3

S P E C IF IE D

B E A R IN G , IT E M 1, TO

N O TED

5 , IN T O

C RANK

DEPTH .

F O L L O W E R , IT E M IT E M

1

8. TO RQ U E

"9 8 8 9 8 " A P P R O X IM A T E L Y

4, TO TO

300

WHERE

C RANK

ARM,

IN - L B

M IN .

D

SHOWN.

2

6

C

C

3

7

1

B

B 1

3 .1 5 5

2

53200- 271

C O M P O U N D , L O C K IN G

8

1

51300- 220- B

O - R IN G

7

1

53201

F IT T IN G , G R E A S E , S T R A IG H T (.1 2 5 - 2 7 N P T )

6

1

79825

RO LLER

5

1

79824

C AM

1

99168

SPAC ER

1

98899

ARM, C RANK

1

98897

C RANK

A/R

4

5 QTY

PART

REQD

B E A R IN G

FO LLO W ER

3

P AR T F LAG S T R A C E A B IL IT Y

NO.

C R IT IC A L L O A D P A T H IT E M C E R T IF IC A T IO N R E Q U IR E D

S P AR E P AR T C O M M IS S IO N IN G O P E R A T IO N A L IN S U R A N C E

DO NOT DOC UMENT TH IS

DOC UMENT

IN F O R M A TIO N PURPOSE

B

3

AN G U LAR C O N TA IN S

M AY

NOR

W R ITTE N

N E ITH E R

USED

FOR

P E R M IS S IO N

TO LER AN C E

P R O P R IE TA R Y BE

TO

M A N U F A C TU R IN G FROM

VARC O

CUT

O TH E R S

PURPOSES

SUCH

FOR

ANY

W ITH O U T

IN TE R N A TIO N A L , IN C .

HYOUNG

L IM

J. P O P E PREPARED

2

(M A C H IN IN G )

1

BY

IT E M

M A T E R IA L

NO.

M A T E R IA L S

SURFAC E

F IN IS H E S

A

*TO R C H C U T 1000 MAX

M A C H IN E D 250 MAX

-

-

98903

PH60d

98900

PH60d

T IT L E

± 0° 30'

IN F O R M A TIO N , A N D

D IS C L O S E D

K. NGUYEN

LTR

4

.X ± .1 C A N B E * T O R C H .X X ± .0 3 0 .X X X ± .0 1 0

S C ALE

TH IR D A N G LE P R O JE C TIO N

DC F0020B 1

OF

IN T E R P R E T D IM E N S IO N S & T O L E R A N C E S P E R A N S I Y 1 4 .5 & A B B R E V IA T IO N S P E R A N S I Y 1 .1

IN C H E S

2

D E S C R IP T IO N

D IM E N S IO N S U N L E S S O T H E R W IS E S P E C IF IE D AR E IN

(M A C H IN IN G )

H O U S IN G

L IS T

A

4

NEXT

ASSY

HYOUNG

PRODUCT

L IM

B . P R IO R C HEC KED

BY

APPROVED

BY

3/7/03 7/93 DATE

R e le a s e d

ASSEM B LY, EXTERNAL S IZ E

DOC UMENT

C

R E V IS IO N

98898

SC ALE

W E IG H T

LB SH EET

1/1 -

C RANK

NO.

03/13/2003

1

1

B OF

1

0 8 :2 6 :5 2 A DC F0021

(R E V

B)

FINAL DOCUMENTATION TDS-11SA - Top Drive Drilling System

Section 4.4 Service Loops and Derrick Kits

www.nov.com

8

6

7

N O TES: U N LESS

O T H E R W IS E

1.

A L L IT E M S

2.

USE

IT E M S

TO

BE

5

4

3

1

2

S P E C IF IE D

S H IP P E D

7, 8, 9, AND

LO O SE

10

TO

IN

T H E IR

ATTAC H

O R IG IN A L C O N T A IN E R S .

IT E M

4

TO

EARTH

C O NDUC TO R.

D

LEN G TH

IT E M S

IT E M

D

(R E F )

1, 2, 3

4

C

C

IT E M

IT E M

5

6

B

TAB LE

I

124977-XXX-XX

VARC O DASH NO.

C AB LE L E N G T H (F T )

TO TAL W E IG H T (L B )

-50

50

450

-75

75

675

-100

100

900

-125

125

1125

-150

150

1400

-175

175

1650

-200

200

1800

2

2

78310-1

W A S H E R , B E L L E V IL L E , 1 / 2 "

2

2

50808-R-S

W ASH ER , FLAT, 1 / 2 "

9

2

2

50208-S

N U T , S E L F - L O C K IN G ,1 / 2 "

8

2

2

50008-12-S

SCREW, HEX

7

1

1

124458-XXX-B

C AB LE

ASSY, AUX

1

1

123985-XXX-B

C AB LE

A S S Y , C O M P O S IT E

-

1

125093-XXX

C AB LE

A S S Y , E A R T H IN G

-

1

114724- RED- XXX

C A B L E A S S Y , P O W E R , W / C O N N E C T O R , R E D (6 4 6 M C M )

3

-

1

114724- W H T- XXX

C A B L E A S S Y , P O W E R , W / C O N N E C T O R , W H T (6 4 6 M C M )

2

-

1

1 1 4 7 2 4 - B LK - XXX

C A B L E A S S Y , P O W E R , W / C O N N E C T O R , B L K (6 4 6 M C M )

(M U L T IC O N D U C T O R C AB LE (S E E B A S IC

C AB LES

O N LY)

LEN G TH

TAB LE

I)

P/N

Q TY

NO.

(1 8 (4 2

(4 4 4

C O N D .)

6

C O N D .)

5 4

MCM)

O T H E R W IS E

S P E C IF IE D

ASSY

USED

O T H E R W IS E

M A C H IN E D MAX 250

5

4

TORCH 1000

CURRENT DRAW N

S P E C IF IE D CUT MAX

IN IT IA L

R. HOLLADAY

T. PHAM

CHECKED

M. MASLYAR

S. CURLEE

APPV D

M. MASLYAR

L. MOLLETT

DATE

NO.

10 / 4 / 0 6

3

04/23/98

A

M A T E R IA L S

T HIS D OC UME NT C ONT AINS PROPRIE T ARY AND C ONF ID E NT IAL INF ORMAT ION W HIC H B E L ONGS T O

I N T E R P R E T D I M / T O L P E R A S M E Y 1 4 .5 M N A T I O N A L - O I L W E L L , L .P . I T I S L O A N E D F O R L IMIT E D PURPOS E S ONL Y AND RE MAINS T HE D IM E N S IO N S A R E IN IN C H E S P R O P E R T Y O F N A T I O N A L - O I L W E L L , L .P . RE PROD UC T ION, IN W HOL E OR IN PART , OR US E .X ± .1 .X X ± .0 3 .X X X ± .0 1 0 OF T HIS D E S IGN OR D IS T RIB UT ION OF T HIS INF ORMAT ION T O OT HE RS IS NOT PE RMIT T E D A N G L E S ± .5 ° W IT HOUT T HE E X PRE S S W RIT T E N C ONS E NT OF D O N O T S C A L E D R A W IN G N A T I O N A L - O I L W E L L , L .P . T H I S D O C U M E N T I S T O

ON

A P P L IC A T IO N UNLESS

OF

1 IT E M

D E S C R IP T IO N

BE

NEXT

6

POWER

REQD L IS T

T D S - 9 / 11S A

7

1/2"

-MC BSC

UNLESS

8

1

B

MC

PART

A

1 / 2 "X

10

RET URNED

TO

C A B L E K IT , J U M P E R ( H O U S E T O D E R R IC K L O O P )

NAT IONAL -

O I L W E L L , L .P . U P O N

REQUEST

AND

IN

ANY

EV ENT

UPON C OMPL E T ION OF T HE US E F OR W HIC H W AS L OANE D . T HIS D OC UME NT AND T HE INF ORMAT ION

T IT L E :

C ONT AINE D

AND

HE RE IN IS T HE C OPY RIGHT E D N A T I O N A L - O I L W E L L , L .P .

IT

REPRESENT ED PROPERT Y

OF

R IG S O LU TIO N S 1 0 0 0 0 R IC H M O N D A V E . H O U S TO N , TE X A S 7 7 0 4 2 U .S .A . (7 1 3 ) 3 4 6 - 7 5 0 0

2

SCALE:

WT

1/ 4 D R A W IN G

LBS:

TABLE 1

P R O J E C T IO N :

S IZ E :

D

SHEET:

1

OF

1

R E V IS IO N :

NUMBER:

124977

D

1

DCF0022

(R E V

D)

FINAL DOCUMENTATION TDS-11SA - Top Drive Drilling System

Section 4.5 Rigging

www.nov.com

8

7

N O TES: U N LESS 1.

APPLY

O T H E R W IS E 53200- 242

6

5

4

3

2

1

S P E C IF IE D : L O C T IT E

(B L U E ) T O

TH READS

OF

IT E M

14, TO RQ U E

PER

DS

00008

AN D

10

L O C K W IR E .

D

D B

B

D E T A IL

A

2X

LOW ER

C O N N E C T IO N

PLATE

ON

7

M AST

6

3

C

C

2X

5

4

2X

3 7

SEE

D E T A IL

S E C T IO N

A

B-B

2X 4X

4X 4X

4X

11

12

16

14

10FT Z6001

1

B

15

2X

2

8

2X 13

9

2

30178991

4

50016-44-C 8D C AP-SC REW , HEX HEAD

14

2

30178940

B O LTIN G , P LA TE

13

4

50816-W -C-5

W A S H E R , F LA T, W - S E R IE S

12

51016- C

W A S H E R , LO C K

11

2

51605- 20- S

P IN , R O LL

10

8

30158499- 04

S LE E V E , W IR E R O P E

9

4'

51220- 3

C A B LE , N Y LO N C O A TE D

8

4

1 1 8 8 4 4 - 1 6 - 2 0 B U S H IN G , 1 .0 0 ID X 1 .2 5 0 , F IB E R G LID E

7

2

30154386

P IN , P IV O T, TIE B A C K

6

2

30154385

H O O K , TIE B A C K

5

P IN , R E TA IN E R

4

2

30154684

4

1 1 8 8 3 6 - 1 6 - 3 2 B U S H IN G , TH R U S T, 1 .0 X 2 .0 X .O 6 , F IB E R G LID E

3

2

117496- 2

P IN , LY N C H

2

1

30178882

TIE B A C K , M A C H IN E , W E LD M E N T

NO.

O T H E R W IS E

S P E C IF IE D

OF

T H IS D O C U M E N T C O N T A IN S P R O P R IE T A R Y A N D C O N F ID E N T IA L IN F O R M A T IO N W H IC H B E L O N G S T O N A T IO N A L - O IL W E L L , L .P . IT IS L O A N E D F O R L IM IT E D P U R P O S E S O N L Y A N D R E M A IN S T H E P R O P E R T Y O F N A T IO N A L - O IL W E L L , L .P . R E P R O D U C T IO N , IN W H O L E O R IN P A R T , O R U S E O F T H IS D E S IG N O R D IS T R IB U T IO N O F T H IS IN F O R M A T IO N T O O T H E R S IS N O T P E R M IT T E D W IT H O U T T H E E X P R E S S W R IT T E N C O N S E N T O F N A T IO N A L - O IL W E L L , L .P . T H IS D O C U M E N T IS T O B E R E T U R N E D T O N A T IO N A L O IL W E L L , L .P . U P O N R E Q U E S T A N D IN A N Y E V E N T U P O N C O M P L E T IO N O F T H E U S E F O R W H IC H IT W A S L O A N E D . T H IS D O C U M E N T A N D T H E IN F O R M A T IO N C O N T A IN E D A N D R E P R E S E N T E D H E R E IN IS T H E C O P Y R IG H T E D P R O P E R T Y O F N A T IO N A L - O IL W E L L , L .P .

IN T E R P R E T D IM / T O L P E R A S M E Y 1 4 .5 M D IM E N S IO N S A R E IN IN C H E S .X X ± .0 3 .X X X ± .0 1 0 .X ± .1 A N G L E S ± .5 ° D O N O T S C A L E D R A W IN G NEXT

ASSY

USED

DRAW N

A P P L IC A T IO N UNLESS

O T H E R W IS E

M A C H IN E D MAX 250

8

7

6

5

4

S P E C IF IE D

TO RC H 1000

CURRENT

ON

CUT MAX

IN IT IA L

M . S H U LTZ

M . SH U LTZ

C HEC KED

R. CHOU

R. CHOU

APPVD

R. CHOU

R. CHOU

12/08/05

11/09/05

DATE

3

R IG S O LU TIO N S 1 0 0 0 0 R IC H M O N D A V E . H O U S TO N , TE X A S 7 7 0 4 2 U .S .A . (7 1 3 ) 3 4 6 - 7 5 0 0

2

B

1

D E S C R IP T IO N

L IS T

Q TY R E Q D U N LESS

15

P LA TE , S P A C E R

4

PART

A

16

LO C K W IR E , .0 5 1 D IA .

IT E M NO.

M A T E R IA L

M A T E R IA L

A

T IT L E :

T IE B A C K , SC ALE:

WT

LB S:

1/4 D R A W IN G

P R O J E C T IO N :

K IT S IZ E :

D

SH EET:

1 OF 1 R E V IS IO N :

NUMBER:

30178883

A

1

DC F0022

(R E V

D)

FINAL DOCUMENTATION TDS-11SA - Top Drive Drilling System

Section 4.6 Accessories

www.nov.com

FINAL DOCUMENTATION TDS-11SA - Top Drive Drilling System

Chapter 5.0 Mechanical Spares List

www.nov.com

TDS-11SA AC IDEAL RIG MECHANICAL SPARES LIST NOTES: 1. M614003010-1 2. M614003010-2 3. M614003010-3

Recommended Commissioning Spares Recommended Operational Spares Recommended Insurance Spares

THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION WHICH BELONGS TO NATIONAL-OILWELL, L.P. IT IS LOANED FOR LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL-OILWELL, L.P. REPRODUCTION, IN WHOLE OR IN PART OR USE OF THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NATIONAL-OILWELL, L.P. THIS DOCUMENT IS TO BE RETURNED TO NATIONAL-OILWELL, L.P. UPON REQUEST AND IN ANY EVENT UPON COMPLETION OF THE USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED AND REPRESENTED IS THE COPYRIGHTED PROPERTY OF NATIONAL-OILWELL, L.P.

CURRENT DRAWN CHECKED APPVD DATE

TITLE

SPARES LIST, MECHANICAL AC IDEAL RIG, TDS-11SA

INITIAL H. LIM D. STEPHENS

SIZE

H. LIM

A

3/27/09

SCALE

DWG NO

REV

M614003010-SPL-001 NONE

WT LBS

SHEET

1

01 OF

5

DCF0045 (REV B)

-1 Recomm. Commission Spare

-2 Recomm. Operational Spare

-3 Recomm. Insurance Spare

Where Used

Description Where Used

-

1

1 -

120900 120900

Motor Housing Assy Motor Housing Assy

98290 Liner, Upper Stem, Std. Bore

-

1

-

120900

Motor Housing Assy

98291 Seal, Polypak

-

1

-

120900

Motor Housing Assy

120900 120900 120900 120900 120900 120900 120900 120900 120900 120900 120900 120900 120900 120900 120900 120900 120900 120900 120900 120900 120900 120900 120900

Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy Motor Housing Assy

Part No.

Description

Motor Housing Assy 30173521 Bearing Isolator 30154362 Shield, Bearing

91250-1 77039 30123290 Z6001 53003-16 53219-2 51300-277-B 51300-425-B 109523 108216-12 118217-40L60 118217-40R60 109555 109528 30122104 117603-1 121272-2 121272-1 120117 115299 120119-2 120119-1 30151875-504

Seal, Oil Seal Assembly, Wash Pipe Lockwire, .051 Plug, Magnetic Fitting, Grease O-Ring, Cover/Bearing Ret. Seal, Hammer Lug Union Adapter, S-Pipe Ball Valve Drilling Motor Assy, LH Drilling Motor Assy, RH Rotor, Brake Brake, Caliper Disc Heat Exchanger, Oil Pump Assembly, Lube Tube Assembly, Breather Tube Assembly, Breather Belt, Timing Encoder, Digital Pulley, Timing Pulley, Timing Shotpin Assembly

-

1 1 1 168 ft 1 1 1 1 1 1

1 1 1 1 2 4 1 1 1 1 1 1 1 -

Reservoir Assy 30113165 108119-16B 71613 51300-038-B 110132 110191-501

Valve, Relief-Popoff Sight Gage Reservoir Breather O-Ring Gasket Bladder, Reservoir (5 gallons)

-

1 1 1 1 1 1

-

110068 110068 110068 110068 110068 110068

Pipe, Wash, 3 Inch Bore Packing Seal Kit, Standard Ring, Snap Wrench, Washpipe

-

1 5 1 1

-

30123290 30123290 30123290 30123290

Wash Pipe Assembly 30123289 123292-2 30123562 53303-14

SIZE

Wash Pipe Assembly Wash Pipe Assembly Wash Pipe Assembly Wash Pipe Assembly

DWG NO

A SCALE

Reservoir, Assembly Reservoir, Assembly Reservoir, Assembly Reservoir, Assembly Reservoir, Assembly Reservoir, Assembly

REV

M614003010-SPL-001 NONE

WT LBS

SHEET

2

01 OF

5

DCF0045 (REV B)

Part No.

Description

-1 Recomm. Commission Spare

-2 Recomm. Operational Spare

-3 Recomm. Insurance Spare

2 8 1 2 1 2 -

1 1 1 1 2 4 4 1 1

30157366 30157366 30157366 30157366 30157366 30157366 30157366 30157366 30157366 30157366 30157366 30157366 30157366 30157366 30157366

Pipe Handler Package Pipe Handler Package Pipe Handler Package Pipe Handler Package Pipe Handler Package Pipe Handler Package Pipe Handler Package Pipe Handler Package Pipe Handler Package Pipe Handler Package Pipe Handler Package Pipe Handler Package Pipe Handler Package Pipe Handler Package Pipe Handler Package

Where Used

Description Where Used

Pipe Handler Package 125098 30125094 30125097 98898 110042 107052 30119592 30122367 119139

Tube Assembly Tube Assembly Tube Assembly Crank Assembly Shell, Actuator, IBOP Lock Tab Cylinder, Hydraulic Assembly U-Bolt, 500 Ton U-Bolt, 350 Ton

114859 114859-1 99498-2 99498-1 110103-500 114706-500

Upper IBOP Repair Kit – Complete Upper IBOP Repair Kit – Soft Seals Lower IBOP Repair Kit – Complete Lower IBOP Repair Kit – Soft Seals Upper IBOP Valve Lower IBOP Valve

-

Friction Pads (2 required) Seal Kit Heavy Duty Spring (4 required) Screw, Return Spring (4 required) Pin, Guide (4 required) Bleed Screw Assembly

4 -

8 1 8 8 8 1

-

109528 109528 109528 109528 109528 109528

Brake, Caliper Disc Brake, Caliper Disc Brake, Caliper Disc Brake, Caliper Disc Brake, Caliper Disc Brake, Caliper Disc

O-Ring O-Ring Glyd Ring Rotary, 11.000 Rod Piston Ring Ring, Thrust Glyd Ring Rotary, 11.500 Rod Glyd Ring Rotary, 10.000 Rod Seal, Wiper Retainer Ring Bushing, Turcite Bushing Bearing, Flanged Relief Valve Seal Bushing, Flanged

-

1 1 1 1 10 1 1 2 2 2 2 2 1

1 1 -

30173277 30173277 30173277 30173277 30173277 30173277 30173277 30173277 30173277 30173277 30173277 30173277 30173277 30173277 30173277

Rotating Link Adapter Rotating Link Adapter Rotating Link Adapter Rotating Link Adapter Rotating Link Adapter Rotating Link Adapter Rotating Link Adapter Rotating Link Adapter Rotating Link Adapter Rotating Link Adapter Rotating Link Adapter Rotating Link Adapter Rotating Link Adapter Rotating Link Adapter Rotating Link Adapter

Bearing, Self Lubrication Bearing, Self Lubrication Bearing, Self Lubrication Roller Cylinder Assy, IBOP Actuator

-

2 2 2 2 -

1

Brake, Caliper Disc 109528-1 109528-2 109528-3 109528-4 109528-5 109528-6 Rotating Link 500 Ton 51300-273-B 51300-381-B 30119319 30173156 30119357 30119143 118375 119547 30117775-2 119358 115176 112754-130 53250-5 77039 112754-116 PH-75 Torque Arrestor Assy 118844-16-08 118844-16-12 118844-22-22 71847 125594

SIZE

Torque Arrestor Assy Torque Arrestor Assy Torque Arrestor Assy Torque Arrestor Assy Torque Arrestor Assy

DWG NO

A SCALE

30157288 30157288 30157288 30157288 30157288

REV

M614003010-SPL-001 NONE

WT LBS

SHEET

3

01 OF

5

DCF0045 (REV B)

-1 Recomm. Commission Spare

-2 Recomm. Operational Spare

-3 Recomm. Insurance Spare

Seal, Piston Seal, Rod Ring, Wiper Ring, Stabilizer

-

2 2 2 2

-

Hydraulic Package 30173216-1 30111013 110562-1 110563-1 110564-1

Filter Element, Hydraulic Filter, 60 micron Counterbalance Accumulator System Accumulator Accumulator

2 1 -

2 1 -

1 1 1

Hydraulic Package Hydraulic Package Hydraulic Package Hydraulic Package Hydraulic Package

Pump Motor Assembly 114113

Motor Assy

-

-

1

Pump Motor Assy

Motor Blower Pressure Switch, IBOP Pressure Switch Pressure Switch, Air Fitting, Grease Pressure Switch

-

-

1 1 1 1 1 1

Electrical Package Electrical Package Electrical Package Electrical Package Electrical Package Electrical Package

Solenoid Valve Solenoid Valve Valve, Relief Hydraulic Motor Valve, Relief Relief Valve, Low Flow Reducing/Relieving Valve Cavity plug, T-13A Short Relief Valve, Ventable

1 1 -

2 2 2 1 1 3 1 1

1 -

114174 114174 114174 114174 114174 114174 114174 114174 114174

Manifold Assy Manifold Assy Manifold Assy Manifold Assy Manifold Assy Manifold Assy Manifold Assy Manifold Assy Manifold Assy

Pilot – To – Open Check Valve Differential Unloading Valve Reducing / Relieving Valve Flow Control Valve Pilot – To – Close Check Valve Check Valve Check Valve Logic Cartridge Relief Valve Cavity Plug, T-11A Short Manual Valve, 3-pos. , Zero Leak

-

4 1 1 1 1 2 3 3 1 1 1

-

114174 114174 114174 114174 114174 114174 114174 114174 114174 114174 114174

Manifold Assy Manifold Assy Manifold Assy Manifold Assy Manifold Assy Manifold Assy Manifold Assy Manifold Assy Manifold Assy Manifold Assy Manifold Assy

Part No. PH-75 Clamp Cylinder 72219 72220 72221 30158690

Electric Package 30172028 83095-1 87541-1 76841 53219-3 83095-2 Manifold 127908-D2 127908-J2 94520-1AN 30158011 94522-1EN 111664-1EN 109858-1AN 93667-M13 P6140000631AN 107029-175N 107028-1ANB 99353-1AN 98402-800D 94537-130N 94536-230N 94536-14N 94534-1CXN 94520-1NN 93667-M11 110538-5

Description

SIZE

30157287 30157287 30157287 30157287

Description Where Used

Clamp Cylinder Clamp Cylinder Clamp Cylinder Clamp Cylinder

DWG NO

A SCALE

Where Used

REV

M614003010-SPL-001 NONE

WT LBS

SHEET

4

01 OF

5

DCF0045 (REV B)

Part No.

Description

-1 Recomm. Commission Spare

-2 Recomm. Operational Spare

-3 Recomm. Insurance Spare

Where Used

Description Where Used

124539 124538 124539 124538 124539 124538 124539 124538 124539 124538 124539 124538 124539 124538 124539 124538 124539 124538 124539 124538 124539 124538

Carriage Assy, Right Carriage Assy, Left Carriage Assy, Right Carriage Assy, Left Carriage Assy, Right Carriage Assy, Left Carriage Assy, Right Carriage Assy, Left Carriage Assy, Right Carriage Assy, Left Carriage Assy, Right Carriage Assy, Left Carriage Assy, Right Carriage Assy, Left Carriage Assy, Right Carriage Assy, Left Carriage Assy, Right Carriage Assy, Left Carriage Assy, Right Carriage Assy, Left Carriage Assy, Right Carriage Assy, Left

Carriage Package 109944

Bushing, Flange

-

8

-

30155438

Cam Followers 6”

-

-

2

30158767-04

Cam Followers 4”

-

-

16

55324-C

Nut

-

-

16

51132-C

Washers

-

-

2

51024-C

Washers

-

-

16

80569

Nut

-

-

2

112875

Bogey Pin

-

-

2

109944

Bushing

-

2

-

30152845

Retaining Pins

-

4

-

30157306

Lynch Pins

-

4

-

Counterbalance Kit 108894-P40 94522-21N 108894-B40 108894-G20 108894-Y4 108894-Z677 94536-175N 92654 112825 110704 110703

Seal, Piston Relief Valve Cartridge Body Seal Rod & Gland Seal Rod & Gland Wrench Spanner Wrench Check Valve Check Valve Cartridge Cylinder Assy, Counterbalance Cylinder Assy, Counterbalance

-

1 1 1 1 1 1 2 1 1 -

1 1

110687 110703 110687 110687 110687 110687 111712 111712 111712 112190 112190

Cylinder Cylinder Assy Cylinder Cylinder Cylinder Cylinder Pre-Fill Valve Assy Pre-Fill Valve Assy Pre-Fill Valve Assy Counterbalance Kit Counterbalance Kit

-

2 2 2

-

30154688 30154688 30154688

Guide Beam Kit Guide Beam Kit Guide Beam Kit

-

-

1

30183283

Service Loop Kit

-

-

1

30183283

Service Loop Kit

-

-

1

30183283

Service Loop Kit

Guide Beam Kit 117496-1 Lynch Pin 117783 Retainer Pin 117782 Joint Pin Service Loops 30175017-75Power Service Loop 4-3-B 30183284-75Control Service Loop 4-4-B 30183959-75Aux Power Service Loop 4-4-B

SIZE

DWG NO

A SCALE

REV

M614003010-SPL-001 NONE

WT LBS

SHEET

5

01 OF

5

DCF0045 (REV B)

FINAL DOCUMENTATION TDS-11SA - Top Drive Drilling System

Chapter 6.0 Control Spares List

www.nov.com

TDS-11SA AC IDEAL 135 SPARES LIST/KIT, ELECTRICAL

NOTES:

RIG/PLANT

1.

10620488-1 Recommended Commissioning Spares

2.

10620488-2 Recommended Operational Spares

3.

10620488-3 Recommended Insurance Spares

NEXT ASSY

PRODUCT

MJOB-8375 ADDITIONAL CODE

SDRL CODE

TOTAL PGS

REMARKS

MAIN TAG NUMBER

DISCIPLINE

CLIENT PO NUMBER

This document contains proprietary and confidential information which belongs to National-Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use of this design or distribution of this information to others is not permitted without the express written consent of NOV. This document is to be returned to NOV upon request and in any event upon completion of the use for which it was loaned. This document and the information contained and represented herein is the copyrighted property of NOV.  National Oilwell Varco

National Oilwell Varco 11000 Corporate Centre Drive Houston, Texas 77041 (USA) Phone + 281-854-0400 Fax + 281-854-0607

CLIENT DOCUMENT NUMBER

DOCUMENT NUMBER

REV

Client Document Number

10620488-SPL

02

www.nov.com

Document number Revision Page Template Name

10620488-SPL 02 2 ORA_SPL_TPL.doc

REVISION HISTORY

02

11/22/2011

Corrected Part Numbers

R. MOENCH

B. BOEPPLE R. MOENCH

01

11/1/2011

Initial Release

B. BOEPPLE

R. MOENCH R. MOENCH

Rev

Date (mm.dd.yyyy)

Reason for issue

CHANGE DESCRIPTION Revision 01 02

Change Description First issue Corrected Part Numbers to Match Assemblies

D7440000254-TPL-001/01

www.nov.com

Prepared

Checked

Approved

Document number Revision Page Template Name

10620488-SPL 02 3 ORA_SPL_TPL.doc

-1 Recom. Commission Spare

-2 Recom. Operational Spare

-3 Recom. Insurance Spare

Where Used

BLOWER MOTOR PRESSURE SWITCHES

-

1

2

-

83095-1

IBOP PRESSURE SWITCH

-

1

1

-

87541-1

LUBE OIL PRESSURE SWITCH

-

1

1

-

83095-2

Bx ELEVATOR CLOSED PRESSURE SWITCH

-

1

1

-

127908-D2

SOLENOID VALVES

-

2

9

-

127908-J2

SOLENOID VALVES

-

1

4

-

93939

FRAME DOLLY RETRACTED PROX SWITCH (OPTIONAL)

-

-

1

-

98263

BARRIER I.S. (OPTIONAL)

-

-

2

108616-6

115299

TD MOTOR INCREMENTAL ENCODER

1

2

2

-

10064178-096

SUPPLY MODULE DC 24V/FUSE

1

1

6

10540174-001

10064178-040

4 CH DIGITAL INPUT MODULE DC 24V

1

3

6

10540174-001

10064178-053

2 CH DIGITAL OUTPUT MODULE DC 24V, 2.0A

3

6

12

10540174-001

10064178-032

INCREMENTAL ENCODER MODULE

1

1

1

10540174-001

10044752-001

RIM SS2 ENCODER SPLITTER

1

1

1

10540174-001

10064178-086

PROFIBUS DP/V1 12 MBd FIELDBUS COUPLER

1

1

1

10540174-001

10042793-001

PROFIBUS CONNECTOR

2

2

2

10540174-001

10044170-001

24VDC POWER SUPPLY 10A

1

1

2

10540174-001

10052294-001

SW, CAM, DISC, 4P, 32A

-

1

1

10540174-001

10049691-001

RLY, SPDT, 24VDC (RLY), 10A AT 250VAC

2

4

4

10540174-001

10505066-007

CB 10A, 2P, 480VAC

1

2

2

10540174-001

10064194-029

FUSE, 6A, 125V, 5 x 20mm

2

2

2

10540174-001

Part No. 76841

Description

D7440000254-TPL-001/01

www.nov.com

Description Where Used TDS-11SA TOP DRIVE TDS-11SA TOP DRIVE TDS-11SA TOP DRIVE TDS-11SA TOP DRIVE TDS-11SA TOP DRIVE TDS-11SA TOP DRIVE TDS-11SA TOP DRIVE BARRIER I.S./N.I.S. J-BOX TD-MOT-01 DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET

Document number Revision Page Template Name

Part No.

Description

10620488-SPL 02 4 ORA_SPL_TPL.doc

-1 Recom. Commission Spare

-2 Recom. Operational Spare

-3 Recom. Insurance Spare

Where Used

10066667-001

TB-6.2MM, GRAY UT4

5

5

5

10540174-001

10065802-001

TB-GROUND BLOCK, UT-4-PE

5

5

5

10540174-001

10066985-001

TB-5.2MM, GRAY, UT2.5

5

5

5

10540174-001

10044673-001

PWR-SPLY REDUNDANT

1

1

1

10540174-001

10064178-070

MODULE, END, FIELDBUS

1

2

2

10540174-001

10068104-001

SPLITTER CABLE

-

1

1

10540174-001

10077584-001

DATA STATION PLUS PROTOCOL

-

1

1

10540174-001

10077585-001

PROFIBUS DP CARD

-

1

1

10540174-001

10512924-001

BANNER WIRELESS GATEWAY

-

1

1

10540174-001

10072732-001

ANTENNA-OMNI

-

-

1

10540174-001

10064179-004

TB-C/B, 4 AMP, THERMALMAGNETIC

1

1

1

10540174-001

D7440000254-TPL-001/01

www.nov.com

Description Where Used DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET DRILL FLOOR TOOL REMOTE I/O CABINET

FINAL DOCUMENTATION TDS-11SA - Top Drive Drilling System

Chapter 7.0 Electrical Trouble Shooting Guide

www.nov.com

FINAL DOCUMENTATION TDS-11SA - Top Drive Drilling System

Chapter 8.0 TDS-11SA, Pocket Guide

www.nov.com

LUBRICATION

LUBRICATION

LUBRICATION

LUBRICATION

LUBRICATION

LUBRICATION

LUBRICATION

LUBRICATION

ACCESSORY TOOLS

ACCESSORY TOOLS

GENERAL INFORMATION

GENERAL INFORMATION

GENERAL INFORMATION

GENERAL INFORMATION

GENERAL INFORMATION

34

FINAL DOCUMENTATION TDS-11SA - Top Drive Drilling System

Chapter 9.0 TDS-11SA VFD Operation Manual

www.nov.com

Operation Manual TDS11 VFD Operation Manual

REFERENCE

RIG/PLANT

REFERENCE DESCRIPTION

TDS11 ADDITIONAL CODE

SDRL CODE

TOTAL PGS

111 REMARKS MAIN TAG NUMBER CLIENT PO NUMBER CLIENT DOCUMENT NUMBER

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DISCIPLINE

This document contains proprietary and confidential information which belongs to National Oilwell Varco; it is loaned for limited purposes only and remains the property of National Oilwell. Reproduction, in whole or in part; or use of this design or distribution of this information to others is not permitted without the express written consent of National Oilwell Varco. This document is to be returned to National Oilwell Varco upon request and in any event upon completion of the use for which it was loaned.  National Oilwell Varco

National Oilwell Varco Rig Solution Group 1530 W. Sam Houston Pky N Houston, Texas 77043 (USA) Phone + 713-935-8000 Fax + 713-346-7426

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REVISION HISTORY

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15.08.2006

Rev

Date (dd.mm.yyyy)

INFORMATION

CHANGE DESCRIPTION Revision 01

Change Description First Issue

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CRR

ML

CRR

Prepared

Checked

Approved

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Technical Manual

Air-Cooled AC Drives

Model 800AC

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TABLE OF ONTENTS 1

2

SAFETY INSTRUCTIONS ................................................................................................ 6 1.1

General ................................................................................................................... 6

1.2

Safety Symbols ....................................................................................................... 6

1.3

Basic Safety Precautions ........................................................................................ 7

INTRODUCTION ............................................................................................................... 9 2.1

3

Abbreviations and Definition ................................................................................... 9

SYSTEM DESCRIPTION ................................................................................................ 10 3.1

Input/Output Reactor ............................................................................................ 11

3.2

Input Rectifier........................................................................................................ 11

3.3

DC Bus ................................................................................................................. 16

3.4

Inverter ................................................................................................................. 16

3.5

Braking Chopper and Resistor Bank..................................................................... 39

3.6

Assignment Contactors ......................................................................................... 42

3.7

AC Induction Motors – Basic Principle of Operation ............................................. 43

3.8

PLC and interface for the Drilling Control System (DCS)...................................... 46

3.9

Technical Data ...................................................................................................... 49 3.9.1 Weights and Dimensions........................................................................... 49 3.9.2 Performance Data ..................................................................................... 52

4

OPERATING INSTRUCTIONS ....................................................................................... 53 4.1

CONTROL PANEL ............................................................................................... 53 4.1.1 Panel operation mode keys and displays .................................................. 54 4.1.2 Status Row ................................................................................................ 54 4.1.3 Drive control from panel ............................................................................ 55 4.1.4 Actual signal display mode ........................................................................ 56 4.1.5 Parameter mode ....................................................................................... 60 4.1.6 Function mode .......................................................................................... 61 4.1.7 Drive selection mode ................................................................................. 65 4.1.8 Reading and entering of Boolean values on the display ........................... 65

4.2

INITIAL MOTOR OPERATION SETUP ................................................................ 67 4.2.1 Visual Inspection ....................................................................................... 67

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4.2.2 Configure Drive ......................................................................................... 67 4.2.3 General Set-up Procedures....................................................................... 70 5

6

INSTALLATION .............................................................................................................. 94 5.1

Mechanical Installation ......................................................................................... 94

5.2

Electrical Installation ............................................................................................. 94

TROUBLESHOOTING .................................................................................................... 98 6.1

Warning and fault indications ................................................................................ 98 6.1.1 Programmable protection functions ........................................................... 98 6.1.2 Preprogrammed faults ............................................................................. 100 6.1.3 Warning messages generated by the drive ............................................. 101 6.1.4 Warning messages generated by the control panel ................................ 105 6.1.5 Fault messages generated by the drive .................................................. 106

7

MAINTENANCE ............................................................................................................ 110

8

OPERATOR SKILLS AND TRAINING ......................................................................... 111

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SAFETY INSTRUCTIONS Read the entire Safety Summary located in the ABB operation maintenance manuals prior to performing any operations or maintenance to this equipment. The following safety instructions must be followed when installing, operating and servicing the National Oilwell air-cooled AC drives. If ignored, damage may occur to the operator and equipment. Read these safety instructions before working on the system.

1.1

General Safety is everyone’s business and must be of primary concern at all times during any operations or maintenance. Knowing the guidelines covered in this manual will help to provide for the safety of the individual, for the group and for the proper operation of the equipment. Only qualified personnel who are well versed in safety procedures should ever be allowed to operate and/or maintain this piece of equipment. If this guideline is strictly followed, this will minimize problems. Safety summaries and safety procedures can never replace good common sense. As detailed as some of these documents may be, some situations will require good common sense. Recognize all standard safety symbols. Understand their importance, read them carefully and make sure you understand their meaning. If something is unclear, ask. Do not take chances with your life and others.

1.2

Safety Symbols There are three types of safety instructions used throughout this manual and on the equipment: warnings, cautions and notes. Look for these standard safety terms and conventions that point out items of importance to the safety of the individual as well as others that may be in the area:

WARNING safety notes MUST be followed carefully. Failure to do so may result in catastrophic equipment failure resulting in SERIOUS INJURY or DEATH.

*

CAUTION safety notes are also very important and should be followed carefully. Failure to do so may

*

Recommended safety conventions. American Petroleum Institute www.nov.com

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result in EQUIPMENT DAMAGE and/or PERSONAL INJURY.

NOTE NOTE is used to notify personnel of information that is IMPORTANT but NOT HAZARD RELATED.

1.3

Basic Safety Precautions As mentioned earlier, all personnel performing operations or maintenance tasks of any kind should be trained in both general safety and hazard recognition around a drilling rig, as well as specific instructions pertaining to the particular rig they are working. All operators and maintenance personnel should be versed in the specifics regarding performance characteristics and limitations of all rig equipment. Any personnel who intend to operate the unit needs to be both qualified and trained on the AC drive operating controls and have a thorough understanding of the limitations and functions of this piece of rig equipment. All personnel should be protected from exposed mechanical dangers such as guards fabricated from expanded metal and other similar hazards. Safeguards such as keeping hands, hair, clothing, jewelry, rags, tools, etc. away from all moving parts should be familiar and a part of all activities. Do not attempt equipment operation with inadequate visibility. Poor lighting can aggravate this, as can bad weather conditions, or other reasons. If you cannot see what you are doing, then do not do it! Operating and maintenance personnel should wear suitable protective clothing in addition to any other personal safety devices that conditions may dictate. Equipment used in heavy lifting and moving of the unit and accessories during operations must be sufficiently rated to handle the weights involved. Promote good safety measures at all times around the equipment and throughout all phases of operations. It is the equipment owners’ / operators’ responsibility to establish good safety measures including personnel training and enforcement of safety practices. The first person hurt by poor safety practices is most commonly the operator in the field.

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Operating instructions tend to be general in nature to make them clear and easy to understand, giving minimal details on individual component operation. If the operator is not thoroughly familiar with all control functions, equipment limits, and safety features – DO NOT OPERATE THIS EQUIPMENT.

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INTRODUCTION This manual is intended for personnel who plan the installation, install, commission, use and service of the system. A fundamental knowledge of electricity, wiring, electrical components and electrical schematic symbols is required. This technical manual includes data and information concerning the National Oilwell air cooled series of Variable Speed Drive Systems (VSDS) referred to as the model 800AC. National Oilwell VSDS are built from adjustable speed frequency converters, inverters, or combinations of both. This manual is written to include all of these devices and their respective system components. All National Oilwell AC variable speed drive systems are similar, but there are many variations according to each customer’s specific requirements. Therefore, it is recommended that the user review the reference document list in conjunction with this manual so that a thorough understanding of your specific system is ensured. The basic function of a model 800AC system is to convert a fixed frequency 3 phase AC voltage into a variable frequency, variable voltage source that is utilized to control motor speed and torque. To accomplish this, the model 800AC utilizes the following three steps:

  

Standard three phase 50 or 60 Hz voltage is converted from AC to DC by 3-phase, full wave rectifiers. The DC voltage is inverted to variable frequency / variable voltage by the inverters. The variable frequency / variable voltage output is applied to a motor to control speed and braking.

The rectifier installed in the model 800AC system is composed of individual diode semiconductors arranged in a full wave rectifier bridge. These diodes are mounted on a finned heat sink which utilizes an electric powered fan motor for cooling. The inverters in the model 800AC systems utilize the ABB model ACS800 inverter modules. These modules are combined to form the inverter or drive part of the system. More detailed information about the individual components, software, or systems can be found later in this manual, in vendor supporting documents or from the factory upon request.

2.1

Abbreviations and Definition ASIC

Application Specific Integrated Circuit

AHD

Active Heave Draw works

CW

Clockwise

CCW

Counter Clock Wise

CCS

Cyberbase Control System

DCS

Driller’s Control System

DW

Draw works

FDS

Functional Design Specification

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GPM

Gallons per minute

HMI

Human-Machine Interface

HP

Horsepower

Hz

Hertz

IGBT

Insulated Gate Bipolar Transistor

LED

Light Emitting Diode

MMI

Man-Machine Interface

MCC

Motor Control Center

MP

Mud Pump

M/U

Make Up

P&ID

Piping & Instrument Diagram

PHE

Plate Heat Exchanger

PLC

Programmable Logic Controller

PSI

Pounds per Square Inch

PWM

Pulse Width Modulation

RAM

Random Access Memory

RISC

Reduced Instruction Set Computer

SVM

Space Vector Modulation

STEP7

Siemens PLC Programming Software

TD

Top drive

VFD

Variable Frequency Drive

FC

Frequency Converter

VSDS

Variable Speed Drive System

DB

Dynamic Braking

VAR

Volt-Amp Reactive

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Converter An arrangement of solid-state devices that converts AC power to DC power Operator

3

The person assigned the responsibility of physically operating and maintaining the equipment

SYSTEM DESCRIPTION A typical Model 800AC drive system (VSDS) includes most or all of the following components:

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       

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Input/Output Reactor Input Rectifier DC Bus Inverter (VFD) Braking Chopper and Resistor Bank Assignment Contactors AC Induction Motors – Basic principle of operation PLC and Interface for the Drilling Control System (DCS)

If you are not sure about what equipment is installed in your particular system, review the electrical drawings referenced in the job specific detail drawings and document list.

3.1

Input/Output Reactor Input reactors are used in most systems to reduce the current ripple on the DC bus. Reducing the current ripple extends the bus capacitor lifetime. Input reactors also attenuate harmonics that are injected onto the AC bus by the rectifier bridge. Line reactors are generally dimensioned to provide 3% impedance at full load current, but may be less than this depending upon the source impedance of the system in which they are installed. Most input reactors are iron core, 3 phase inductors, but some systems utilize 3 single-phase reactors in order to save space. The primary function of the output reactor is to filter the output waveform of the inverter. The output reactor reduces motor temperature and audible noise caused by high frequency switching of the inverter. In addition, it reduces the risk of motor bearing currents and provides short circuit protection for the motor.

3.2

Input Rectifier The input rectifier transforms incoming AC voltage into DC voltage using a three-phase full wave diode bridge arrangement. The most basic three-phase bridge arrangement utilizes 6 diodes arranged as follows:

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Figure 3-1: Basic Three-Phase Rectifier Bridge In the arrangement above, two of the diodes are “on” at a time. The diodes turn “on” when they are forward biased. The AC input supply voltage determines which diodes are forward biased at a given time. During operation, diodes A+ and C-, C- and B+, B+ and A-, A- and C+, C+ and B-, B- and A+ are forward biased at the same times. The resulting output of this operation is a DC output voltage with magnitude related to the AC input voltage magnitude. Various voltage sources are possible when using an AC drive. Transformers are used primarily in offshore applications, and generally have multiple secondary windings. The multiple winding supply transformer steps down incoming generator voltage to either 480 or 600/690 volts, depending on the system. Multi-winding transformers are used in high power offshore systems. Multiple phase-shifted windings make it possible to build VSDS systems that introduce very low harmonic distortion to the system supply bus. The most common power source for a portable land based VSDS are synchronous generators. The number and size of the generators varies from one system to another, however nearly all are 3 phase, 600VAC generators. Model 800 VSDS rectifiers typically fall within two basic classes, 6-pulse and 12-pulse. Both the 6 and 12 pulse diode bridges are built using assemblies made from 6 www.nov.com

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semiconductor diodes in a 3 phase, full wave bridge arrangement. A 6-pulse rectifier is built from a single assembly, while a 12 pulse bridge is constructed using two 6-pulse assemblies. In the 12-pulse arrangement, the two 6-pulse assemblies are supplied from the secondary of a ||/Y transformer whose secondary outputs are phase shifted by 30 electrical degrees. Occasionally, 24 pulse rectifiers systems are built using dual 12 pulse rectifiers and 2 ||/Y transformers, where each is phase shifted at the primaries +/- 7.5 electrical degrees. The 6-pulse rectifier is shown in figure 3-1 on the previous page. Figure 3-2 below shows the 12-pulse rectifier with an inter-phase reactor for load sharing.

6 P u lse R e ctifie r

O p tio n a l In te rp h a se R e a cto r

+

6 p u lse T ra n sfo rm e r

To AC M a in s 1 2 P u lse D C O u tp u t 6 P u lse R e ctifie r

-

Figure 3-2: 12 Pulse Diode Rectifier with Inter-phase Reactor The inter-phase reactor balances current in 12 pulse rectifiers by forcing current sharing between the  and Y bridges of the system. Current can become unbalanced in the rectifiers when there are slightly different impedances in the  and Y windings of the transformer.

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The relationship between the AC input voltage and the output voltage of the 6-pulse rectifier is given by the equation VLL x 1.35 = Vdc. For a 12 pulse rectifier, the relationship is VLL x 1.39 = Vdc For either bridge, the unloaded DC value is approximately equal to the peak RMS value of the input voltage, or VLL x 1.414 = Vdc . The following table (3-1) shows some typical DC voltages for various inputs: Input Voltage - RMS line to line

6 Pulse Average DC Output Voltage

12 Pulse Unloaded DC output Voltage

480

648

667

600

810

848

690

932

960

Table 3-1: AC-DC Rectifier Voltages Note that under heavy load, the drive’s DC link voltage may drop slightly. The DC link voltage can be monitored at the drive controller keypad in the main monitor menu. The following figures show the output waveforms of the 6 and 12-pulse rectifier bridges.

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Figure 3-3: 6 Pulse Rectifier Bridge Output Waveform, Vin = 600VAC

Figure 3-4: 12 Pulse Rectifier Bridge Output Waveform: Vin = 600VAC

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3.3

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DC Bus The Model 800AC VSDS systems may utilize a common DC bus. This means that 2 or more inverters are connected to the DC bus via disconnect switches and share a one or more rectifier bridges. There are certain advantages to the common DC bus, the most important being input power is conserved when one or more of the motors in the system are braking while others are motoring. An AC motor that is braking behaves as a generator, and its power is returned to the DC bus by the inverter. Therefore, the power required to operate the VSDS is reduced by utilizing the energy required to brake the VSDS motors. The net power supplied to the VSDS by the system generators is the load power less the regenerated power. For example, if 2 motors are consuming 1500 kW while another motor is braking and supplying 700kw to the DC bus, the net power required to run the system is 1500 – 700 = 800kW. Therefore, the system generators need only supply 800kW and 700kW have been conserved during the braking cycle. A DC link reactor may be used on systems with a common DC bus. This device is similar to an input reactor in that its purpose is to smooth the current ripple on the DC bus. DC link reactors are typically smaller than input reactors. Systems containing only one inverter cubicle typically will not require a DC bus. In these systems the output of the input rectifier is usually cabled to the input of the inverters directly. Please refer to the job specific drawings for more information.

3.4

Inverter The inverter section is the output section of the VSDS and is composed of IGBT semiconductor switches and electrolytic capacitors mounted on aluminum heat sinks. The IGBT collectors and emitters are electrically connected between the positive and negative DC busses, respectively. They are switched on and off in a specific sequence to produce a three phase output voltage of variable amplitude and frequency. The switching technique employed in National Oilwell VSDs is a variation of Pulse Width Modulation (PWM) used in high performance motor control. By varying the duration of the switching pulses, the inverter can directly control the magnitude of the motor voltage, and in so doing control motor current and torque. The fundamental frequency of the Model 800AC is adjustable from 0 to 300 Hz. The inverter converts filtered DC into variable frequency, variable voltage three phase AC. An inverter cubicle contains a single 2 pole disconnect switch, a pre-charge circuit, protective fusing, one or more IGBT inverter modules, and a digital control module with keypad.

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The output current of the voltage source inverter is nearly sinusoidal and can be measured with any quality current probe. If measuring the output current, be sure to adjust the inverter’s output frequency to within the tolerance range of the current probe, as most current probes are designed to work at frequencies between 40 and 60 Hz. Unlike the current, the inverter’s output voltage is non-sinusoidal and cannot be measured with ordinary test instruments. Fortunately, the line-to-line output voltage can be viewed on the DCM’ s LCD display by accessing the motor voltage parameter in the monitor menu.

Figure 3-5: Inverter Power Units Inverter Main Circuit Components and Operation – Model 800AC VSDS Each inverter cubicle is supplied DC voltage through either the input rectifier bridge directly, or a common DC bus. Pre-charge Circuit

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The pre-charge circuit is designed to gradually charge the DC bus capacitors and avoid damaging them. Voltage transients applied to capacitors produce sharp temperature rises and may cause them to rupture or explode. There are several different pre-charge methods employed depending on the system, but the general principle is the same for all. In every case, a resistance is temporarily inserted between the DC source and the capacitor bank so that the charging current is limited to a safe level. All drives are pre-charged before the main rectifier’s power is directly applied to the drive. Never attempt to bypass or defeat the precharge circuit or serious damage to the converter could result. Pressing the “Push to Charge” button initiates the capacitor pre-charge sequence. The operator can monitor the pre-charge status via the “DC Bus Charged” lamp. The purpose of the capacitor bank is to filter the rectified DC voltage and supply magnetizing VARs to the motor. The pre-charge circuit is utilized to prevent damage to the capacitor bank that would otherwise occur if the main rectifier’s output voltage were suddenly applied. Recall that a capacitor acts like a short circuit to a voltage transient; therefore the pre-charge circuit is designed to charge the capacitors slowly. It does this by temporarily inserting a resistance between the capacitor bank and the applied main rectifier voltage. By controlling the charging current, the pre-charge circuit gradually increases the voltage of the capacitor bank. It typically takes between 500ms-1s for the DC bus to reach nominal voltage. The AINT board senses the rising DC voltage, which reports the voltage level to the control module. Although it takes less than a second to reach nominal DC voltage, it may take many additional seconds for the control module to indicate that pre-charge is complete. The control module will then close a contact which controls the “DC Bus Charged” lamp. Once the ”DC Bus Charged” lamp is lit, the operator may close the disconnect switch (or circuit breaker) which connects the main DC supply bus directly to the inverter’s DC link. (Note: please refer to the job specific details. Not all systems contain disconnect switches in the inverter cubicles. Pre-charge circuit operation may vary.) Inverter Control Each Inverter module contains 3 output phases each consisting of a set of full-bridge IGBT’s and associated gate-firing and measurement electronics. With motor and cable attached, the IGBTs have a voltage rise time of between 3 and 5kV/uS. The switching frequencies are nonadjustable on the Model 800, fixed at 1.5kHz. Parallel 1000 amp fuses protect each of the inverter units. These fuses act to limit fault current between inverter units in the event of an internal short circuit. An RDCU drive control unit controls each inverter module used in a Model 800AC VSDS. These units are found behind the swing out compartment in the door of a VSD cubicle. Communication between the RDCU and each inverter unit is made through a fiber optic link. Fiber optical lines are run from the RDCU unit to an optical branching unit, then from the

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branching unit to each inverter. Fiber optic connections can be made to its internal AINT board on the front face of the inverter modules. The inverter is controlled, protected, and monitored by a Digital Control Module (DCM). The DCM is responsible for all motor control operations and inverter bridge control. The control module is loaded with a firmware file. This file contains the all-necessary motor control programs as well as the DCM’s operating system. The two basic embedded motor control programs to choose from in the model 800AC inverter are open and closed loop control. Figures 3-6a and 3-6b show the two main components of the DCM installed in a NOI VSDS system.

Figure 3-6a: Motor Control Board (RDCU)

Figure 3-6b: Display/Keypad

The DCM receives inverter bridge feedback from the AINT board via a fiber optic communication link. IGBT current, DC link voltage, and heat-sink temperatures are the

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primary feedback signals processed by the AINT board and transmitted to the DCM. Phase current is sensed directly at the IGBTs by the measurement boards, which have the added responsibility of delivering gate pulses to the IGBTs. Based on input speed commands, load torque, motor speed, the DCM adjusts the switching patterns of the IGBTs so that the commanded motor speed and torque is realized. The DCM itself consists of a RMIO board and a LCD control panel. The RMIO board is designed with 3 open slots for I/O extension modules in addition to a section with designated I/O used with predetermined external signals. Slot 1 may host one of many option modules including: I/O extension (RAIO, RDIO), pulse encoder interface (RTAC), or Fieldbus adapter (RPBA). Slot 2 can house either I/O extension (RAIO, RDIO) or a pulse encoder interface (RTAC). Option module slot 3 is configured for a DDCS communication option module (RDCO-02). In addition, a keypad with an LCD display is mounted to the face of the control module’s enclosure via ADP1-01 adapter. The next two figures show the DCM control interface (3-7) and the typical I/O connections (3-8).

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Figure 3-7: Control Interface of Inverter Unit

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STANDARD APPLICATION PROGRAM I/O

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Figure 3-8: External Control Connections

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Data Sheet 3-1: RMIO Board Technical Specifications

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Figure 3-9: Isolation and Grounding Diagram Figure 3-9 above details the proper isolation and grounding arrangements to be followed. Care should be taken to ensure all signal grounds are as per this arrangement.

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Option Modules / Extended I/O Profibus-DP Adapter Module (RPBA-01) The PROFIBUS-DP Adapter module is an optional device designed to enable the connection of a drive to a PROFIBUS network. Each drive connected to the PROFIBUS network through an RPBA-01 module is considered a slave device. The RPBA-01 PROFIBUS-DP Adapter module allows the following:      

Give control commands to the drive Start,Stop, Run Enable, etc… Feed a motor speed or torque reference to the drive Read status information and actual valures from the drive Change drive parameter values Reset a drive fault

Figure 3-10: RPBA-01 Option Module

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The Profibus cable is connected to the connector labeled X1 on the RPBA-01 module. The diagram and table below depict the connector pin allocation. This configuration follows PROFIBUS standard.

Table 3-2: X1 Connector Pin Allocation for the RPBA-01 Module

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Bus termination is achieved by switching on a DIP switch located on the front of the RPBA-01 module. Bus termination prevents signal reflections from the cable ends. If the module is the first or last module on the network, bus termination must be set to ON. If using PROFIBUS specific D-sub connectors with built in termination, the RPBA-01 termination must be switched off. Figure 3-11 below shows the DIP switch details. ***Note: The built-in termination circuitry of the RPBA-01 is of the active type, so the module has to be powered for the termination to work. If the module needs to be switched off during operation of the network, the bus can be terminated by connecting a 220 ohm, 1/4 W resistor between the A and B lines.

Figure 3-11: Bus Termination DIP Switch

Rotary node address selectors on the RPBA-01 module are used to select the node address number of the drive. Each node address number is of decimal type ranging in value from 01 to 99. The left selector represents the first digit and the right selector the second digit. Node addresses may be changed while operating, but the module must be re-initialized for changes to take effect. ***Note: If 00 is selected, the node number is defined by a parameter in the fieldbus parameter group of the drive.

Figure 3-12: Node Selectors

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The diagram below is a demonstration of PROFIBUS network wiring. The PROFIBUS cable shields are directly earthed at all nodes. All cable is standard PROFIBUS cable consisting of a twisted pair and screen.

Figure 3-13: Cable Connection and Grounding Diagram for Standard Profibus Cable

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Pulse Encoder Interface Module (RTAC-01) The RTAC-01 Pulse Encoder Interface Module allows a digital pulse encoder feedback to be used for determining accurate motor speed or position. In most NOI Model 800AC systems the RTAC-01 module will be installed in slot 2 on the RMIO board. Signal and power connection is automatically made through a 38-pinm connector, upon installation of the module.

Figure 3-14: RTAC-01 Module Layout

Table 3-3 on the next page details the terminal designations for the encoder module. Most NOI model 800AC systems supply power to the encoder module using an external 24VDC power supply. When this is the case, the external 24VDC power supply should be connected to terminal X1-5 and the factory installed jumper across X1-5 and X1-6 should be removed.

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Table 3-3: Encoder Board Terminal Definitions and Signal Descriptions

***Note: Encoder inputs can be used with encoders having +15V to +24V signal levels. www.nov.com

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DDCS Communication Module (RDCO-02)

A DDCS Communication Module may be used in NOI Model 800AC systems where a Master/Slave drive configuration is desired. The DDCS module offers an optical communication link between 2 drives. There are four fiber optical channels available on the DDCS module designated as shown below. DDCS modules will be installed in Slot 3 on the drive RMIO board. CH1 – Overriding system (e.g. fieldbus adapter) CH1 – I/O extensions CH2 – Master/Follower link CH3 – PC tools (such as Drive Ware)

Figure 3-15: RDCO-02 Module Layout

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Branching Unit (NDBU-44C) The NDBU-44C Branching Unit (shown in figure 3-16) is used to link the AINT boards of multiple inverter power units to one DCM. The optical inputs and outputs of the module are separated into sections labeled CH1-4 and AMC. Each of the optical channels has a transmitter and receiver. A channel is assigned to each inverter and then two optical cables are run between each inverter unit and the NDBU-42 module.

Figure 3-16: NBDU-44C Module Layout

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The TXD connector on the NPBU-44C unit is cabled to the RXD connector on the Inverter AINT board. The RXD connector on theNPBU-44C unit is cabled to the TXD connector. The RXD and TXD connectors are distinguished by color: Black= RXD and Gray=TXD. The AMC channel of the NDBU unit is cabled to the RMIO board of the DCM. Figure 3-17 on the next page shows an actual picture of the front of an inverter module where the fibers are connected to the AINT board.

Figure 3-17: AINT Board Connections on the Front Face of the Inverter Power Unit

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Motor Control The firmware program is the interface between the user I/O and the motor control program. Its job is to process all external control inputs such as start, stop, motor direction, and speed. The processed input data is then passed from the firmware program to the motor control program. Likewise, the firmware program receives information from the motor control program about such things as the inverter output current, motor speed, and DC bus volts, and passes it back to keypad display or the fieldbus. User control is most commonly exercised via fieldbus, but discrete control signals are also commonly used. The fieldbus protocol used with most NOI equipment is Profibus DP. Figure 3-18 is an inverter control block diagram illustrating the basic control theory of the Model 800AC.

T y p ic a l In v e rte r B lo c k D ia g ra m             

      

                     

             

                    

L IN E R E A C T O R

    

      

      

SHAFT ENCODER

       

   

0



 





B U S C A P A C IT O R S

           

D C L IN K

         

IN P U T R E A C T O R

           

FREQ UENCY CO NVERTER

Figure 3-18 Frequency Converter / Inverter Control

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Multi-motor Modes of Operation There are two basic modes of operation that are used by National Oilwell when motors are operated in parallel. The first mode is known as master/follower mode, the second mode simply parallel inverter units. Each has certain advantages and disadvantages and they are utilized accordingly in each application. When a common shaft mechanically couples two or more motors, the optimum solution is for the associated inverters to force load sharing among the respective motors. This can be achieved using the master/follower mode of operation, in which the master drive is given a speed reference by the PLC or hardwired input. The remaining ‘followers’ receive a torque reference from the master drive via the controller’s system bus. In this way, the follower drives all receive the same torque reference as the master, insuring that load sharing is achieved. In this mode, the master drive is a “speed master” while those receiving their torque references from the master are known as “torque followers”. If one motor or drive is lost in a two drive system while in operating in master/follower mode, the remaining drive will automatically be configured to operate in master mode as soon as the other is removed from the fieldbus, or has it’s input power removed. Master/follower mode of operation is generally employed where precise load sharing between motors is required. An example of such an application is a multimotor drawworks. The second most commonly applied mode of operation employs dividing the output of one drive between multiple motors. In this mode of operation a single drive receives a speed reference, and generates an internal torque reference according to the load. Load sharing is achieved by virtue of the mechanical coupling between motors. Each motor receives the same voltage and current output as its counter part. This mode of operation is used quite frequently in dual motor top drives and mud pumps. It is also used in active heave drawworks applications where operation of the drawworks must continue without interruption. The reason this method is preferred to master/follower mode in a multi-motor system (more than 2 on a common shaft) is that in the event of a motor or drive fault, it is not necessary to re-wire or reconfigure the drive’s system bus in order to continue operation. With this method, the drive only responds to a single speed reference and is never looking to another drive for a torque reference in order to function. Motor Control Modes There are two basic types of motor control available from the National Oilwell VSDs. Open loop frequency control, or scalar control is the first method, and generally applied to motors connected to pumps, fans or other applications in which precise torque control isn’t required. In this type of control, the digital control module operates without speed feedback, and simply applies a constant ratio of voltage to output frequency. Without speed feedback, the DCM has no direct knowledge of the rotor slip or position. Consequently, precise speed and torque control in open loop is not possible. This mode of operation is still adequate where high starting torque is not required, such as a pump.

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The second method of motor control is known as closed loop speed control. In this mode, the DCM receives speed feedback via an incremental encoder, which is normally mounted on the motor shaft. In this mode of operation, precise speed and torque control is possible throughout the entire speed range of the inverter. This mode of operation is quite useful in applications that require holding a load stationary, such as a drawworks or a crane, as well as in applications where the motor operates above its base speed. For closed loop control to be successful, the encoder must supply information about rotor position and speed. Closed loop speed control is the most efficient and precise means of controlling a 3-phase induction motor. Closed loop speed control is used on all National Oilwell drawworks, cranes, pipe-handling equipment, and top drives. It may or may not be employed on other drilling machinery, depending on the customer’s performance requirements for the installed system. The summary of the major physical components of each inverter can be found in the following table.

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INVERTER COMPONENT SUMMARY Device

Function

Pre-charge Circuit Digital Control Module (DCM)

User interface with the inverter. The keypad is used for changing drive operating parameters, monitoring drive data, and issuing control commands.

Bus Capacitors

Provide filtering of the DC bus voltage and furnish magnetizing VARs to the motor

Insulated Gate Bipolar Transistors (IGBT) (qty 2-6 modules per inverter)

Converts DC voltage into 3-phase AC voltage of variable frequency and amplitude.

AINT board

Controls inverter firing and serves as an interface between the IGBT measurement boards and the digital control module. Table 3-4: Inverter component summary

3.5

Braking Chopper and Resistor Bank The brake chopper is a semiconductor switch used to reduce the DC link voltage when the motors are overhauling. The set point varies depending on the system voltage and the application. The proper set point for your system may be found on the parameter list in the Operating Parameters section of the manual. All AC drives installed on a drawworks, TD, or cranes employ a DB chopper of some kind. Some, but not all AC driven mud pumps also employ a braking chopper, depending on the nature of the drilling program, and the type of pump used. Generally speaking, drawworks and cranes require full braking capacity from the DB choppers and resistor banks, so they tend to be sized quite differently than systems that require only intermittent use or light braking. Stand-alone TD choppers are typically rated to provide longer deceleration ramps and braking cycles than a drawworks or crane, but their operation is the same.

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Figure 3-19 on the next page illustrates the basic configuration of a chopper unit. Note that the braking resistor is connected to the (+) DC bus and the collector of the lower IGBT switch, so that the lower switch provides the path between the braking resistor and the (–) DC bus. The upper switch is unused in this arrangement. In current NOI systems that do not require intensive dynamic braking, the choppers used are typically air cooled, non-programmable, “dumb” units that trigger on a fixed voltage. These units carry an 80kW to 400kW continuous rating, and are not re-configurable. There may or may not be an external DCM. Dynamic braking or electrical braking is achieved by forcing an AC motor to operate as an induction generator. This occurs whenever the inverter’s output frequency is less than the corresponding rotor speed. A common example of this is when the load drives a motor, and the commanded inverter frequency is slower than the actual motor speed. In this mode of operation, the inverter issues firing pulses and supplies magnetizing VARs to the stator. As long as the inverter supplies the stator with a magnetic field, the motor will operate as generator. When acting in this manner, the interaction between the stator’s rotating magnetic field and the induced magnetic field in the rotor will generate a torque that opposes the load torque. As soon as the inverter is stopped (firing pulses are suppressed), the stator and rotor magnetic fields will collapse and all braking torque will be lost. The power flow between the inverter and the motor is such that real power flows from the motor to the drive, while reactive power flows from the drive to the motor. The AC current flowing back to the drive is rectified by the inverter’s fly back diodes and flows into the inverter’s DC bus as direct current. The direct current charges the DC link capacitors, causing DC bus voltage to rise. Once the voltage reaches a pre-determined set point, the chopper will switch on and connect the braking resistor bank across the positive and negative DC bus terminals. In addition to lowering the DC bus voltage, the braking choppers and resistor banks will dissipate the excess power in the resistor bank. The total dissipated power in the resistor, inverter, and motor will equal the braking power applied to the load. In systems that share a DC bus and chopper(s), the other inverters may consume much of the regenerated energy, in which case the braking chopper is only required to dissipate the excess power. Mechanical braking is only needed for emergency braking or for parking the load when the AC Drive is stopped. In general, the dynamic braking power and torque can reach 150-175% of the motor’s nominal ratings over brief periods of time in hoisting applications, or where very short deceleration ramps are used. The shorter the deceleration ramp, the higher the peak braking torque and power will be.

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Figure 3-19: Typical DC Chopper Circuit

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Assignment Contactors Assignment contactors are used to control the inverter output to meet system needs. One inverter can be switched between two or more motors, or one motor can be switched between two or more inverters. The number of contactors varies depending on the system’s requirements. Not all systems utilize assignment contactors. Figure 3-20 shows a few possibilities for assignment contactors.

M

M

M

M

T Y P IC A L A S S IG N M E N T C O N T A C T O R ARRANGEM ENTS

Figure 3-20 Sample Output Contactor Single Line Drawing Assignment contactors are either 3-phase AC contactors, or constructed from individual, single phase contactors. The VSDS PLC ordinarily controls their operation, but they are electrically interlocked to prohibit undesirable states in the event of a PLC malfunction.

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The following components are not considered part of the VSD, but a working knowledge of how they operate and the function they serve is useful in understanding and maintaining the variable speed drive system. 

One or more 3-phase AC induction motors. Ordinarily, each VSD powers a single motor at a time.



Drilling Control System (DCS). The Drilling Control System provides the MMI for the driller and interfaces with the Model 800 VSDS to provide control of drilling equipment and to receive feedback information.

3.7 AC Induction Motors – Basic Principle of Operation The motors controlled by the Model 800AC VSDS are used to operate specific rig equipment, such as the drawworks, top drive, pumps, cranes, etc. The most commonly used motor is the 3phase “squirrel cage” induction motor. In most drilling systems, the motors are open frame and are cooled by an external blower, that forces cooling air directly onto the rotor and stator windings. Some motors installed on cranes are closed frame, and cooled using a combination of channels cut into the stator frame with fans mounted on the non-load end of the motor. In both types, the cooling blowers and fans are controlled from independent voltage sources located in the VSDS. Since the motor’s main shaft is not used to drive a cooling fan or blower, these motors may operate indefinitely at very low speeds as long as the cooling fans are functioning. Induction motors have certain characteristics that distinguish themselves from DC motors, including:    

They require little maintenance other than periodic lubrication of the bearings. They are intrinsically safe – they don’t generate arcing or sparks as with DC motors. They are capable of holding full torque at zero speeds indefinitely without sustaining damage to internal components. Generator operation (for braking purposes) is somewhat easier with an AC induction motor than a DC motor.

The induction motor is composed of two main parts: a stator winding and a rotor. The stator is a set of copper coils wound into slots in the motor frame. As its name implies, it is stationary. The leads of the stator are connected to the 3 phase terminals of inverter. The stator windings are spatially arranged so that a 3-phase voltage source establishes a rotating magnetic field around the rotor. Stators are made up of pole pairs, so the minimum number of poles is 2. Nearly all AC drilling motors have 6 poles, however 4 pole motors are also commonly found on cranes and winches. www.nov.com

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The squirrel cage rotor is made of copper or aluminum bars that are held in place by the motor bearings at each end of the motor frame. Rotation is caused by the interaction of magnetic fields between the stator and the rotor. Specifically, the rotating magnetic fields of the stator induce a voltage in the rotor bars, which cause a current to flow in the rotor. In turn, the rotor current generates its own magnetic field, which attempts to align itself with the stator field. It is the relative motion between the stator and rotor magnetic fields that generates motor torque. Rotor speed is dependent on both the stator frequency and the motor load. Rotor speed is related to the stator frequency by the formula: Synchronous Rotor Speed =

(120 x stator frequency) Number of poles

It’s important to note the rotor’s fields never actually catch up with the stator fields; instead the rotor turns at some speed slower than the synchronous speed. So in practice, the actual speed of the rotor will differ from the synchronous speed, and is referred to as the motor slip. Slip is usually expressed as a percentage, and in which case it is expressed by the formula: %Slip = (Synchronous speed – Actual speed) x 100 Synchronous Speed The nominal or base speed of the motor expresses actual rotor speed for a fully loaded motor running at base frequency, usually 60 Hz. Therefore the rated slip of the motor can be found from this number, and it is at the rated slip the nameplate full load current, torque, and power apply. The nominal speed is usually found on the manufacturer’s nameplate. The following table lists motor nameplate information that is required input to the inverter’s DCM parameter list: MOTOR PARAMETER

UNIT

EXPLANATION / DEFINITION

Nominal Voltage

VAC

Rated RMS line to line voltage

Nominal Frequency

Hz

Field Weakening point

Nominal Speed

RPM

No load motor speed @ nominal frequency

Nominal Current

AAC

Full load current

Nominal Power

KW

Rated Power [kW] = (HP x 746)/1000

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Power Factor (cos phi)

N/A

Typically 0.85

Maximum Safe Speed

RPM

Highest speed at which motor should be operated

Table 3-5 Required Motor Nameplate Data There are 2 basic regions of operation for an induction motor. The first region is between 0 RPM and the nominal motor speed, and is known as the constant torque region. The second region is between the motor’s nominal speed and it’s maximum speed, and is known as the constant horsepower region. In the constant torque region, the stator voltage is applied linearly with increasing frequency, so that the ratio of Voltage/stator frequency is held constant. Full (rated) voltage is applied when the motor speed is equal to the nominal nameplate speed. At this point, the FC has reached its voltage limit (output voltage cannot exceed input voltage), so the converter’s voltage is held constant as the stator frequency is increased. As frequency increases, the induction motor’s back-emf increases, and stator current begins to drop off because the difference between the converter’s output voltage and the motor’s opposing voltage becomes less. As current drops off, so does torque, but the horsepower remains constant even as torque drops off because the speed is increasing. Figure 1-9 illustrates these 2 regions.

14000 T Y P IC A L S P E E D V S T O R Q U E P R O F IL E

OVERLOAD TORQUE

O F A N IN D U C T IO N M O T O R

M O T O R T O R Q U E (L b -F t)

12000

10000 RATED TORQUE 8000

CONSTANT HORSEPOW ER R E G IO N

CONTANT T O R Q U E R E G IO N

6000

4000

2000

2450 M ax. RPM 0 0

200

400

600

800

1000

1200

1400

1600

1800

2000

M O TO R SPEED ( RPM )

Figure 3-21 Typical Induction Motor Curve www.nov.com

2200

2400

2600

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The motor receives varying voltage and frequency from the IGBTs. Lowering the VFDs output frequency will change the motor’s speed. When the load forces the motor to rotate faster than the applied inverter frequency, the motor becomes a generator and converts rotational energy into electrical power. This electrical power is fed to the DC Bus via the inverter phase cells. The brake choppers and braking resistors then dissipate the excess power as heat. 3.8

PLC and interface for the Drilling Control System (DCS)

The Drilling Control System is based on the Siemens S7 300 family of modular mini-PLCs. The PLC provides the link between the operator and the inverter either through a touch screen or other control panel. The PLC is responsible for controlling the inverter’s start, stop, and speed commands based on the user input, load conditions, and other system information. The PLC communicates with the inverter using the Profibus DP protocol, and therefore can access information from the converter and provide information to it. Among other things, the PLC may be used to change the inverter’s operating parameters, monitor and control the cooling system, manage system power, and report system alarm/system fault data to the operator. The PLC acts as the bridge between the MMI (Man-Machine Interface) console and the VFDS system components. A typical DCS is illustrated in below in Figure 3-22.

Fig. 3-22 Sample Drilling Control System with Supervisory PLC The Siemens S7 PLC is usually located in the Incomer cubicle, or its own PLC cubicle. The PLC communicates with the other devices over a PROFIBUS communications network. There is I/O located on the PLC rack, as well as Remote I/O racks typically located in the MCC and the Operator Console. The purpose of having remote is to reduce the number of wires that need to be run between the field, the MCC, www.nov.com

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and the PLC cubicle. By using remote I/O only the 2 wire PROFIBUS cable needs to be run. For remote racks located far away from the PLC, such as in the operator’s console that is normally located on the drill floor, fiber optic cables are used instead of the hard-wired system. In this case, an Optical Link Module is used to convert from the Profibus signal to the fiber optic communications. The variable inverters and the choppers also communicate with the PLC over the same PROFIBUS network. Each device on the network has a unique address to distinguish itself to the PLC. The Operator’s Console allows the operator to control the system with devices such as switches, throttles and potentiometers. The console also displays system status with pilot lights and gauges. These inputs and outputs are wired into a remote I/O rack that is connected to the PLC over the Profibus network. The PLC also switches on the auxiliary motors by controlling the motor starters. Some systems may include a remote I/O rack that controls this action. Based on the operator’s commands, the PLC sends commands to the drives. By communicating over the PROFIBUS network, the PLC can start the drive, send it speed and torque commands, as well as read back drive’s status information. The status information includes items such as voltage, current, run status and fault information. This information inside the PLC is usually sent to a touchscreen or remote monitoring system for troubleshooting purposes. The following table contains the fault and alarm codes and descriptions that can be read by the PLC. FAULT/WARNING BUFFER READ BY THE PLC

Fault ACS 800 TEMP AI< MIN FUNC BRAKE ACKN COMM MODULE DC OVERVOLT EARTH FAULT ENCODER AB ENCODER ERR IN CHOKE TEMP MOTOR STALL MOTOR TEMP MOTOR 1 TEMP MOTOR 2 TEMP PANEL LOSS SHORT CIRC THERMISTOR UNDERLOAD DC UNDER VOLTAGE EXTERNAL FLT I/O COMM MOTOR PHASE OVERCURRENT OVERFREQ www.nov.com

ID NUMBERS 95-99

Code 4210 8110 ff74 7510 3210 2330 7302 7301 ff81 7121 4310 4312 4313 5300 2340 4311 Ff6a 3220 9000 7000 ff56 2310 7123

Comment Inverter Temp

Check Field Bus Short circuit See sub codes Check encoder module wiring

(programmable fault fcn) (not used typically) (not used typically) (progammable fault fcn) (progammable fault fcn) (progammable fault fcn) Check mains and fuses (progammable fault fcn) Check fiber on CH1 (progammable fault fcn) Check encoder/Accel time

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5300 5210 3130

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(progammable fault fcn) Check fibres at AINT board Check mains for imbalance

Table 3-6: PLC Fault/Alarm code Reference Table

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Technical Data The following table (3-7) includes technical specifications about the National Oilwell inverters and choppers. If more information is required, please consult the National Oilwell Factory in Houston, Texas.

MODEL 800 INVERTER

Parameter

Specification Unit

Environmental/Mechanical Ambient Operating Temperature Reduced Output (1%/1C) Storage Temperature Transportation Relative Humidity (no condensation) Altitude (w/o derating) Altitude (w/ derating) TYPICAL CHOPPER UNIT Parameter Environmental/Mechanical

0/32 to +50/122 C/F +40/104 to +50/122 -40/-40 to +70/158 C/F -40/-40 to +70/158 C/F 5< 95% 0..3000/0..1000 Ft/M 3000..12000/1000..4000 Ft/M

Ambient Operating Temperature Storage Temperature Relative Humidity (no condensation) Altitude (w/o derating)

-10/14 to +40/104 C/F -40/-40 to +70/158 C/F 5< 95% 3300/1000 Ft/M

Specification

Unit

Table 3-7 National Oilwell Technical Specifications

3.9.1 Weights and Dimensions The components of a Model 800AC VSDS will vary from job to job. Assignment cubicles, if utilized, may contain different numbers of contactors. The number of VFDs may vary also, as will the size of the cooling system. The item that can vary the most is the incomer cubicle, depending on whether it is multi-pulse and what it’s amperage capacity is. Refer to the weight and outline dimensions as shown on the drawings for each job-specific system. A general guideline for dimensions of individual component cubicles of the system is as follows: CUBICLE DIMENSIONS HEIGHT

WIDTH

DEPTH LAND

DEPTH OFFSHORE

INVERTER (2X Inverter units)

90” / 2286mm

24” / 559 mm

38” / 966mm

50” / 1270mm

INVERTER (3X Inverter units)

90” / 2286mm

36” / 559 mm

38” / 966mm

50” / 1270mm

INVERTER (4X Inverter units)

90” / 2286mm

48” / 559 mm

38” / 966mm

50” / 1270mm

CUBICLE

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90” / 2286mm

24” / 914mm

38” / 966mm

50” / 1270mm

90” / 2286mm

30” / 762mm

38” / 966mm

50” / 1270mm

Table 3-8 National Oilwell Cubicle Typical Weights and Dimensions

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Inverter Module Dimensions and Diagrams INVERTER UNIT PHYSICAL DIMENSIONS MODEL W1 H1 MODEL 800AC 9.6450 54.4880

[in] D1 21.1800

MODEL 600/630/6000 INPUT TERMINALS

Figure 3-23 Inverter Model Outline Drawings and Dimensions

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3.9.2 Performance Data The following table (3-9) provides some fundamental performance information about National Oilwell VSDs. Ratings Nominal ratings

IMAX

Drive type

Icont.max A (AC)

A

UN=690 V ACS800-104-0580-7 ACS800-104-1160-7 ACS800-104-1740-7 ACS800-104-2320-7 ACS800-104-3490-7

486 953 1414 1866 2770

724 1419 2107 2780 4127

Light-overload use Heavy-duty use

IN

IHD

A

A

467 914 1358 1792 2659

362 710 1053 1390 2063

Frame Noise level Heat dissipation Air flow 3 dBA kW m /h R8i 2xR8i 3xR8i 4xR8i 6xR8i

73 74 75 76 78

Table 3-9 Inverter Model Performance Data Summary

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7.0 14.0 21.0 28.0 42.0

1200 2400 3600 4800 7200

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OPERATING INSTRUCTIONS The Inverters are normally controlled from the Driller’s Cabin via Profibus DP. During normal operation, the operator will provide start / stop commands and speed references, and monitor the performance of the equipment as it operates. No other operator interactions are normally required. The control keypad mounted on the front of the Inverter cubicles allows local monitoring and parameter adjustments of the Inverters. The details of this keypad are listed below. More information regarding the keypad and control unit is available in the ABB User Manual.

4.1

CONTROL PANEL The control panel is the link between the ABB frequency converter and the user. The ABB control panel features an alphanumeric display with 4 lines of 20 characters. There are four modes of operations:    

Actual Signal Display Mode (ACT key) Parameter Mode (PAR key) Function Mode (FUNC key) Drive Selection Mode (DRIVE key)

The operation mode of the panel dictates the uses of the arrow keys and ENTER. The drive control keys are described below

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Figure 4-1: Illustrates the ABB control panel and control keys

4.1.1 Panel operation mode keys and displays

Figure 4-2: Panel Operation

4.1.2 Status Row

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Figure 4-3: Description of status row

4.1.3 Drive control from panel The user may elect to control the drive by control panel as described below:  Start, stop, and change direction of motor  Give the motorspeed reference or torque reference  Reset the fault and warning messages  Change between local and external drive control The drive can always be controlled from the control panel while the drive is under local control and the status row is visible on the display. The next figure shows how to start, stop and change direction and how to set a speed reference both from the control panel.

Figure 4-4: Start, Stop and Change Direction from Keypad

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Figure 4-5: Setting a Speed Reference from Keypad

4.1.4 Actual signal display mode While in Actual Signal Display Mode, the user may:  Show three actual signals on the display at a time  Select the actual signals to display  View the fault history  Reset the fault history The panel will enter Actual Signal Display Mode automatically within one minute if the keypad is left alone.

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Figure 4-6: Selecting Actual Signals to the Display

Figure 4-7: Displaying Full Name of Actual Signals

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Figure 4-8: Displaying Fault History

***Note: Fault history cannot be reset if there are active faults or warnings.

Figure 4-9: Resetting an Active Fault

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Fault history updates information on current events (faults, warnings, and resets) of the drive. Below demonstrates how events are displayed in the fault history.

Figure 4-10: Displaying Events

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4.1.5 Parameter mode In the Parameter Mode, the user may:  View parameter values  Alter parameter settings

Figure 4-11: How to Select a Parameter and Change the Value

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4.1.6 Function mode In the Function Mode, the user can:  Start a guided procedure for adjusting the drive settings (assistants)  Upload the drive parameter values and motor data from the drive to the panel  Download group 1 to 97 parameter values and motor data from the drive to the panel  Adjust the contrast of the display

Below is an example of how the Motor Setup task can be executed with Start-up Assistant.

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Figure 4-12: Motor Set-up with Start-up Assistance

Uploading data from the drive to the control panel

Note:  Upload before downloading

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

Ensure the program versions of the destination drive are the same as the versions of source drive, see parameters 33.01 and 33.02  Before removing the panel from a drive, ensure the panel is in remote operating mode (change with the LOC/REM key)  Stop the drive before downloading _____________________________________________________________ ___ Before upload, repeat the following steps in each drive:  Setup the motors  Activate the communication to the optional equipment (See parameter group 98 OPTION MODULES) Before upload, do the following in the drive from which the copies are to be taken:  Set the parameters in groups 10 to 97 as preferred  Proceed to the upload sequence (below)

Figure 4-13: Uploading Data from the Drive to the Panel

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Downloading data from the control panel to the drive

Figure 4-14: Downloading Data from the Panel to the Drive

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Figure 4-15: Setting the Contrast of the Display

4.1.7 Drive selection mode **Not applicable to NOI Model 800 VSDS systems. This mode would allow users to select drive of interest if multiple drives were to share one control panel.

4.1.8 Reading and entering of Boolean values on the display Some actual values and parameters are packed Boolean, i.e. each individual bit has a defined meaning (explained at the corresponding signal or parameter). On the control panel, packed Boolean values are read and entered in hexadecimal format. In this example, bits 1, 3 and 4 of the packed Boolean value are ON:

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Figure 4-16: Example of Reading Boolean Values

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4.2

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INITIAL MOTOR OPERATION SETUP The following steps are to be performed prior to running a motor for the first time.

1. Verify the machine’s lubrication system is functioning properly, if applicable. 2. Verify the machine’s associated auxiliary motors are functioning properly bye briefly energizing them from the MCC or local control panel. Ensure the motor blower rotation is correct. 3. Ensure the motor is un-loaded. Verify the motor/machine brakes are operation if so equipped, and any shipping bolts installed to lock the rotor have been removed. 4. Verify that the motor cables and motor have undergone an appropriate insulation test by a trained electrician or technician. 5. Verify the motor’s frame is solidly earthed. 6. If equipped with an encoder, verify the encoder shaft coupling is tight and properly installed. Carefully inspect the encoder cable and verify it is properly terminated, in accordance with the electrical drawings. Verify the encoder cable is run at least 12” from any of the AC motor’s phase conductors.

4.2.1 Visual Inspection A visual inspection of the entire system should be performed before any other steps are taken during the system set-up. The system should be inspected for any damage that may have occurred during shipping or unpacking. Verify there are no loose electrical connections in both the control and main circuits of the entire system. Be sure to correct any problems before proceeding.

4.2.2 Configure Drive Each VFD of a NOI VSDS system must be specifically configured for the intended application. The following sections briefly describe the drive configuration procedure.

4.2.2.1 Inverter Drive Size Under normal conditions, the inverter size dimensioning parameters only need to be set once; and this is done at the factory prior to shipping the drive. When the drive is powered up, pressing the “Drive” button on the Control Panel can check the inverter size. If the inverter size is incorrect, it must be corrected before the Motor ID run can be performed. To do this, please contact NOI in order to obtain the information on reconfiguring drive size.

4.2.2.2 Performing a Motor ID Run A Motor ID run should be performed before any other action is taken with the drive. The motor data should be entered from the information found on the motor nameplate.

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4.2.2.2.1 Entering Motor Data The motor data can be entered in two ways. The first is by going to Parameter group 99 and entering the data as it appears on the motor nameplate. The second method is to press the “Func” button on the Control Panel and then selecting “Motor Set-up.” This will begin the Start-up Assistant, which will guide you through the motor set-up. The parameters should be set-up as follows: 

99.01 Language English or English AM If English is chosen, the motor nominal power must be in kilowatts, and if English AM is chosen, the nominal power is in horsepower.



99.02 Application Macro This should be set to “Factory” unless the drive will be acting as a slave drive. In a slave drive, this is set this to “T-Ctrl” (Torque Control)



99.03 Application Restore



99.04 Motor Control Mode DTC In most cases DTC (Direct Torque Control) will be suitable.



99.05 Motor Nominal Voltage



99.06 Motor Nominal Current (off motor nameplate)



99.07 Motor Nominal Frequency (off motor nameplate)



99.08 Motor Nominal Speed



99.09 Motor Nominal Power (off motor nameplate)



99.10 Motor ID Run Standard The standard ID run will achieve the best accuracy. The motor must be uncoupled from the load. The procedure will take about 1 minute, however times will vary so do not be alarmed. If motor ID Run has not completed within 5 minutes, then look at Group 20 limit parameters as described below that may interfere with the ID Run profile. The drive will spin the motor and will run between 50% and 80% of the motor nominal speed, so make sure it is safe to spin the motor. Note that the motor is accelerated at a very fast ramp during the ID Run, thus the motor will tend to rock do to the rotor inertia. Make sure that the motor is placed on a solid base. The Motor ID Run is always operated in the Forward direction according to the drive phasing, so make sure the motor rotation during the test is consistent with forward rotation of the load/machine. If motor rotation is reversed with respect to the load, interchange any 2 motor cable phases after the ID Run is complete.

No

(off motor nameplate)

(off motor nameplate)

Before performing the ID run, other parameters must be checked. See the following section.

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4.2.2.3 Parameters for Motor ID Run

4.2.2.3.1 Group 20 Go to Parameter Group 20 “Limits” and check the following parameters: 

Parameter 20.02 Maximum Speed The default for this is motor nominal speed. It should be kept there for the ID run.



Parameter 20.03 Maximum Current The default for this is two times the motor nominal current. For the ID run it needs to be greater than the nameplate value



Parameter 20.04 Torque Max Lim 1 This needs to be at least 100%. It is best to keep it at default (300%) for the ID run.



Parameter 20.05 Overvoltage Control This should be set turned ON for the ID run. Under normal operation of the drive, if there is a chopper and brake resistor in the system, this should be turned off in order for the chopper to turn on.

4.2.2.3.2 Remove PROFIBUS Control Profibus control must also be removed from the system. In order to do this, check the following parameters: 

Parameter 10.01 EXT1 STRT/STP/DIR This should be set to “Keypad” during the ID run.



Parameter 11.03 EXT REF1 SELECT This should be set to “Keypad” during the ID run.



Parameter 11.02 EXT1/EXT2 SELECT This should be set to “EXT1” during the ID run.

4.2.2.3.3 Run Enable In Parameter Group 16 “System Control Inputs,” set parameter 16.01 “Run Enable” to “YES” during the ID run.

4.2.2.3.4 Encoder

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If an encoder is being used for speed feedback for the control of the drive, the encoder must be disabled during the ID run. By default, the encoder is not activated; Parameter 98.01 ENCODER MODULE will be set to “NO”. If the encoder feedback was already enabled by setting parameter 98.01 to a value other than “NO”, then disable the speed feedback of the encoder by going to Parameter Group 50 “Encoder Module” and set Parameter 50.06 “Encoder FB Sel” to “Internal” during the ID run. If motor rotation has been proven to be correct, then while the ID Run is running it is also beneficial to check the encoder wiring. To do this, compare ACTUAL SIGNALS 2.18 SPEED MEASURED (Encoder measured RPM) to 1.02 SPEED (drive’s internal calculated speed). Both numbers should be approximately equal and with the same polarity. If rpm does not match then check accuracy of encoder configuration in Group 50 ENCODER MODULE or look for improper wiring or encoder supply voltage (RTAC-01 module does not work with 5V DC encoder signals). If polarity is opposite, and motor rotation is correct, then swap “A” for “B” and “A-“ for “B-“ on the encoder feedback wiring. Note, “Z and Z-“ wires are unused in the ABB drives.

4.2.2.3.5 Master/Follower If the drive that you are working on is set up in the follower mode, this must be disabled in order to perform the ID run. In order to do this, go to Parameter Group 60 “Master/Follower” and change parameter 60.01 “Master Link Mode” to “Not in Use.” Also remember to set Parameters 10.01, 11.02, 11.03 as described above.

4.2.2.3.6 Start Interlock The Start Interlock must be active to start the ID run. To do this, place a jumper between X22:8 and X22:11.

4.2.2.4 Starting the Motor ID Run In order to start the motor ID run, put the Keypad in the Local mode by pressing the “Loc/Rem” key on the Panel. An “L” should appear in the upper left hand corner of the display. Return to Parameter Group 99 and change parameter 99.10 “Motor ID Run” and choose “Standard.” Once this is chosen, the screen should read “**Warning** ID Run Sel.” After pressing the green button to start the ID run the screen will read “**Warning** Motor Starts.” During the ID Run, the screen will read “**Warning** ID Run.” By pressing the “ACT” key on the keypad, you can monitor the drive current and speed. When the ID run finishes, the screen will read “**Warning** ID Done.”

4.2.2.5 ID Run Completed Once the ID run has been completed, the parameters that have been changed can be returned to their original values. Now the drive can be customized for the current application.

4.2.3 General Set-up Procedures The following procedure assumes that main power is available to the VSDS. It also assumes all normal procedures relating to resistance and insulation tests have been performed on the VSDS cabinet, supply bus, and the motors it powers. Each VSDS undergoes a system hi-potential test at the factory; however it is important to inspect the main power source network prior to starting the VFD.

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1. Before attempting to energize the inverters, verify that the VSDS system preliminary startup procedure has been followed. See the Reference Documents section for the appropriate procedure. 2. Verify that the inverter is isolated from its main power source. 3. Inspect all main power connections and verify they agree with the system drawings. Inspect each connection and Verify the motor cables not connected to the inverter, either at the plug panel, or at the motor itself. 4. Inspect all control connections to the inverter and verify they agree with the system drawings. Inspect each connection for tightness. 5. Ensure no condensation is evident on the inverter’s phase cells or electronics. 6. Ensure all fiber optic lines and control cables are properly installed according to VFD module interconnect drawings. 7. Ensure that all inverter cubicle doors are closed.

All VSDS cubicle doors must remain closed while the system is energized

8. Connect converter to the main power supply by closing the feeder circuit breaker or main

disconnect switch. Verify that the control panel has powered up and no fault or warning message is displayed. If the display indicates a warning or fault message, see the troubleshooting section and clear the fault before proceeding. 9. Using either the keypad or the Drive Windows commissioning tool, set the parameters according to the requirements of your application. See the Reference Document list for the proper parameters if these are not known. 10. Start the drive from the control console and monitor the output frequency on the keypad from the Actual Signal Display Mode. Issue a frequency reference from the operator’s

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console and verify that the converter output frequency follows the reference. If this does not occur, refer to the troubleshooting section for assistance. 11. EMERGENCY STOP While the inverter is running activate the Emergency Stop switch for the drive. Usually this is located on the users remote console. If operating properly, the drive will stop issuing firing pulses and the output frequency will drop to 0. Be sure the emergency stop logic is working properly before proceeding to run any motors. 12. From the operator’s console, stop the inverter and remove power by opening the circuit breaker or main disconnect switch. The LCD display should go blank within 1 minute after removing power from the inverter. Wait at least 3 minutes after the LCD goes blank before opening the cubicle doors or touching the drive. Always use a voltmeter to check the converter’s DC bus before proceeding. 13. Lockout the inverter’s CB or main power source. Connect the motor cables to the inverter output at the appropriate panel. Make certain the motor/machine brakes are released, and there is no load on the motor. 14. Restore power to the inverter, verify there are no faults displayed, and start the drive from the console. Give a forward speed reference to the inverter and verify the rotation of the motor is correct. If not, reverse any two phases at the motor and re-test. 15. Speed Feed Back: Change encoder module parameter 50.06 to ENCODER. While monitoring both actual and estimated speed on the keypad, give the drive a speed reference and verify the following Table:

Variable

Direction

Speed Reference

Forward

Output Frequency (hz)

Positive

Estimated Speed (rpm)

Positive, equal to Speed Reference

Actual Speed (rpm)

Positive, equal to Estimated Speed

Speed Reference

Reverse

Output Frequency (hz)

Negative

Estimated Speed (rpm)

Negative, equal to Speed Reference

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Actual Speed (rpm)

Negative, equal to Estimated Speed Table 4-1: Variable VS. Direction

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The proper motor start sequence is diagramed in Figure 4-15 below. The diagram shows the relationship between several drive parameters and the role they play in that sequence.

Ts Start torque at brake release (Parameter 42.07 and 42.08) tmd Motor magnetizing delay tod Brake open delay (Parameter 42.03) ncs Brake close speed (Parameter 42.05) tcd Brake close delay (Parameter 42.04)

Figure 4-15: Drive/Motor Starting Sequence (w/ brake control function)

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Table 4-2 Actual Drive Signals

No. Name/Value

Description

01 ACTUAL SIGNALS 01.01 PROCESS VARIABLE

Basic signals for monitoring of the drive. Process variable based on settings in parameter group 34 PROCESS VARIABLE.

01.02 SPEED

Calculated motor speed in rpm. Filter time setting by parameter 34.04.

01.03 FREQUENCY

Calculated drive output frequency.

01.04 CURRENT

Measured motor current.

01.05 TORQUE

Calculated motor torque. 100 is the motor nominal torque. Filter time setting by parameter 34.05.

01.06 POWER

Motor power. 100 is the nominal power.

01.07 DC BUS VOLTAGE V

Measured intermediate circuit voltage.

01.08 MAINS VOLTAGE

Calculated supply voltage.

01.09 OUTPUT VOLTAGE

Calculated motor voltage.

1=1V

01.12 EXTERNAL REF 2

Temperature of the heatsink. External reference REF1 in rpm. (Hz if value of parameter 99.04 is SCALAR.) External reference REF2. Depending on the use, 100% is the motor maximum speed, motor nominal torque, or maximum process reference.

1 = 1 °C

01.13 CTRL LOCATION

Active control location. (1,2) LOCAL; (3) EXT1; (4) EXT2.

01.14 OP HOUR COUNTER

Elapsed time counter. Runs when the control board is powered.

01.10 ACS 800 TEMP 01.11 EXTERNAL REF 1

FbEq 1=1 -2000 = -100% 2000 = 100% of motor abs. max. speed -100 = -1 Hz 100 = 1 Hz 10= 1 A

-10000 = -100% 10000 = 100% of motor nom. torque 0 = 0% 1000 = 100% of motor nom. power 1=1V 1=1V

1 = 1 rpm 0 = 0% 10000 = 100% See Descr. 1=1h

01.15 KILOWATT HOURS

kWh counter. Application block output signal. E.g. the process PID controller 01.16 APPL BLOCK OUTPUT output when the PID Control macro is active. Status of digital inputs. Example: 0000001 = DI1 is on, DI2 to DI6 01.17 DI6-1 STATUS are off.

1 = 100 kWh 0 = 0% 10000 = 100%

Value of analogue input AI1.

1 = 0.001 V

01.19 AI2 [mA]

Value of analogue input AI2.

1 = 0.001 mA

01.20 AI3 [mA]

1 = 0.001 mA

01.21 RO3-1 STATUS

Value of analogue input AI3. Status of relay outputs. Example: 001 = RO1 is energized, RO2 and RO3 are de-energized.

01.22 AO1 [mA]

Value of analogue output AO1.

1 = 0.001 mA

01.23 AO2 [mA]

Value of analogue output AO2. Feedback signal for the process PID controller. Updated only when parameter 99.02 = PID CTRL Feedback signal for the process PID controller. Updated only when parameter 99.02 = PID CTRL

01.18 AI1 [V]

01.24 ACTUAL VALUE 1 01.25 ACTUAL VALUE 2

Deviation of the process PID controller, i.e. the difference between the reference value and the actual value. Updated only when 01.26 CONTROL DEVIATION parameter 99.02 = PID CTRL.

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1 = 0.001 mA 0 = 0% 10000 -10000 = -100% 10000 = 100% -10000 = 100% 10000 = 100%

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01.27 APPLICATION MACRO Estimated motor temperature. 01.28 EXT AO1 [mA] Value of output 1 of the analogue I/O extension module (optional). 01.29 EXT AO2 [mA] Value of output 2 of the analogue I/O extension module (optional). IGBT maximum temperature in inverter no. 1 (used only in high 01.30 PP 1 TEMP power units with parallel inverters). IGBT maximum temperature in inverter no. 2 (used only in high 01.31 PP 2 TEMP power units with parallel inverters). IGBT maximum temperature in inverter no. 3 (used only in high 01.32 PP 3 TEMP power units with parallel inverters). IGBT maximum temperature in inverter no. 4 (used only in high 01.33 PP 4 TEMP power units with parallel inverters). 01.34 ACTUAL VALUE Process PID controller actual value. See parameter 40.06. 01.35 MOTOR 1 TEMP Measured temperature of motor 1. See parameter 35.01 01.36 MOTOR 2 TEMP Measured temperature of motor 2. See parameter 35.04.

0 / No Inversion

1 = 0.001 mA 1 = 0.001 mA 1 = 1 °C 1 = 1 °C 1 = 1 °C 1 = 1 °C 0 = 0% 10000 = 100% 1 = 1 °C 1 = 1 °C 1 = 1 °C

01.37 MOTOR TEMP EST

Estimated motor temperature. Value of analogue input AI5 read from AI1 of the analogue I/O extension module (optional). A voltage signal is also displayed in 01.38 AI5 [mA] mA (instead of V). Value of analogue input AI6 read from AI2 of the analogue I/O extension module (optional). A voltage signal is also displayed in 01.39 AI6 [mA] mA (instead of V). Status of digital inputs DI7 to DI12 read from the digital I/O extension modules (optional). E.g. value 000001: DI7 is on, DI8 to 01.40 DI7-12 STATUS DI12 are off Status of the relay outputs on the digital I/O extension modules (optional). E.g. value 0000001: RO1 of module 1 is energized. 01.41 EXT RO STATUS Other relay outputs are de-energized. Motor actual speed in percent of the Absolute Maximum Speed. If 01.42 PROCESS SPEED REL parameter 99.04 is SCALAR, the value is the relative actual output frequency. Motor run time counter. The counter runs when the inverter 01.43 MOTOR RUN TIME modulates. Can be reset by parameter 34.06. Running time of the drive cooling fan. Note: The counter can be reset by the DriveWindow PC tool. 01.44 FAN ON-TIME Resetting is recommended when the fan is replaced. 01.45 CTRL BOARD TEMP No. Name/Value

Control board temperature. Description

02 ACTUAL SIGNALS

Speed and torque reference monitoring signals.

02.01 SPEED REF 2

Limited speed reference. 100% corresponds to the Absolute Maximum Speed of the motor.

02.02 SPEED REF 3

Ramped and shaped speed reference. 100% corresponds to the Absolute Maximum Speed of the motor. Speed controller output. 100% corresponds to the motor nominal torque.

02.09 TORQ REF 2

02.10 TORQ REF 3

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Torque reference. 100% corresponds to the motor nominal torque.

1 = 0.001 mA

1 = 0.001 mA

1=1

1=1

1=1

1 = 10 h 10

FbEq

0 = 0% 20000 = 100% of motor absolute max. speed 20000 = 100% 0 = 0% 10000 = 100% of motor nominal torque 10000 = 100%

Document number Revision Page 02.13 TORQ USED REF 02.14 FLUX REF 02.17 SPEED ESTIMATED 02.18 SPEED MEASURED

03 ACTUAL SIGNALS

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Torque reference after frequency, voltage and torque limiters. 100% corresponds to the motor nominal torque. Flux reference in percent.

10000 = 100%

Estimated motor speed. 100% corresponds to the Absolute Maximum Speed of the motor. Measured motor actual speed (zero when no encoder is used). 100% corresponds to the Absolute Maximum Speed of the motor. Data words for monitoring of fieldbus communication (each signal is a 16-bit data word).

20000 = 100%

03.01 MAIN CTRL WORD

A 16-bit data word.

03.02 MAIN STATUS WORD

A 16-bit data word.

03.03 AUX STATUS WORD

A 16-bit data word.

03.04 LIMIT WORD 1

A 16-bit data word.

03.05 FAULT WORD 1

A 16-bit data word.

03.06 FAULT WORD 2

A 16-bit data word.

03.07 SYSTEM FAULT

A 16-bit data word.

03.08 ALARM WORD 1

A 16-bit data word.

03.09 ALARM WORD 2

A 16-bit data word.

03.11 FOLLOWER MCW

A 16-bit data word.

03.12 INT FAULT INFO

A 16-bit data word.

10000 = 100%

20000 = 100%

03.13 AUX STATUS WORD 3 A 16-bit data word. 03.14 AUX STATUS WORD 4 A 16-bit data word. 03.15 FAULT WORD 4

A 16-bit data word.

03.16 ALARM WORD 4

A 16-bit data word.

03.17 FAULT WORD 5

A 16-bit data word.

03.18 ALARM WORD 5

A 16-bit data word.

3.20 LATEST FAULT

Fieldbus code of the latest fault.

3.21 2. LATEST FAULT

Fieldbus code of the 2nd latest fault.

3.23 3. LATEST FAULT

Fieldbus code of the 3rd latest fault.

3.24 4. LATEST FAULT

Fieldbus code of the 4th latest fault.

3.25 5. LATEST FAULT

Fieldbus code of the 5th latest fault.

3.26 LATEST WARNING

Fieldbus code of the latest warning.

3.27 2. LATEST WARNING

Fieldbus code of the 2nd latest warning.

3.28 3. LATEST WARNING

Fieldbus code of the 3rd latest warning.

3.29 4. LATEST WARNING

Fieldbus code of the 4th latest warning.

3.30 5. LATEST WARNING

Fieldbus code of the 5th latest warning.

09 ACTUAL SIGNALS

Signals for the Adaptive Program

09.01 AI1 SCALED

20000 = 10 V Value of analogue input AI1 scaled to an integer value.

09.02 AI2 SCALED Value of analogue input AI2 scaled to an integer value. 09.03 AI3 SCALED Value of analogue input AI3 scaled to an integer value. 09.04 AI5 SCALED

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Value of analogue input AI5 scaled to an integer value.

20000 = 20 mA 20000 = 20 mA 20000 = 20

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09.05 AI6 SCALED

Value of analogue input AI6 scaled to an integer value.

09.06 DS MCW

09.07 MASTER REF1 09.08 MASTER REF2 09.09 AUX DS VAL1 09.10 AUX DS VAL2 09.11 AUX DS VAL3

Control Word (CW) of the Main Reference Dataset received from the master station through the fieldbus interface Reference 1 (REF1) of the Main Reference Dataset received from the master station through the fieldbus interface Reference 2 (REF2) of the Main Reference Dataset received from the master station through the fieldbus interface Reference 3 (REF3) of the Auxiliary Reference Dataset received from the master station through the fieldbus interface Reference 4 (REF4) of the Auxiliary Reference Dataset received from the master station through the fieldbus interface Reference 5 (REF5) of the Auxiliary Reference Dataset received from the master station through the fieldbus interface

20000 = 20 mA 0 ... 65535 (Decimal) -32768 ... 32767 -32768 ... 32767 -32768 ... 32767 -32768 ... 32767 -32768 ... 32767

Table 4-3 Relevant Drive Parameters/Selections Index

Name/Selection

10 START/STOP/DIR 10.01 EXT1 STRT/STP/DIR NOT SEL

Description

FbEq

The sources for external start, stop and direction control Defines the connections and the source of the start, stop and direction commands for external control location 1 (EXT1). No start, stop and direction command source. Start and stop through digital input DI1. 0 = stop; 1 = start. Direction is fixed according to parameter 10.3 DIRECTION. WARNING! After a fault reset, the drive will start if the start signal is ON. Start and stop through digital input DI1. 0 = stop, 1 = start. Direction through digital input DI2. 0 = forward, 1 = reverse. To control direction, parameter 10.03 DIRECTION must be REQUEST. WARNING! After a fault reset, the drive will start if the start signal is ON. Pulse start through digital input DI1. 0 -> 1: Start. Pulse stop through digital input DI2. 1 -> 0: Stop. Direction of rotation is fixed according to parameter 10.03 DIRECTION. Pulse start through digital input DI1. 0 -> 1: Start. Pulse stop through digital input DI2. 1 -> 0: Stop. Direction through digital input DI3. 0 = forward, 1 = reverse. To control direction, parameter 10.03 DIRECTION must be REQUEST. Pulse start forward through digital input DI1. 0 -> 1: Start forward. Pulse start reverse through digital input DI2. 0 -> 1: Start reverse. Pulse stop through digital input DI3. 1 -> .0.: stop. To control the direction, parameter 10.03 DIRECTION must be REQUEST.

1

DI6

See selection DI1.

7

DI6, 5

See selection DI1, 2. Control panel. To control the direction, parameter 10.03 DIRECTION must be REQUEST.

8

COMM.CW

Fieldbus Control Word.

10

DI7

See selection DI1

11

DI1

DI1, 2

DI1P, 2P

DI1P, 2P, 3

DI1P, 2P, 3P

KEYPAD

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2

3

4

5

6

9

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DI7, 8 See selection DI1, 2.

12

DI7P, 8P See selection DI1P, 2P.

13

DI7P, 8P, 9

See selection DI1P, 2P, 3.

14

DI7P, 8P, 9P

See selection DI1P, 2P, 3P.

15

PARAM 10.04

Source selected by 10.04 Defines the connections and the source of the start, stop and direction commands for external control location 2 (EXT2).

16

10.02 EXT2 STRT/STP/DIR NOT SEL

See parameter 10.01.

1

DI1

See parameter 10.01.

2

DI1, 2

See parameter 10.01.

3

DI1P, 2P

See parameter 10.01.

4

DI1P, 2P, 3

See parameter 10.01.

5

DI1P, 2P, 3P

See parameter 10.01.

6

DI6

See parameter 10.01.

7

DI6, 5

See parameter 10.01.

8

KEYPAD

See parameter 10.01.

9

COMM.CW

See parameter 10.01.

10

DI7

See parameter 10.01.

11

DI7,8

See parameter 10.01.

12

DI7P, 8P

See parameter 10.01.

13

DI7P, 8P, 9

See parameter 10.01.

14

DI7P, 8P, 9P

See parameter 10.01.

15

PARAM 10.05

Source selected by 10.05 Enables the control of direction of rotation of the motor, or fixes the direction.

16

10.03 DIRECTION FORWARD

Fixed to forward

1

REVERSE

Fixed to reverse

2

REQUEST

Direction of rotation control allowed

3

11 REFERENCE SELECT

Panel reference type, external control location selection and external reference sources and limits

11.01 KEYPAD REF SEL

Selects the type of the reference given from panel. Speed reference in rpm. (Frequency reference (Hz) if parameter 99.04 is SCALAR.) REF2(%) %-reference. The use of REF2 varies depending on the application macro. For example, if the Torque Control macro is selected, REF2 is the torque reference. 11.02 EXT1/EXT2 SELECT Defines the source from which the drive reads the signal that selects between the two external control locations, EXT1 or EXT2. DI1 thru DI6 Digital input DI1 – D6. 0=EXT1, 1=EXT2 REF1(rpm)

1

2

1-6

EXT1 Decel Time 2

7

EXT2 COMM.CW(11) DI7 thru DI12 PARAM 11.09 11.03 EXT REF1 SELECT

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Sp.ref interp TC Fieldbus Control Word, bit 11. See selection DI1 Source selected by parameter 11.09. Selects the signal source for external reference REF1

8 9 10-15 16

Document number Revision Page KEYPAD VARIOUS AI and JOYSTICK SELECTIONS COMM. REF 11.04 EXT REF1 MINIMUM 0… 18000 rpm

11.05 EXT REF1 MAXIMUM 0 ... 18000 rpm

12 CONSTANT SPEEDS **********

13 ANALOGUE INPUTS **********

14 RELAY OUTPUTS 14.01 RELAY RO1 OUTPUT NOT USED READY RUNNING FAULT FAULT(-1) FAULT(RST) STALL WARN STALL FLT MOT TEMP WRN

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D25TDS11-MAN-001 01 81

Control panel. The first line on the display shows the reference value. See parameter 11.03 See parameter 11.03. Defines the minimum value for external reference REF1 (absolute value). Corresponds to the minimum setting of the source signal used. Setting range in rpm. (Hz if parameter 99.04 is SCALAR.) Example: Analogue input AI1 is selected as the reference source (value of parameter 11.03 is AI1). The reference minimum and maximum correspond the AI minimum and maximum settings as follows: EXT REF1 Range

Note: If the reference is given through fieldbus, the scaling differs from that of an analogue signal. See the chapter Fieldbus control for more information. Defines the maximum value for external reference REF1 (absolute value). Corresponds to the maximum setting of the used source signal. Setting range. (Hz if value of parameter 99.04 is SCALAR.) See parameter 11.04. 1 . 18000 Constant speed selection and values. An active constant speed overrides the drive speed reference. Note: If parameter 99.04 is SCALAR, the constant speeds are given in Hertz and only speeds 1 to 5 and speed 15 are in use. GROUP NOT TYPICALLY USED IN NOI APPLICATIONS The analogue input signal processing GROUP NOT TYPICALLY USED IN NOI APPLICATIONS Status information indicated through the relay outputs, and the relay operating delays Selects a drive status indicated through relay output RO1. The relay energizes when the status meets the setting. Not used. Ready to function: Run Enable signal on, no fault. Running: Start signal on, Run Enable signal on, no active fault. Fault Inverted fault. Relay is de-energized on a fault trip. Fault. Automatic reset after the autoreset delay. See parameter group 31 AUTOMATIC RESET. Warning by the stall protection function. See parameter 30.10. Fault trip by the stall protection function. See parameter 30.10. Warning trip of the motor temperature supervision function. See parameter 30.04.

1 2-19, 21-38 20

1 … 18000

1... 18000

**********

**********

1 2 3 4 5 6 7 8 9

Document number Revision Page MOT TEMP FLT

D25TDS11-MAN-001 01 82

Fault trip of the motor temperature supervision function. See parameter 30.04.

12\0

ACS TEMP WRN

Warning by the drive temperature supervision function: 115 °C (239°F).

11

ACS TEMP FLT

Fault trip by the drive temperature supervision function: 125 °C(257°F). Fault or warning active Warning active Motor rotates in reverse direction. Drive is under external control. External reference REF 2 is in use. A constant speed is in use. See parameter group 12 CONSTANT SPEEDS. The intermediate circuit DC voltage has exceeded the overvoltage limit. The intermediate circuit DC voltage has fallen below the undervoltage limit. Motor speed at supervision limit 1. See parameters 32.01 and 32.02. Motor speed at supervision limit 2. See parameters 32.03 and 32.04. Motor current at the supervision limit. See parameters 32.05 and 32.06. External reference REF1 at the supervision limit. See parameters 32.11 and 32.12. External reference REF2 at the supervision limit. See parameters 32.13 and 32.14. Motor torque at supervision limit 1. See parameters 32.07 and 32.08. Motor torque at supervision limit 2. See parameters 32.09 and 32.10. The drive has received the start command. The drive has no reference. The actual value has reached the reference value. In speed control, the speed error is less or equal to 10% of the nominal motor speed. Process PID controller variable ACT1 at the supervision limit. See parameters 32.15 and 32.16. Process PID controller variable ACT2 at the supervision limit. See parameters 32.17 and 32.18. The relay is controlled by fieldbus reference REF3. See the chapter Fieldbus control. Source selected by parameter 14.16. On/Off control of a mechanical brake. See parameter group 42 BRAKE CONTROL. Selects the drive status to be indicated through relay output RO2. The relay energizes when the status meets the setting.

12 13 14 15 16 17

FAULT/WARN WARNING REVERSED EXT CTRL REF 2 SEL CONST SPEED DC OVERVOLT DC UNDERVOLT SPEED 1 LIM SPEED 2 LIM CURRENT LIM REF 1 LIM REF 2 LIM TORQUE 1 LIM TORQUE 2 LIM STARTED LOSS OF REF AT SPEED ACT 1 LIM ACT 2 LIM COMM.REF3(13) PARAM 14.16 BRAKE CTRL 14.02 RELAY RO2 OUTPUT SELECTIONS SAME AS 14.01 COMM. REF3(14) PARAM 14.17 BRAKE CTRL 14.03 RELAY RO3 OUTPUT SELECTIONS SAME AS 14.01 FAULT MAGN READY USER 2 SEL COMM. REF3(15) PARAM 14.18 BRAKE CTRL

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See parameter 14.01. See parameter 14.01. Source selected by parameter 14.17. See parameter 14.01. Selects the drive status to be indicated through relay output RO3. The relay energizes when the status meets the setting. See parameter 14.01. See parameter 14.01 The motor is magnetized and ready to give nominal torque (nominal magnetizing of the motor has been reached). User Macro 2 is in use. See parameter 14.01. Source selected by parameter 14.18. See parameter 14.01.

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

1-32 33 34 35

1-3, 5-30 4 31 32 33 34 35

Document number Revision Page

15 ANALOGUE OUTPUTS **********

D25TDS11-MAN-001 01 83

Selection of the actual signals to be indicated through the analogue outputs. Input signal processing. GROUP NOT TYPICALLY USED IN NOI APPLICATIONS

**********

16 SYSTEM CTRL INPUTS

Run Enable, parameter lock etc. Sets the Run Enable signal on, or selects a source for the external Run Enable signal. If Run Enable signal is switched off, the drive will not start or stops if it is running. The stop mode is set by parameter 21.07. YES Run Enable signal is on DI1 External signal required through digital input DI1. 1 = Run Enable. DI2 thru DI12 See selection DI1. COMM.CW(3) External signal required through the Fieldbus Control Word (bit 3). PARAM 16.08 Source selected by parameter 16.08. 16.04 FAULT RESET SEL Selects the source for the fault reset signal. The signal resets the drive after a fault trip if the cause of the fault no longer exists. NOT SEL Fault reset only from the control panel keypad (RESET key). 16.01 RUN ENABLE

1 2 3-7, 9-14 8 15

1 DI1

DI2 thru DI12 COMM.CW(7) ON STOP

Reset through digital input DI1 or by control panel: - If the drive is in external control mode: Reset by a rising edge of DI1. - If the drive is in local control mode: Reset by the RESET key of the control panel. See selection DI1. Reset through the fieldbus Control Word (bit 7), or by the RESET key of the control panel. Reset along with the stop signal received through a digital input, or by the RESET key of the control panel.

2 2-7, 10-15 8 9

20 LIMITS

Drive operation limits. Defines the allowed minimum speed. The limit cannot be set if parameter 99.04 = SCALAR. Note: The limit is linked to the motor nominal speed setting i.e. parameter 99.08. If 99.08 is changed, the default speed limit will also change. -18000 / (no. of pole pairs) . Minimum speed limit Par. 20.02 rpm 20.02 MAXIMUM SPEED Defines the allowed maximum speed. The value cannot be set if parameter 99.04 = SCALAR. Note: The limit is linked to the motor nominal speed setting i.e. parameter 99.08. If 99.08 is changed, the default speed limit will also change. 20.01 MINIMUM SPEED

-18000 / (no. of pole pairs) . Par. 20.01 rpm 20.03 MAXIMUM CURRENT 0.0… 200.0% · Ihd 20.04 TORQ MAX LIM1 0.0… 600.0% 20.05 OVERVOLTAGE CTRL

OFF

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1 = 1 rpm

Maximum speed limit 1 = 1 rpm Defines the allowed maximum motor current in percent of the rated heavy-duty use output current (I2hd). Current limit Defines the maximum torque limit 1 for the drive. Value of limit in percent of motor nominal torque. Activates or deactivates the overvoltage control of the intermediate DC link. Fast braking of a high inertia load causes the voltage to rise to the overvoltage control limit. To prevent the DC voltage from exceeding the limit, the overvoltage controller automatically decreases the braking torque. Note: If a brake chopper and resistor are connected to the drive, the controller must be off (selection NO) to allow chopper operation. Undervoltage control deactivated.

0… 20000 0… 60000

0

Document number Revision Page ON 20.07 MINIMUM FREQ -300.00 . 50 Hz

20.08 MAXIMUM FREQ

D25TDS11-MAN-001 01 84

Undervoltage control activated. Defines the minimum limit for the drive output frequency. The limit can be set only parameter 99.04 = SCALAR. Minimum frequency limit. Note: If the value is positive, the motor cannot be run in the reverse direction. Defines the maximum limit for the drive output frequency. The limit can be set only if parameter 99.04 = SCALAR

-50… 300.00 Hz 20.11 P MOTORING LIM 0… 600% 20.12 P GENERATING LIM -600… 0% 20.13 MIN TORQ SEL MIN LIM1 DI1 DI2 thru DI12 AI1 AI2 thru AI6 PARAM 20.18 NEG MAX TORQ 20.14 MAX TORQ SEL MAX LIM1 DI1 DI2 thru DI12 AI1 AI2 PARAM 20.19 20.15 TORQ MIN LIM1 -600.0… 0.0%

21 START/STOP 21.01 START FUNCTION AUTO

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Maximum frequency limit Defines the allowed maximum power fed by the inverter to the motor. Power limit in percent of the motor nominal power

65535

-30000 . 5000

-5000 . 30000 0… 60000

Defines the allowed maximum power fed by the motor to the inverter. Power limit in percent of the motor nominal power Selects the minimum torque limit for the drive. Value of parameter 20.15. Digital input DI1. 0: Value of parameter 20.15. 1: Value of parameter 20.16. See selection DI1. Analogue input AI1. See parameter 20.20 on how the signal is converted to a torque limit. See selection AI1. Limit given by 20.18 Inverted maximum torque limit defined by parameter 20.14 Defines the maximum torque limit for the drive. Value of parameter 20.14. Digital input DI1. 0: Value of parameter 20.04. 1: Value of parameter 20.17. See selection DI1. Analogue input AI1. See parameter 20.20 on how the signal is converted to a torque limit. See selection AI1. Limit given by 20.19 Defines the minimum torque limit 1 for the drive. Value of limit in percent of motor nominal torque Start and stop modes of the motor. Selects the motor starting method. Automatic start guarantees optimal motor start in most cases. It includes the flying start function (starting to a rotating machine) and the automatic restart function (stopped motor can be restarted immediately without waiting the motor flux to die away). The drive motor control program identifies the flux as well as the mechanical state of the motor and starts the motor instantly under all conditions. Note: If parameter 99.04 = SCALAR, no flying start or automatic restart is possible by default. The flying start feature needs to be activated separately by parameter 21.08.

-60000 . 0 1 2 3-13 14 15-18 19 20 1 2 3-13 14 15-18 19 0… 60000

1

Document number Revision Page DC MAGN

CNST DC MAGN

D25TDS11-MAN-001 01 85

DC magnetizing should be selected if a high break-away torque is required. The drive pre-magnetizes the motor before the start. The premagnetizing time is determined automatically, being typically 200 ms to 2 s depending on the motor size. DC MAGN guarantees the highest possible break-away torque. Note: Starting to a rotating machine is not possible when DC magnetizing is selected. Note: DC magnetizing cannot be selected if parameter 99.04 = SCALAR. Constant DC magnetizing should be selected instead of DC magnetizing if constant pre-magnetizing time is required (e.g. if the motor start must be simultaneous with a mechanical brake release). This selection also guarantees the highest possible break-away torque when the pre-magnetizing time is set long enough. The premagnetizing time is defined by parameter 21.02. Note: Starting to a rotating machine is not possible when DC magnetizing is selected. Note: DC magnetizing cannot be selected if parameter 99.04 = SCALAR.

WARNING! The drive will start after the set magnetizing time has passed although the motor magnetization is not completed. Ensure always in applications where a full break-away torque is essential, that the constant magnetizing time is long enough to allow generation of full magnetization and torque. 21.02 CONST MAGN TIME Defines the magnetizing time in the constant magnetizing mode. See parameter 21.01. After the start command, the drive automatically premagnetizes the motor the set time. 30.0… 10000.0 ms Magnetising time. To ensure full magnetising, set this value to the same value as or higher than the rotor time constant. If not known, use the rule-of-thumb value given in the table below:

2

3

30… 10000 21.03 STOP FUNCTION COAST

RAMP 21.07 RUN ENABLE FUNC

RAMP STOP

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Selects the motor stop function. Stop by cutting of the motor power supply. The motor coasts to a stop.

WARNING! If the mechanical brake control function is on, the application program uses ramp stop in spite of the selection COAST (see parameter group 42 BRAKE CONTROL). Stop along a ramp. See parameter group 22 ACCEL/DECEL. Selects the stop mode applied when the Run Enable signal is switched off. The Run Enable signal is put into use by parameter 16.01. Note: The setting overrides the normal stop mode setting (parameter 21.03) when the Run Enable signal is switched off.

WARNING! The drive will restart after the Run Enable signal restores (if the start signal is on). The application program stops the drive along the deceleration ramp defined in group 22 ACCEL/DECEL.

1 2

1

Document number Revision Page COAST STOP

OFF2 STOP

OFF3 STOP

21.09 START INTRL FUNC OFF2 STOP

OFF3 STOP

22 ACCEL/DECEL 22.01 ACC/DEC SEL ACC/DEC 1 ACC/DEC 2 DI1

DI2 thru DI12 PAR 22.08&09 22.02 ACCEL TIME 1

0.00… 1800.00 s

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D25TDS11-MAN-001 01 86

The application program stops the drive by cutting off the motor power supply (the inverter IGBTs are blocked). The motor rotates freely to zero speed.

WARNING! If the brake control function is on, the application program uses ramp stop in spite of the selection COAST STOP (see parameter group 42 BRAKE CONTROL). The application program stops the drive by cutting off the motor power supply (the inverter IGBTs are blocked). The motor rotates freely to zero speed. The drive will restart only when the Run Enable signal is on and the start signal is switched on (the program receives the rising edge of the start signal). The application program stops the drive along the ramp defined by parameter 22.07. The drive will restart only when the Run Enable is on and the start signal is switched on (the program receives the rising edge of the start signal).

Drive running: 1 = Normal operation. 0 = Stop by coasting. Drive stopped: 1 = Start allowed. 0 = No start allowed. Restart after OFF2 STOP: Input is back to 1 and the drive receives rising edge of the Start signal. Drive running: 1 = Normal operation. 0 = Stop by ramp. The ramp time is defined by parameter 22.07 EM STOP RAMP. Drive stopped: 1 = Normal start. 0 = No start allowed. Restart after OFF3 STOP: Start Interlock input = 1 and the drive receives rising edge of the Start signal. Acceleration and deceleration times. Selects the active acceleration/deceleration time pair. Acceleration time 1 and deceleration time 1 are used. See parameters 22.02 and 22.03. Acceleration time 2 and deceleration time 2 are used. See parameters 22.04 and 22.05. Acceleration/deceleration time pair selection through digital input DI1. 0 = Acceleration time 1 and deceleration time 1 are in use. 1 = Acceleration time 2 and deceleration time 2 are in use. See selection DI1. Acceleration and deceleration times given by parameters 22.08 and 22.09 Defines the acceleration time 1 i.e. the time required for the speed to change from zero to the maximum speed. - If the speed reference increases faster than the set acceleration rate, the motor speed will follow the acceleration rate. - If the speed reference increases slower than the set acceleration rate, the motor speed will follow the reference signal. - If the acceleration time is set too short, the drive will automatically prolong the acceleration in order not to exceed the drive operating limits. Acceleration time

2

3

4

1

2

1 2

3 4-14 15

0… 18000

Document number Revision Page 22.03 DECEL TIME 1

0.00… 1800.00 s 22.07 EM STOP RAMP TIME

D25TDS11-MAN-001 01 87

Defines the deceleration time 1 i.e. the time required for the speed to change from the maximum (see parameter 20.02) to zero. - If the speed reference decreases slower than the set deceleration rate, the motor speed will follow the reference signal. - If the reference changes faster than the set deceleration rate, the motor speed will follow the deceleration rate. - If the deceleration time is set too short, the drive will automatically prolong the deceleration in order not to exceed drive operating limits. If there is any doubt about the deceleration time being too short, ensure that the DC overvoltage control is on (parameter 20.05). Note: If a short deceleration time is needed for a high inertia application, the drive should be equipped with an electric braking option e.g. with a brake chopper and a brake resistor. Deceleration time Defines the time inside which the drive is stopped if - the drive receives an emergency stop command or - the Run Enable signal is switched off and the Run Enable function has value OFF3 (see parameter 21.07). The emergency stop command can be given through a fieldbus or an Emergency Stop module (optional). Consult the local ABB representative for more information on the optional module and the related settings of the Standard Application Program

0.00… 2000.00 s

Deceleration time

27 BRAKE CHOPPER

Control of the brake chopper. For more information, see the Brake Chopper User's Manual (code: 3AFE 64273507 [English])

27.01 BRAKE CHOPPER CTL OFF ON

Activates the brake chopper control. Inactive Active. Note: Ensure the brake chopper and resistor are installed and the overvoltage control is switched off (parameter 20.05).

30 FAULT FUNCTIONS

Programmable protection functions

30.10 STALL FUNCTION

Selects how the drive reacts to a motor stall condition. The protection wakes up if: - the motor torque is at the internal stall torque limit (not useradjustable) - the output frequency is below the level set by parameter 30.11 and - the conditions above have been valid longer than the time set by parameter 30.12. The drive trips on a fault. The drive generates a warning. The indication disappears in half of the time set by parameter 30.12. Protection is inactive. Activates the motor phase loss supervision function The drive generates a warning. The drive trips on a fault. Selects how the drive reacts in a fieldbus communication break, i.e. when the drive fails to receive the Main Reference Data Set or the Auxiliary Reference Data Set. The time delays are given by parameters 30.19 and 30.21. Protection is active. The drive trips on a fault and stops the motor as defined by parameter 21.03. Protection is inactive.

FAULT WARNING NO 30.17 EARTH FAULT WARNING FAULT 30.18 COMM FLT FUNC

FAULT NO

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0… 18000

0… 200000

0 6553

1 2 3 0 65535

1 2

Document number Revision Page CONST SP 15

LAST SPEED

D25TDS11-MAN-001 01 88

Protection is active. The drive generates a warning and sets the speed to the value defined by parameter 12.16.

WARNING! Make sure that it is safe to continue operation in case of a communication break. Protection is active. The drive generates a warning and freezes the speed to the level the drive was operating at. The speed is determined by the average speed over the previous 10 seconds.

WARNING! Make sure that it is safe to continue operation in case of a communication break.

42 BRAKE CONTROL 42.01 BRAKE CTRL OFF ON 42.02 BRAKE ACKNOWLEDGE OFF DI5 DI6 DI11 DI12 42.07 START TORQ REF SEL NO AI1 AI2-AI6 PAR 42.08 42.08 START TORQ REF -300… 300%

50 ENCODER MODULE

Control of a mechanical brake. The function operates on a 100 ms time level. For the function description, see the chapter Program features. Activates the brake control function. Inactive Active Activates the external brake on/off supervision and selects the source for the signal. The use of the external on/off supervision signal is optional. Inactive Active. Digital input DI5 is the signal source. DI5 = 1: The brake is open. DI5 = 0: the brake is closed. See DI5. See DI5. See DI5. Selects the source for the motor starting torque reference applied at the brake release. The value is read in percent of the motor nominal torque. No source selected. This is the default value Analogue input AI1 Analogue input AI2-6 Defined by parameter 42.08. Defines the motor starting torque at brake release if parameter 42.07 has value PAR 40.28. Torque value in percent of the motor nominal torque Encoder connection. Visible only when a pulse encoder module (optional) is installed and activated by parameter 98.01. The settings will remain the same even though the application macro is changed.

50.01 PULSE NR 0… 29999 ppr 50.02 SPEED MEAS MODE A -B DIR

States the number of encoder pulses per one revolution. Pulse number in pulses per round (ppr)

A -

Channel A: positive and negative edges calculated for speed. Channel B: not used. Channel A: positive and negative edges are calculated for speed. Channel B: direction. All edges of the signals are calculated.

3

4

1 2

1 2 3 4 5

1 2 3-6 7

-30000… 30000

0… 29999

Defines how the encoder pulses are calculated. Channel A: positive edges calculated for speed. Channel B: direction. 1

A - B DIR A - B -

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2 3 4

Document number Revision Page 50.03 ENCODER FAULT

WARNING FAULT 50.05 ENCODER DDCS CHANNEL

CHANNEL 1

CHANNEL 2 50.06 SPEED FB SEL INTERNAL ENCODER

51 COMMUNICATION MODULE

52 STANDARD MODBUS **********

60 MASTER/ FOLLOWER 60.01 MASTER LINK MODE NOT IN USE MASTER FOLLOWER

D25TDS11-MAN-001 01 89

Defines the operation of the drive if a failure is detected in communication between the pulse encoder and the pulse encoder interface module, or between the module and the drive. Encoder supervision function activates if either of the following conditions is valid: -There is a 20% difference between the estimated speed and the measured speed received from the encoder. - No pulses are received from the encoder within the defined time (see parameter 50.04) and the motor torque is at the allowed maximum value. The drive generates a warning indication. The drive trips on a fault, gives a fault indication and stops the motor. Defines the fibre optic channel of the control board from which the drive program reads the signals coming from the pulse encoder interface module. The setting is valid only if the module is connected to the drive via the DDCS link ( i.e. not to the option slot of the drive). Signals via channel 1 (CH1). The pulse encoder interface module must be connected to CH1 instead of CH2 in applications where CH2 is reserved by a Master station (e.g. a Master/Follower application). See also parameter 70.03. Signals via channel 2 (CH2). Can be used in most cases. Defines the speed feedback value used in control. Calculated speed estimate Actual speed measured with an encoder The parameters are visible and need to be adjusted, only when a fieldbus adapter module (optional) is installed and activated by parameter 98.02. For details on the parameters, refer to the manual of the fieldbus module. These parameter settings will remain the same even though the macro is changed. The settings for the Standard Modbus Link. See the chapter Fieldbus control. GROUP NOT TYPICALLY USED IN NOI APPLICATIONS

1 65535

1 2

65535

**********

Master/Follower application. For more information, see the chapter Program features and a separate Master/Follower Application Guide. Defines the role of the drive on the Master/Follower link. The Master/Follower link is not active. Master drive Follower drive

1 2 3

70 DDCS CONTROL Settings for the fibre optic channels 0, 1 and 3. 70.01 CHANNEL 0 ADDR Defines the node address for channel 0. No two nodes on-line may have the same address. The setting needs to be changed when a master station is connected to channel 0 and it does not automatically change the address of the slave. Examples of such masters are an ABB Advant Controller or another drive. 1… 125 Address. 70.02 CHANNEL 3 ADDR Node address for channel 3. No two nodes on-line may have the same address. Typically the setting needs to be changed when the drive is connected in a ring which consists of several drives and a PC with the DriveWindow® program running. 1… 254 Address.

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1… 125

1… 254

Document number Revision Page 70.03 CH1 BAUDRATE

8 Mbits 4 Mbits 2 Mbits 1 Mbits 70.04 CH0 DDCS HW CONN RING STAR

83 ADAPT PROG CTRL

D25TDS11-MAN-001 01 90

The communication speed of channel 1. Typically the setting needs to be changed only if the pulse encoder interface module is connected to channel 1 instead of channel 2. Then the speed must be changed to 4 Mbits. See also parameter 50.05. 8 megabits per second 4 megabits per second 2 megabits per second 1 megabits per second Selects the topology of the channel 0 link Devices are connected in a ring. Devices are connected in a star. Control of the Adaptive Program execution. For more information, see the Adaptive Program Application Guide (code: 3AFE 64527274 [English]).

0 1 2 3

0 1

83.01 ADAPT PROG CMD Selects the operation mode for the Adaptive Program. STOP START EDIT

Stop. The program cannot be edited. Run. The program cannot be edited. Stop to edit mode. Program can be edited. ****NOTE: Edit mode must be selected on the target and source when trying to download an adaptive program.*****

84 ADAPTIVE PROGRAM

- selections of the function blocks and their input connections. - diagnostics THIS GROUP SHALL NOT BE ALTERED BY ANY PERSONS OTHER THAN QUALIFIED NOI PERSONEL

**********

84 ADAPTIVE PROGRAM **********

**********

Storage of the Adaptive Program constants and messages. THIS GROUP SHALL NOT BE ALTERED BY ANY PERSONS OTHER THAN QUALIFIED NOI PERSONEL

**********

98 OPTION MODULES 98.01 ENCODER MODULE NTAC

NO RTAC-SLOT1 RTAC-SLOT2 RTAC-DDCS

98.02 COMM. MODULE LINK NO FIELDBUS

ADVANT

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Activates the communication to the optional pulse encoder module. See also parameter group 50 ENCODER MODULE. Communication active. Module type: NTAC module. Connection interface: Fibre optic DDCS link. Note: Module node number must be set to 16. Inactive Communication active. Module type: RTAC. Connection interface: Option slot 1 of the drive Communication active. Module type: RTAC. Connection interface: Option slot 2 of the drive. Communication active. Module type: RTAC. Connection interface: Option module rack of the drive (communicates with the drive through a fibre optic DDCS link). Note: Module node number must be set to 16. Activates the external serial communication and selects the interface. No communication The drive communicates via a fieldbus adapter module in option slot 1 of the drive, or via CH0 on the RDCO board. See also parameter group 51 COMMUNICATION MODULE. The drive communicates with an ABB Advant OCS system via CH0 on the RDCO board (optional). See also parameter group 70 DDCS CONTROL.

1 2 3 4

5

1

2

3

Document number Revision Page STD MODBUS

CUSTOMISED

D25TDS11-MAN-001 01 91

The drive communicates with a Modbus controller via the Modbus Adapter Module (RMBA) in option slot 1 of the drive. See also parameter 52 STANDARD MODBUS. The drive communicates via a customer specified link. The control sources are defined by parameters 90.04 and 90.05.

4 5

99 START-UP DATA Language selection. Definition of motor set-up data. 99.01 LANGUAGE ENGLISH(AM) 99.02 APPLICATION MACRO

FACTORY HAND/AUTO

PID-CTRL

T-CTRL

SEQ CTRL

USER 1 LOAD USER 1 SAVE

USER 2 LOAD USER 2 SAVE

99.05 MOTOR NOM VOLTAGE ½… 2 · UN 99.06 MOTOR NOM CURRENT

0… 2 · I2hd

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Selects the display language. American English. If selected, the unit of power used is HP instead of kW. Selects the application macro. See the chapter Application macros for more information. Note: When you change the default parameter values of a macro, the new settings become valid immediately and stay valid even if the power of the drive is switched off and on. However, backup of the default parameter settings (factory settings) of each standard macro is still available. See parameter 99.03. Factory for basic applications Two control devices are connected to the drive: - device 1 device communicates through the interface defined by external control location EXT1. - device 2 communicates through the interface defined by external control location EXT2. - EXT1 or EXT2 is active at a time. Switching through a digital input. PID control. For application in which the drive controls a process value. E.g. pressure control by the drive running the pressure boost pump. Measured pressure and the pressure reference are connected to the drive. Torque Control macro ****Note this selection is set on the slave drive, if application utilizes the master/slave drive arrangement**** Sequential Control macro. For applications that are frequently run through a pre-defined speed pattern (constant speeds and acceleration and deceleration ramps). User 1 macro loaded into use. Before loading, check that the saved parameter settings and the motor model are suitable for the application. Save User 1 macro. Stores the current parameter settings and the motor model. Note: There are parameters that are not included in the macros. See parameter 99.03. User 2 macro loaded into use. Before loading, check that the saved parameter settings and the motor model are suitable for the application. Save User 2 macro. Stores the current parameter settings and the motor model. Note: There are parameters that are not included in the macros. See parameter 99.03. Defines the nominal motor voltage. Must be equal to the value on the motor rating plate Voltage. Allowed range is 1/2… 2 · UN of the drive Defines the nominal motor current. Must be equal to the value on the motor rating plate. Note: Correct motor run requires that the magnetizing current of the motor does not exceed 90 percent of the nominal current of the inverter. Allowed range: 1/6 . 2 · I2hd of ACS800 (parameter 99.04 = DTC). Allowed range: 0 . 2 · I2hd of ACS800 (parameter 99.04 = SCALAR).

1

1

2

3

4

5 6

7 8

9

1=1V

1 = 0.1 A

Document number Revision Page 99.07 MOTOR NOM FREQ 8… 300 Hz 99.08 MOTOR NOM SPEED

1… 18000 rpm 99.09 MOTOR NOM POWER 0... 9000 kW 99.10 MOTOR ID RUN

NO

STANDARD

REDUCED

D25TDS11-MAN-001 01 92

Defines the nominal motor frequency. Nominal frequency (50 or 60 Hz typically) Defines the nominal motor speed. Must be equal to the value on the motor rating plate. The motor synchronous speed or another approximate value must not be given instead! Note: If the value of parameter 99.08 is changed, the speed limits in parameter group 20 LIMITS change automatically as well. Nominal motor speed Defines the nominal motor power. Set exactly as on the motor rating plate. Nominal motor power Selects the type of the motor identification. During the identification, the drive will identify the characteristics of the motor for optimum motor control. The ID Run Procedure is described in the chapter Start-up; and control through the I/O. Note: The ID Run (STANDARD or REDUCED) should be selected if: - The operation point is near zero speed, and/or - Operation at torque range above the motor nominal torque within a wide speed range and without any measured speed feedback is required. Note: The ID Run (STANDARD or REDUCED) cannot be performed if parameter 99.04 = SCALAR. No ID Run. The motor model is calculated at first start by magnetizing the motor for 20 to 60 s at zero speed. This can be selected in most applications. Standard ID Run. Guarantees the best possible control accuracy. The ID Run takes about one minute. Note: The motor must be de-coupled from the driven equipment. Note: Check the direction of rotation of the motor before starting the ID Run. During the run, the motor will rotate in the forward direction.

WARNING! The motor will run at up to approximately 50 . 80% of the nominal speed during the ID Run. ENSURE THAT IT IS SAFE TO RUN THE MOTOR BEFORE PERFORMING THE ID RUN! Reduced ID Run. Should be selected instead of the Standard ID Run: - if mechanical losses are higher than 20% (i.e. the motor cannot be decoupled from the driven equipment) - if flux reduction is not allowed while the motor is running (i.e. in case of a motor with an integrated brake supplied from the motor teminals). Note: Check the direction of rotation of the motor before starting the ID Run. During the run, the motor will rotate in the forward direction.

WARNING! The motor will run at up to approximately 50 . 80% of the nominal speed during the ID Run. ENSURE THAT IT IS SAFE TO RUN THE MOTOR BEFORE PERFORMING THE ID RUN!

Designates Parameter Group Typical NOI Application Setting

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800… 30000

1… 18000

0… 90000

1

2

3

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D25TDS11-MAN-001 01 93

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D25TDS11-MAN-001 01 94

INSTALLATION This section contains guidelines for installing NOI Model 800AC VSDS systems. This installation section is not intended to be a step-by-step procedure for installing the system, but more of an overall guide to aid in the installation. It will be necessary to refer to system drawings and documents for specific details about sub-systems. Once the system has been installed, the start up procedure should be followed. Any information not contained in this document can be found in the system manual or the system drawings. Any personnel involved in the installation and start up of this system should read all the documentation to before proceeding with any part of system installation and startup.

5.1

Mechanical Installation The VSDS system should only be lifted according to the job specific requirements. The systems may vary depending on customer requirements. Most systems are designed to be lifted either by forklift, or crane. Most systems lifted by forklift are provided with a lifting base with forklift fork accommodations typically in the base of the system. Systems that require a crane for movement typically have lifting bars or eyes for overhead lifting. Some systems will include shipping splits which are used to reduce the length and weight of the shipping sections. It is important to ensure that the individual shipping splits are placed in the correct orientation and bolted tightly together.

5.2

Electrical Installation The following section provides general guidelines that should be observed before applying power to the VSDS. It is important to ensure the VSDS system has the adequate ground connections. For stand alone systems installed in drilling modules, ensure that the base of the systems is seam welded to the deck. Also ensure that the cubicle frames are bolted (with star washers if cubicles are painted metal) properly to the system base. For systems which include a drive house, ensure that the proper size grounding conductor is installed to the dedicated ground bus on the house. Ensure the required control connections (encoders, profibus, fiber, etc.) are connected per the job specific drawings. Also ensure that the shielding on these signals is correct. The input and output power connections vary from system to system, so it is important to refer to your job’s electrical drawings in conjunction with this manual. Table 5-1 contains main terminal markings.

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Terminal Designator

Definition

Connected to

B+ BU V

Positive DC bus Negative DC bus Inverter output phase A Inverter output phase B

+ DC main bus - DC main bus Motor phase A Motor phase B

Document number Revision Page W

Inverter output phase C

D25TDS11-MAN-001 01 95

Motor phase C

Table 5-1 Inverter Main Terminal Designations Input power cables to the VSDS should be sized according to the cable schedule provided in the document package. As a general rule, the cable insulation should be rated for 600V and a temperature rise of 90C. It is also recommended that multi-core, 3 conductor cable be used to supply the input rectifiers. If not specified in the cable schedule, the ampacity of the cable should be adequate to carry the full load of the source which supplies the VSDS. It is recommended that multi-core, shielded VFD cable be used to connect the VSDS to the motor(s). For a 600V system, this cable is typically rated for 2000V, and a minimum of a 90 degree Celsius temperature rise. Be sure to consult the factory if unsure about cable sizes or ratings. See job specific drawings for exact termination point for input and output cables. The following list of guidelines should be observed before connecting any cable to the VSDS 1. Before connecting the motor or input cables to the VSDS, a qualified electrician or service technician should perform insulation tests on the cable. Check both the phase to ground insulation resistance and the phase to phase insulation resistance. In both cases, the resistance should be equal to or greater than 1 M 2. Before connecting the cables to the motors, be sure a qualified electrician or service engineer tests the motor insulation. The phase to ground and phase-to-phase insulation resistance should be a minimum of 1 M. The test voltage should be appropriate for the motor’s rated voltage. 3. Do not place the VSDS motor cables near other cables, such as supply or control cables. Avoid placing the motor cables in long parallel lines with other cables wherever possible. If motor cables are to be run along other cables, the following table is a guideline to use for establishing minimum distance between cables: DISTANCE BETWEEN CABLES 0.3m (1 foot) 1.0m (3.3 feet)

SHIELDED CABLE Less than or equal to 50m (164 feet) Greater than 50m (164 feet)

Table 5-2 Cable Spacing Guideline

4. Wherever possible, motor cables should cross other cables at 90 angles

Special care must be given to the motor cables. They are unlike standard three phase cables. Each motor cable contains three drain wires as well as an overall shield.

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D25TDS11-MAN-001 01 96

Figure 5-1 VFD Motor Cable Drawing

The three phase conductors are connected to the inverter and motor using crimp style lugs and stainless steel hardware (except in the case where plugs are used). The drain wires and overall shield should be connected as per the diagram below.

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D25TDS11-MAN-001 01 97







Figure 5-2 VFD Motor Cable Connection Diagram Care should be taken to ensure that the earth cables or overall shield does not make contact with the phase conductors. This condition will create an electrical short in the cable and damage either the motor or the inverter. A solid connection to chassis ground must be established for the earth cables as well as the shield wire. These wires should be connected to an unpainted surface using crimp style lugs and stainless steel hardware. The length of these wires should be kept to the shortest length that is possible. The three earth cables are to be connected at both the motor and AC drives ends to provide the system earth connection. The shield armour connection only occurs at the inverter end of the cable. The motor end of the cable is left unconnected. It is important to ensure that all electrical cables have a tight connection. It is advisable to go over the entire system and check each connection point for loose connections. During shipment, some of the screws or bolts may have become loose due to vibrations.

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6

D25TDS11-MAN-001 01 98

TROUBLESHOOTING The following troubleshooting guideline is intended to act as an aid to fault tracing in the inverter. The majority of fault tracing is done through the inverter’s keypad. The information provided deals with the most common problems you may encounter. Therefore, a familiarity with the drive’s keypad/LCD display and how to navigate through its various menus is essential to being able to isolate the source of a problem. Due to the complex and unique operating environment in which this equipment operates, it is impossible to anticipate every possible problem and solution. If the equipment continues to present problems, or if the type of trouble exhibited by the equipment is not covered in this section, please contact your nearest National Oilwell representative to arrange service.

6.1

Warning and fault indications The drive is equipped with an internal system for indicating abnormal or failure conditions. In the event the drive detects an undesirable condition, it will display a warning or fault message on the control panel display. The latest warnings and faults are recorded together in the Fault History along with a time stamp identifying when the event occurred. Once the fault has been traced to its cause and then corrected, the drive may be reset. The drive can be reset by pressing the RESET key on the keypad, by digital input or fieldbus, or powering down the drive.

6.1.1 Programmable protection functions AI -7°C (20°F)

Grade 150

-29°C to -4°C (-20°F to 25°F) Synthetic Gear Oil

Grade 320

-9°C to 16°C (15°F to 60°F)

EP Gear Oil

Grade 460

Grade 15

Grade 15

Hydraulic Oil3 Hydraulic Oil3

Grade 10W

Grade 32

Hydraulic Oil2

AT Fluid

Grade 46

Grade 46

ASTM/ ISO-VG/SAE

Hydraulic Transmission Oil

Hydraulic Oil1

Lube Type

10°C to 52°C (50°F to 125°F)

-40°C to 0°C (-40°F to 32°F)

-30°C to 17°C) -22°F to 63°F

-12°C to 52°C (-10°F to 125°F)

Environment

#1

#2

---

---

---

---

---

---

---

---

---

---

NLGI

---

---

---

#4 EP

#6 EP

#7 EP

---

---

---

---

---

---

AGMA

Kinematic Viscosity

---

---

14.4 cSt @ 100°C (77.1 SUS @ 210°F)

14.5 cSt @ 100°C 78.1 SUS @ 210°F

24.0 cSt @ 100°C (120 SUS @ 210°F)

30.3 cSt @ 100°C (150 SUS @ 210°F)

---

---

149

95

95

95

377

140

3.72 cSt @ 100°C (39 SUS @ 210°F) 5.5 cSt @ 100°C (44 SUS @ 210°F)

172

155

6.4 cSt @ 100°C (47.5 SUS @ 210°F) 7.5 cSt @ 100°C (51 SUS @ 210°F)

100 min.

105

Viscosity Index

6.9 cSt @ 100°C (49 SUS @ 210°F)

6.9 cSt @ 100°C (49 SUS @ 210°F)

Must be Premium Grade with Anti-Rust and Anti-Wear Additives. Must be Premium Shear Stable High VI, anti-wear hydraulic oil. Must be Supreme Grade High Shear stability, anti-wear hydraulic oil with anti-rust and anti-wear additives. Lithium base, general-purpose, extreme pressure grease.

Repositioner Bearing

Gearbox and Swivel Bearing

Hydraulic System

Component

Lubricants and Fluids Reference Chart

---

---

-46°C (-50°F)

-23°C (-10°F)

-18°C (0°F)

-7°C (20°F)

-60°C (-76°F)

-42°C (-44°F)

-48°C (-54°F)

-50°C (-58°F)

-37°C (-35°F)

-30°C (-22°F)

Pour Point

Lubricants and Hydraulic Fluids D811000719-PRO-001 Revision 05 Page 18 of 20

18

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1. 2. 3. 4.

Primrose Plus # 327 C

Extreme Operating Conditions

---

---

Primrose Plus # 327

For example: Jet-Lube KOPR-KOTE or NOV “Copper Top.” Use the lubrication product specified by the original equipment manufacturer. Polyurea-based grease or as specified by the motor manufacturer. Lithium base, general-purpose, extreme pressure grease.

Conventional Washpipe Packing Grease

#3

#2

#1

#2

---

Moderate Operating Conditions

EP Grease4

---

---

> -4°C (20°F)

General Grease Bearings

Misting Oil

#2

#1.5

#2

NLGI

Grade 32

---

Metalon  Hi-Tech 1.5 Grease2

EP Grease3

---

EP Grease1

Lube Type

< -4°C (20°F)

All

Air Lubricators

Blower Motor Bearings

All

All

IBOP/Kelly Valve Actuator

Drilling Motor Bearings

All

Environment

External Pinion and Gear Sets, and Elevator and Main Links contact surfaces

Component

ASTM/ ISO-VG/ SAE

---

---

---

---

---

---

---

---

AGMA

---

---

---

Kinematic Viscosity

---

---

---

---

29-35 cSt @ 38°C (136-165 SUS @ 100°F)

Lubricants and Fluids Reference Chart

---

---

---

---

125

---

---

---

Viscosity Index

---

---

---

---

-12°C (10°F)

---

---

---

Pour Point

D811000719-PRO-001 Revision 05 Page 19 of 20 Lubricants and Hydraulic Fluids

19

> 6°C (43°F)

Environment Wire Rope Lubricant1

Lube Type ---

#2

NLGI ---

AGMA ---

Kinematic Viscosity ---

Viscosity Index

---

Pour Point

1. Lithium 12 base, containing additives and inhibitors for non sheening, extreme pressure, corrosion, low temperature flexibility, strong adhesion, and low fling off.

Wire Rope

Component

ASTM/ ISO-VG/ SAE

Lubricants and Fluids Reference Chart Lubricants and Hydraulic Fluids D811000719-PRO-001 Revision 05 Page 20 of 20

20

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FINAL DOCUMENTATION TDS-11SA - Top Drive Drilling System

Chapter 17.0 Hydraulic Fluid Cleanliness

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Hydraulic Fluid Cleanliness

Supplement SM00081 Rev. C

October 26, 2000

Copyright 2000, Varco International, Inc. All rights reserved. This publication is the property of and contains information proprietary to Varco International, Inc. No part of this publication may be reproduced or copied in any form or by any means, including electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Varco International, Inc. Product names mentioned in this publication may be trademarks or registered trademarks of their respective holders and are hereby acknowledged.

ii

Hydraulic Fluid Cleanliness

SM00081-C

Contents Supplement Hydraulic Fluid Cleanliness Scope .................................................................................................................... 5 Hydraulic Fluid Cleanliness ................................................................................. 6 Hydraulic fluid ............................................................................................... 6 Hydraulic Fluid Contamination ............................................................................ 7 Solid contamination ....................................................................................... 7 Classes of contamination ......................................................................... 7 Measuring the contamination of a system ............................................... 9 Taking samples .................................................................................. 9 Analyzing the samples .......................................................................... 10 Cleanliness during installation ........................................................................... 11 Service loops ................................................................................................ 11 Hydraulic pipe cleaning ............................................................................... 11 Reference documents: ........................................................................... 11 Pipe cleaning (carbon steel): ................................................................. 11 Pipe cleaning (stainless steel) ................................................................ 13

SM00081-C

Contents

iii

October 26, 2000

iv

Hydraulic Fluid Cleanliness

SM00081-C

Supplement Hydraulic Fluid Cleanliness

Scope The purpose of this document is to provide guidance to the installers and users of Varco’s hydraulically powered equipment and to ensure that each piece of equipment performs as intended. Prior to connecting Varco equipment to a hydraulic system, the piping/plumbing/hoses/service loops must be cleaned and the hydraulic fluid filtered to minimize hydraulic fluid contamination. The following paragraph defines the hydraulic fluid cleanliness levels required for operating Varco equipment. Failure to maintain these cleanliness levels could result in premature equipment damage and nullification of the equipment warranty. This document outlines fluid cleanliness measurement and analysis criteria and also describes procedures for filtering and cleaning a hydraulic system. Each final assembly item from Varco will be function tested with clean hydraulic fluid maintained at ISO 4406 18/15 (was 9) or better (See Table 1). The hydraulic fluid cleanliness levels will be recorded on Test Specification document (TS00419) for each piece of equipment prior to shipment.

SM00081-C

Hydraulic Fluid Cleanliness

5

October 26, 2000

Hydraulic Fluid Cleanliness Hydraulic fluid Varco recommends hydraulic fluid levels be maintained at a cleanliness level of ISO 4406 18/15 (was 9) or better prior to the initial connection, startup, and commissioning of Varco equipment. After initial system operation, Varco recommends that the hydraulic supply system be capable of continuously maintaining this level of cleanliness or better to assure that fluid contamination is not a factor in any component failure during the desired useful life of the hydraulic powered equipment. The final level of acceptable cleanliness prior to equipment hook up must be determined by a hydraulic fluid sample and should be analyzed by a qualified laboratory.

6

Hydraulic Fluid Cleanliness

SM00081-C

Hydraulic Fluid Contamination

Hydraulic Fluid Contamination Solid contamination When determining contamination of hydraulic fluids, you must consider the size and quantity of the solid particle contamination within a representative fluid sample. The contamination of hydraulic fluids by solid particles is covered by a number of different classification systems: ❏ ISO DIS 4406 ❏ MIL STD 1246 A ❏ NAS 1638 ❏ SAE 749 D ❏ CETOP RP 70 H

CLASSES OF CONTAMINATION The various classes of contamination define the quantity of particles of a certain size in a 100 ml sample of fluid. A classification is determined by counting and sizing the contaminating solid particles. The classification is performed either under a microscope, or by using an electronic particle counter. The electronic counter method is more objective than using the microscope. Above a dirt concentration of about 20 mg per liter, or if the fluid is very turbid, the contamination can only be ascertained by weight, i.e., by gravimetric analysis. However, with this method, the individual dirt particles cannot be classified.

SM00081-C

Hydraulic Fluid Cleanliness

7

NAS 1638 (1967)

SAE 749 D (1963)

Particles per ml >10 µm

ACFTD solids content mg/L

26/23

140000

1000

25/23

85000

23/20

14000

21/18

4500

20/18

2400

20/17

2300

20/16

1400

19/16

1200

10

18/15

580

9

6

17/14

280

8

5

16/13

140

7

4

15/12

70

6

3

14/12

40

14/11

35

5

2

13/10

14

4

1

12/9

9

3

0

18/8

5

2

10/8

3

10/7

2.3

10/6

1.4

9/6

1.2

0

8/5

0.6

00

7/5

0.3

6/3

0.14

5/2

0.04

Figure 1.

8

Mil STD 1246 A (1967)

ISO DIS 4406 or Cetop RP 70 H

Hydraulic Fluid Cleanliness

1000 100

700 12 500 11

10

300 1

200

0.1

100 1 0.01

Acceptable range for Varco equipment

Acceptable range for Varco equipment

October 26, 2000

50 0.001

Comparison of contamination classifications

SM00081-C

Comparison of contamination classifications

MEASURING THE CONTAMINATION OF A SYSTEM Solid particle contamination is measured by taking a sample of fluid from the output of the hydraulic supply system at a location just prior to the Varco equipment and analyzing it. The analysis can reveal the following: ❏ Solid particle contamination of fluid delivered by suppliers ❏ Effectiveness of the system filters ❏ Flushing time when commissioning a system ❏ State of the system and any possible damage to components when making regular checks

Taking samples Take a sample from a moving fluid (known as dynamic sampling) Sampling point: Take the sample within a system that is operating and which contains turbulent flow. (See ISO 4021.) Since obtaining a fluid sample can be an input for contamination the following general measures should be utilized when taking a fluid sample. ❏ Utilize continuous flow monitoring equipment that records a cleanliness level over a period of time whenever possible. ❏ Take a sample of the circulating fluid of a system that is at operating conditions and temperature. All fluid samples shall be taken from a system test-port fitting using a on/off flow sampling device. Never loosen or break a hydraulic fitting to establish a leak point as a fluid source for fluid contamination sampling. ❏ Before attaching the sampling device, carefully flush out the device and clean the system test-port fitting. ❏ Open sampling device and allow approximately 2 liters of fluid to flow through the test port prior to sampling the fluid. ❏ Without shutting the test port, open and fill the sterile sampling bottle by holding it in the continuous fluid stream. Cap and seal the test bottle. ❏ Label and date the sample bottle to identify the tool and sample hydraulic circuit location.

e

SM00081-C

Only properly trained personnel should be allowed to take the fluid samples. Errors in sampling procedures can greatly affect contamination classes below ISO 18/IS.

Hydraulic Fluid Cleanliness

9

October 26, 2000

ANALYZING THE SAMPLES Analyzing the fluid samples involves using a microscope to make a quick estimate of the amount of solid particle contamination. From this assessment, you can roughly assess the state of the system. To avoid errors in sampling, conduct particle counting off site. Do not allow rig personnel to attempt to check the samples at the time of sampling. Send the samples to an appropriate institute for testing. Usually, samples are analyzed by means of an electronic particle counter. These particle counters are employed by major users of hydraulics, manufacturers of hydraulic filters, and by various institutions. Since testing by an outside source may not be easily accessible from a rig, you can make a quick assessment of the fluid samples on the spot by using the assessment test charts in this document.

z

10

Mobile laboratory services can also perform the measurements for customers.

Hydraulic Fluid Cleanliness

SM00081-C

Cleanliness during installation

Cleanliness during installation Service loops Varco service loops are blown clean in the factory and capped prior to shipment. They are not flushed. All service loops and hoses should be flushed as part of the overall hydraulic system prior to connecting Varco equipment.

Hydraulic pipe cleaning

z

Clean hydraulic piping is critical to the cleanliness of the overall hydraulic system. The following processes are examples of pickling, cleaning, and flushing procedures for cleaning carbon steel and stainless steel pipes prior to hydraulic system installation and are provided for information and reference only. Varco is typically not responsible for any part of the pickling, cleaning, or flushing process of derrick and rig floor piping. The process for cleaning and preparing hydraulic pipes is dependent on the type of pipe (carbon or stainless), the condition of the pipe (pickled or not pickled), the types and levels of contamination, the types and temperatures of the pickling and flushing solutions in use, and the type of flushing equipment.

REFERENCE DOCUMENTS: ❏ ASTM Standard 5.02 D-4174, standard practice for cleaning, flushing, and purification of petroleum fluid hydraulic system.

PIPE CLEANING (CARBON STEEL): Obtain the following chemicals: Hydrochloric acid - 35% commercial grade Alkaline cleaner, KD-500 Potable water - Unless otherwise specified Passivator - iron phosphate, KO-30 Inhibitor - Rodine 214 for HCL

SM00081-C

Hydraulic Fluid Cleanliness

11

October 26, 2000

Degrease Spray, immerse, or circulate with alkaline cleaner. Degreasing time for pipe depends on the nature of any contaminants present. Pipes and fittings with heavy rust, varnish or other tough soils should be sandblasted prior to pickling. Rinse Rinse carbon steel pipe with potable water until all alkaline cleaner is removed. Acid pickle Immerse or spray the pipe with a 10-15% inhibited hydrochloric acid solution at ambient temperature (for at least one hour) until all scale, slag, rust, etc. Is removed. Rinse with potable water until all alkaline cleaner is removed. Rinse Rinse the pipe with potable water until the water reaches a neutral PH (7.0). Flush Begin flushing the piping with the hydraulic power unit until the desired state of cleanliness is met.

12

Hydraulic Fluid Cleanliness

SM00081-C

Cleanliness during installation

PIPE CLEANING (STAINLESS STEEL) Use the following recommended procedure for cleaning stainless steel pipe: Obtain the following chemicals: Nitric acid - 42% technical grade Hydrofluoric acid - 35% technical grade Alkaline cleaner, KD-500 Potable water - unless otherwise specified Degrease Spray, immerse, or circulate with alkaline cleaner. Degreasing time for pipe depends on the nature of any contaminants present. Rinse Rinse pipe with portable water until all alkaline cleaner is removed. Acid pickle Immerse or spray the pipe with a 15-17% nitric acid/3-5% hydrofluoric acid mixture at ambient temperature (for at least two hours) until all scale, slag, rust, etc. is removed. Rinse Rinse the pipe with potable water until the water reaches a neutral PH. Passivate Use a 10 - 15% nitric acid/75-80% potable water mixture at ambient temperature for approximately one-half the time used in acid pickling. Rinse Rinse with potable water until the PH of the effluent equals the pH of the influent. Dry Dry with oil-free air until all visible traces of moisture are removed. Final inspection Use a white light to inspect all pipe and/or fittings for visible contamination. Prior to hooking up equipment pump clean hydraulic fluid through the plumbing and measure the contamination of the system per this specification. Additional flushing and cleaning may be required if contamination levels do not meet the requirements of this specification.

SM00081-C

Hydraulic Fluid Cleanliness

13

FINAL DOCUMENTATION TDS-11SA - Top Drive Drilling System

Chapter 18.0 Service Center Directory

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National Oilwell Varco Service Center Directory

Reference

Reference Description

This document contains proprietary and confidential information which is the property of National Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use of this design or distribution of this information to others is not permitted without the express written consent of NOV. This document is to be returned to NOV upon request or upon completion of the use for which it was loaned. This document and the information contained and represented herein is the copyrighted property of NOV. © National Oilwell Varco

www.nov.com Form D811001123-GEN-001/06

National Oilwell Varco RIG SOLUTIONS 11000 Corporate Centre Drive Houston, TX 77041

Document Number

Rev.

D811001337-DAS-001

04

D811001337-DAS-001 Revision 04

Revision History

04

12.11.2011

Operations update

T. Drake

S. Sobreira

T. Harmon

03

18.01.2011

Operations update

T. Drake

T. Harmon

T. Harmon

02

02.10.2009

Operations update

T. Drake

T. Harmon

P. Williams

01

08.09.2009

First Issue

T. Drake

T. Harmon

P. Williams

Rev

Date (dd.mm.yyyy)

Reason for issue

Prepared

Checked

Approved

Change Description Revision

Change Description

01

First Issue

02

• Moved Cairo office under North Africa heading. • Changed address information for India office.

03

• Removed outdated Louisiana contact information. • Added the new Louisiana service and repair center contact information.

04

• • • • •

www.nov.com

Updated/added Brazil, Canada, Colombia, UK contact information (page 3 through page 8). Added North Dakota contact information (page 4). Updated the contact information for the China office (page 6). Added addresses and contact information for Singapore and India (page 6). Updated contact information for NOV Dubai and NOV Abu Dhabi. (page 8).

D811001337-DAS-001 Revision 04

Service Center Directory

SC

The link below provides after-hours contact information for emergencies or other equipment issues requiring an immediate response by NOV service personnel. http://www.nov.com/ContactUs/24HrEmergencyContacts.aspx

Americas Brazil National Oilwell Varco do Brasil Rodovia Amaral Peixoto, s/n KM164,5 - n° 8.500 Imboassica – Macaé – RJ – Brazil CEP 27925-290 +55 22 2773 0600 (reception) +55 22 9882 7591 (after hours) +55 22 9702 8866 (drilling equipment) +55 22 9974 7056 (PCE / MoComp equipment) +55 22 9894 6608 (lifting and handling equipment) +55 22 2773 0635 (repair shop) +55 22 2773 0675 (inside sales) +55 22 2123 2452 (tech college)

Canada NOV Rig Solutions Aftermarket Service, Repair and Rentals (Leduc) Varco Canada ULC CO 009 6621 – 45 Street Leduc, Alberta, Canada T9E 7E3 +1 780 986 1712 (main) NOV Rig Solutions Spares (Edmonton) Varco Canada ULC CO 009 7127 – 56 Ave Edmonton, Alberta, Canada T6B 3L2 +1 780 801 1800 (main) +1 780 619 5579 (24 hour on-call)

Colombia National Oilwell Varco de Colombia Bogota, DC Top Drive Rental and Service +57 316 875 8748 (mobile) +57 317 515 3321 (mobile)

3 www.nov.com Form D811001123-GEN-001/06

SC

Service Center Directory

D811001337-DAS-001 Revision 04 Page 4 of 10

Americas USA Colorado NOV Service and Repair (Colorado) 420 South Ash St. Fruita, CO 81521 +1 970 858 4522 +1 281 569 3050 (after hours)

Louisiana NOV Service and Repair (Covington) 73765 Penn Mill Rd. Covington, LA 70435 +1 985 892 8216 (direct) +1 800 722 4425 (toll free) (Cranes: AmClyde, Unit, OS National, Dreco, Kingpost) +1 985 871 8609 (service) +1 985 871 8603 (parts NOV Service and Repair Center (New Iberia) 5212 Highway 90 Service Road West New Iberia, Louisiana 70560 (All NOV spare parts; legacy Shaffer, Varco, and NOI equipment) +1 337 374 1400

Minnesota NOV Service (St. Paul) 240 East Plato Blvd. St. Paul, Minnesota 55107 (lifting and handling equipment) +1 651 293 4745 (service) +1 651 293 4776 (service) +1 651 293 4600 (parts) +1 651 293 4603 (parts)

North Dakota NOV Service, Repair, and Spare Parts 3201 1st Avenue W. Williston, ND 58801 +1 307 473 8888 +1 281 569 3050 (after hours)

Oklahoma NOV Service and Repair (Oklahoma City) 7713 North West 3rd St. Oklahoma City, Oklahoma 73127 +1 405 495 1000 +1 281 569 3050 (after hours)

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Americas USA Pennsylvania NOV Service (Pittsburgh) 1349 Saw Mill Run Blvd. Pittsburgh, Pennsylvania 15226 +1 412 884 1027 +1 281 569 3050 (after hours)

Texas NOV Service and Repair (Alice) 2351 Energy Avenue Alice, Texas 78380 +1 361 668 4154 +1 281 569 3050 (after hours) NOV Service and Repair (Houston) 5100 North Sam Houston Parkway West Houston, Texas 77086 +1 281 569 3050 (24/7 technical support) +1 281 569 3051 (eHawk remote support)

Wyoming NOV Service and Repair (Casper) 1080 North Robertson Road Casper, Wyoming 82601 +1 307 473 8888 +1 281 569 3050 (after hours)

Venezuela NOV Rental and Service (Maturin, Monagas) Varco International de Venezuela Top Drive Rental and Service +58 291 651 6489 +58 414 394 2784 (mobile) +58 291 651 4384 (fax)

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Asia China NOV Service 18th Floor, Raffles City Beijing Office Tower No. 1, Dongzhimen South Street, Dongcheng District Beijing 100007 P. R. China +86 139 0121 9392 +86 800 810 5109 (24/7 technical support)

India NOV Service and Repair R-619, TTC Industrial Area Rabale, MIDC Navi Mumbai – 400 701 Maharashtra, India +91 22 3916 9700 +91 982 009 1322 +91 983 349 6154 (after hours) NOV Machining Centre (Pressure Control) 11A/2 (NP) Sidco Industrial Estate Ambattur Chennai, Tamil Nadu, India 600098 +91 44 4285 8074 +91 95 0008 4149 (after hours)

Singapore NOV Service and Repair 29 Tuas Bay Drive Singapore 637429 +65 6594 1000 +65 6594 1222 (24/7 technical support) NOV Machining Centre (Pressure Control) 22 Jalan Terusan Singapore 619299 +65 6265 1900 +65 9128 2545 (after hours)

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Europe France NOV Service +33 24 068 3600 +33 24 068 3611 +33 24 068 3600 (after hours) +33 677 790 943 (after hours)

Norway NOV Service (Asker) Blakstadmarka 26 1386 Asker – Norway +47 6400 5000 +47 6400 5001 (after hours) NOV Service (Kristiansand) Skibaasen 2 4636 Kristiansand – Norway +47 3819 2000 +47 3819 2482 (after hours) NOV Service (Molde) Granfjaera 24 6415 Molde – Norway +47 7120 2020 +47 9169 9664 (after hours) NOV Repair (Stavanger) Dusavik Base Notberget 46 4029 Stavanger – Norway +47 5781 8181 NOV Service (Stavanger) Lagerveien 8 4069 Stavanger – Norway +47 5181 8181 +47 4140 0041 (after hours) +47 9511 8181 (24/7 eHawk remote support)

Russia NOV Service and Support Russia, 119071, Moscow Leninsky prosp., 15A, 7th floor +7 495 287 2601 (direct) +7 495 981 3470 (fax) +7 985 410 5272 (mobile)

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Europe UK NOV Service and Repair (Aberdeen/Montrose) Forties Road Montrose Scotland DD10 9ET +44 1674 677222 UK after hours, on-call contacts +44 (0) 7711 415 485 (mechanical) +44 (0) 7711 415 484 (electrical) +44 (0) 7739 170 079 (repair workshop) +44 (0) 7713 643 012 (spare parts) +44 (0) 7770 325 333 (distribution) +44 (0) 7801 078 092 (IMO/MD Totco)

Middle East UAE NOV Service and Repair (Abu Dhabi) Varco Al Mansoori Services LLC P. O. Box 27011 Abu Dhabi, United Arab Emirates +971 2 555 2668 +971 2 554 2280 (fax) +971 2 554 0012 (fax) +971 50 811 6083 (after hours service) +971 50 617 1235 (after hours workshop) NOV Service and Repair (Dubai) P.O. Box 61490 R/A No.13, Plot MO 0682 Daimler Chrysler Street Jebel Ali Free Zone Dubai, United Arab Emirates +971 4 883 8776 +971 4 883 8795 (fax) +971 56 686 2184 (after hours service on-call)

North Africa NOV Service (Algeria) Overseas Equipment Service Africa BP 852 Zone Industrielle Algerie Hassi Messaoud Ouargla Algeria 30500 +213 29 73 1236 +213 29 75 4105 (fax)

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Middle East North Africa NOV Service and Repair (Badr City) IMPEC (Sea Harvest Company) Part B, 47 Acer Area Badr City, Cairo, Egypt +20 2 231 08001 +20 2 231 08002 +20 2 231 08003 (fax)

Saudi Arabia NOV Service and Repair (Dammam) P. O. Box 20754, Al-Khobar 31952 Al Khobar, Saudi Arabia Gate No. 2, Makkah Street (opposite of Saudi Electricity Company) Dammam Second Industrial City Dammam, Saudi Arabia +966 3 835 3061 +966 3 830 2453 (fax)

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