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RG/PLANT
PS2-500A & PS2-750A
REFERENCE

REFERENCE DESCRPTON
PS2-500A & PS2-750A DC Top Drive
ADDTONAL CODE

SDRL CODE

TOTAL PGS
26

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 Varco. 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. 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.
Copyright National Oilwell Varco - 2005


National Oilwell Varco
Rig Solutions - Western Hemisphere
11000 Corporate Centre Dr. Ste 200
Houston Texas USA 77041

Phone 281 854 0400
Fax 281 854 0508

REMARKS

MAN TAG NUMBER

DSCPLNE

CLENT PO NUMBER

CLENT DOCUMENT NUMBER


DOCUMENT NUMBER

700-605
REV

03
Top Drive Controls
Commissioning Procedure






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REVISION HISTORY






03 30.04.2009 For nformation TJH MJF MJF
Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved


CHANGE DESCRIPTION
Revision Change description
03 For nformation


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INTRODUCTION.......................................................................................................................... 5
1 PRELIMINARY CHECKS .................................................................................................. 5
1.1 nterconnect Wiring ................................................................................................. 5
1.2 PLC Program .......................................................................................................... 5
1.3 Driller's Console Lamp Test .................................................................................... 6
1.4 Signal Conditioners ................................................................................................. 6
2 ALARMS ........................................................................................................................... 6
2.1 Stalled Motor Fault & Auto Unwind Sequence ........................................................ 6
2.1.1 Sequence .................................................................................................... 6
2.1.2 Test ............................................................................................................. 8
2.2 Air Flow Loss Alarm ................................................................................................ 8
2.3 Top Drive Drill Motor High Temperature Alarm ....................................................... 9
2.4 Top Drive Low Gear Oil Pressure Alarm ............................................................... 10
2.5 TD Control Console & Transfer Panel Purge Alarm .............................................. 10
2.6 Upper Crown Alarm and Lower Crown Warning ................................................... 10
3 TOP DRIVE / ROTARY TABLE ...................................................................................... 11
3.1 Top Drive Assignment / De-assignment ................................................................ 11
3.1.1 TD Assignment .......................................................................................... 11
3.1.2 TD De-assignment ..................................................................................... 12
3.2 Rotary Table Assignment / De-assignment ........................................................... 13
3.2.1 RT Assignment .......................................................................................... 13
3.2.2 RT De-assignment ..................................................................................... 13
3.3 Torque Set Points ................................................................................................. 14
3.4 TD Transmission ................................................................................................... 15
3.5 Speed and Torque ................................................................................................ 15
3.6 Mode Latch ........................................................................................................... 16
4 TOP DRIVE OPERATIONAL MODES ............................................................................ 16
4.1 Drill Mode .............................................................................................................. 16
4.2 Spin Mode ............................................................................................................. 17
4.2.1 Spin Speed and Torque ............................................................................. 17
4.2.2 Spin Out .................................................................................................... 17
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4.2.3 Spin n ....................................................................................................... 17
4.3 Makeup Mode ....................................................................................................... 18
4.3.1 Makeup Completes .................................................................................... 18
4.3.2 Makeup Completes Switch Held for Five Seconds ................................. 18
4.3.3 Mode Switch to Makeup Before Spin n Complete .................................... 18
4.3.4 Mode Switch Released from Makeup Before Makeup Completes ............. 19
4.3.5 Top Drive Fails to Reach Makeup Torque ................................................. 19
4.3.6 Top Drive Rotates During Makeup ............................................................ 19
4.4 Breakout Mode ...................................................................................................... 20
4.4.1 Breakout Completes .................................................................................. 20
4.4.2 Breakout Fails ........................................................................................... 20
5 BRAKE AND PIPE HANDLING EQUIPMENT ................................................................ 21
5.1 Drill Motor Brake ................................................................................................... 21
5.1.1 Brake Modes ............................................................................................. 21
5.2 BOP ..................................................................................................................... 21
5.2.1 BOP Open ................................................................................................ 21
5.2.2 BOP Close ................................................................................................ 22
5.3 Grabs .................................................................................................................... 22
5.4 Drawworks Clutch Solenoid .................................................................................. 23
5.5 Handling Ring ....................................................................................................... 24
5.5.1 Lock/Unlock ............................................................................................... 24
5.5.2 Spin Left/Right ........................................................................................... 24
5.6 Link Tilt .................................................................................................................. 24
5.7 Counterbalance ..................................................................................................... 25
5.8 Top Drive Hour Meter............................................................................................ 25
6 SIGNAL CONDITIONERS............................................................................................... 26
6.1 Potentiometer Signal Conditioners (Control Console) (Type G438) ...................... 26
6.2 Analog Signal Conditioners (Control Console) (Type G408) ................................. 26
6.3 Analog Signal Conditioners (Transfer Cabinet) (Type G408) ................................ 26
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INTRODUCTION
The purpose of this document is to provide guidelines for commissioning the PS2-750 top drive
control system. Although the preliminary checks should be completed first, there is no particular
order needed for the commissioning tests. Note: References to PLC program networks can
sometimes change due to unreported field modifications. Use the references as a guide to find
the correct code. Even if the code has changed, the references should be close.


1 PRELIMINARY CHECKS
Perform these basic preliminary tests before testing with the top drive controls connected to
the top drive equipment.

1.1 Interconnect Wiring
Using the system interconnect (SD) and termination (TER) diagrams, verify that all wiring
is terminated correctly.



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Date _______________________________________________


1.2 PLC Program
Verify hardware configuration. Verify communications. Verify all digital and analog /O.



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1.3 Drillers Console Lamp Test
Turn the alarm silence/test to the 'test' position. Verify that all console lamps are lit, the
alarm horn sounds, and all meters deflect to full scale.


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Date _______________________________________________


1.4 Signal Conditioners
Verify that each signal conditioner is set up with the dip switch settings shown on the
internal wiring diagrams (NWs) for the Transfer Cabinet and the Driller's Console. Note
that on some installations the NWs are found on the general arrangement drawings
(GADs) for the Transfer Cabinet and the Driller's Console. f a dip switch setting needs to
be changed, then power must be disconnected to the signal conditioner. Moving a dip
switch while power is applied to the signal conditioner will damage it. Check that each
signal conditioner is calibrated. f a signal conditioner needs calibration, then use the
procedure in section 6.


Verified_______________________________________________



Date _______________________________________________

2 ALARMS
Verify the operation of the following alarms.

2.1 Stalled Motor Fault & Auto Unwind Sequence
Before performing this test, be sure to read and understand the top drive auto unwind
sequence.

2.1.1 Sequence

When the drill bit gets stuck down hole, the drill string will begin to windup like a large
spring. Eventually the windup torque in the drill string will equal the top drive's drilling
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torque setting. When the wind up torque equals the drilling torque the top drive drill motor
will no longer be able to rotate and will ultimately stall.

When the drilling mode is selected and the top drive control system senses that drill stem
speed is less than 7 RPM and armature current is greater than 160 amps, a 5 second
nuisance alarm delay timer will be energized. f the stalled motor condition is still present
after the 5 second delay, the stalled motor light will flash at a rate of 1 Hz and a 20 second
delay timer will be energized. f the stalled motor condition is still present after the 20
second delay, the top drive will then go into an unwind mode allowing the drill string to
slowly unwind. Once the unwind mode starts, it cannot be stopped until the drill string
completely unwinds. The unwind mode will let the drill string unwind at a speed of
approximately 5 RPM by slowly ramping down the drilling torque current limit which will
allow the wind up torque to overcome the drilling torque. During the unwind cycle, the top
drive hand throttle and drilling torque current limit pot will be disabled, the speed signal to
the SCR bay will be held at what ever value the hand throttle was issuing and the stalled
motor alarm light will flash at a rate of 2 Hz. When unwind is complete and the current limit
is at zero, the motor stalled light will stop flashing and stay on. The speed signal will be
stepped down to zero. The hand throttle will have to be turned to the zero throttle position
for the light to de-energize and the system to reset. The amount of time the drill string
takes to completely unwind will vary and will be dependent on the drill string length and
how much wind up torque is present.

Note: f the top drive hand throttle or drilling torque are suddenly turned down to the zero
position and the drill motor brake selector switch is in the off position during the 20 second
stalled motor time interval, the drill stem will unwind in an uncontrolled fashion. f the brake
is in the auto position, it will engage if the throttle is turned down to the zero position.
However, the drill stem will unwind in an uncontrolled fashion if the drilling torque is
suddenly turned down to zero.

Note: f the drill string is hoisted causing the drill bit to become unstuck and windup torque
to be removed from the drill string before the auto unwind mode can completely ramp down
the drilling torque current limit, the control system will become stuck in the auto unwind
mode. This will cause the drill stem to rotate at whatever speed command was being
issued when auto unwind began. However, the hand throttle will have no control over top
drive speed. To get out of this condition, the drill motor brake must be placed in the on
position. This will allow the auto unwind mode to finish ramping down the drilling torque
current limit.

n the breakout, spin-in, or makeup modes the motor will stall as part of the respective
operation. Therefore, when a stalled motor condition is sensed in any of these modes the
stalled motor light will flash at 1 Hz. However, there will be no stalled motor alarm
generated.



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2.1.2 Test
Start the top drive and set drilling torque to 4000 ft-lbs. Turn the brake off-auto-on switch to
the 'on' position. Open the TD/RT throttle to a very slow speed set point (just greater than
zero). The top drive will be prevented from rotating by the brake. After five seconds the
alarm horn will sound and the stalled motor light will flash at 1 Hz. Silence the alarm horn.
After 20 more seconds, the top drive torque set point starts ramping to zero. The stalled
motor light flashes at 2 Hz. The ramp will take about 5 seconds. Then the stalled motor
light will stop flashing and stay on. Return the throttle to zero. The stalled motor light will
turn off and the drilling torque set point will return to 4000 ft-lbs. Return the brake off-auto-
on switch to the 'auto' position.



Verified_______________________________________________



Date _______________________________________________

2.2 Air Flow Loss Alarm
Start the top drive. The top drive blower motor should start running. Turn off the blower at
the motor starter. After 10 seconds, the alarm horn should sound and the air flow light will
flash at 1 Hz. The top drive should not shut down, but continue to run. Silence the alarm
and turn the blower back on. Reset the alarm. The light should stop flashing.


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2.3 Top Drive Drill Motor High Temperature Alarm
To make this check with a potentiometer you will need a radio, an ohm meter, a
screwdriver, jumper wire, and you will need to go aloft to work at the solenoid junction box.
Follow all rig safety procedures for working aloft. At the solenoid junction box disconnect
the interconnect wires coming from the RTD junction box at .S. TB3 terminals 301, 302,
and 303. Connect 302 and 303 with a jumper wire. Now connect a 10 turn,1K ohm
potentiometer. Connect the bottom lead of the potentiometer to 302 and connect the wiper
lead to 301. Do not connect the top lead. f the alarm goes off then turn the potentiometer
all of the way counter clockwise and have the driller reset the alarm. Now slowly turn the
potentiometer clockwise until the alarm goes off. Use the ohm meter to check the
resistance between 301 and 302. t should read approximately 158 ohms. t may read
slightly higher depending on how quickly you stop turning the potentiometer once the alarm
goes off. You should repeat this test several times to be sure your reading is accurate.
The alarm horn should sound and the drill motor high temperature light should flash at 1
Hz. Remove the potentiometer and jumper wire. Reconnect the interconnect wires to .S.
TB3 terminals 301, 302, and 303.

Alternatively, simulate a top drive drill motor temperature of 151C using the PLC (FC23
network 3). The alarm horn should sound and the drill motor high temperature light should
flash at 1 Hz. Silence the alarm and remove the simulated temperature. Reset the alarm.
While this is easier because it does not require going aloft, it does not verify the operation
of the .S. barrier. The operation of the barrier can be checked by looking at the
temperature reading in the PLC (FC23 network 3) after the top drive has been idle for
several hours (4 or more). The temperature reading should be near the ambient air
temperature.


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2.4 Top Drive Low Gear Oil Pressure Alarm
Use the PLC to observe the low pressure alarm logic in FC23 network 4. With the top drive
assigned with a zero throttle command, verify that the gear oil pressure switch status is 0
(false). Continue to monitor the pressure switch status while slowly increasing the top drive
throttle to a speed of 20 rpm. The pressure switch status should change to a 1 (true) at or
near 15 rpm. Return the throttle to zero.

Now force the alarm enable bit in the PLC. After 10 seconds the alarm horn should sound
and the gear oil pressure light should flash at 1 Hz. Silence the alarm. Remove the force
on the enable bit and reset the alarm.


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Date _______________________________________________

2.5 TD Control Console & Transfer Panel Purge Alarm
Open the top drive control console door. The alarm horn should sound and the system air
purge light should flash at 1 Hz. Silence the alarm. Close the top drive control console
door. Reset the alarm. Now open the transfer panel door. The alarm horn should sound
and the system air purge light should flash at 1 Hz. Silence the alarm. Close the transfer
panel door. Reset the alarm.


Verified_______________________________________________



Date _______________________________________________


2.6 Upper Crown Alarm and Lower Crown Warning
The upper and lower crown alarms can be verified either by sending someone aloft with a
metal tool (a screwdriver will work fine) or by slowly hoisting the top drive with the
drawworks. f someone goes aloft then they will need a radio or some means of
communicating with an operator below. Of course, all of the rig's precautions and safety
procedures for working aloft must be followed. Once aloft, the person will need to use the
metal tool to activate the lower crown warning proximity switch. The alarm horn will sound
and the lower crown warning light will flash at 1 Hz. The operator silences the alarm and
communicates to the person aloft that it is OK to proceed to the upper crown alarm test.
When the person aloft removes the metal tool from the lower crown proximity switch, the
operator can reset that alarm. The person aloft then activates the upper crown alarm
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proximity switch. The alarm horn will sound and the upper crown alarm light will flash at 1
Hz. The operator silences the alarm and communicates to the person aloft that the test is
complete. f the drawworks is used, then the top drive is slowly hoisted until it sets off the
lower crown warning. After silencing the horn, the top drive is slowly hoisted until the upper
crown alarm is activated. The drawworks can then lower the top drive. Caution must be
exercised when hoisting the top drive in case one or both of the alarms does not activate
properly.


Verified_______________________________________________



Date _______________________________________________

3 TOP DRIVE / ROTARY TABLE

3.1 Top Drive Assignment / De-assignment
3.1.1 TD Assignment

The following conditions must all be true before the top drive can start. Verify each
condition by causing the actual condition to be false (with all the other conditions true) and
then attempting to start the top drive. The conditions for starting are: 1) top drive not
locked out at the transfer panel; 2) TD/RT assignment switch in the TD position; 3) mode
switch in drill position; 4) TD throttle at zero; 5) the TD or RT is not already assigned.

Once all of the start conditions have been checked start the top drive with the direction
switch in the 'forward' position. The blower will start and once the blower pressure switch
senses air flow, the top drive contactors will pull in. The forward contactors pull in first
followed by the main power contactor. Turn the top drive off and disconnect the input wire
to the PLC from the blower pressure switch. Be sure to close the transfer panel door. Start
the top drive. The blower will start but the contactors will not pull in. The air flow loss
alarm will sound and the air flow loss light will flash. Turn the top drive on/off switch to 'off'
and reconnect the blower pressure switch. Now open the transfer panel cabinet door to get
a purge alarm. Start the top drive. The blower will start but the contactors will not pull in.
Close the transfer panel door. Once the purge pressure builds up in the transfer cabinet,
the contactors will pull in. Turn the top drive on/off switch to 'off'.

Start the top drive with the 'forward' direction selected. Set a drill torque set point of
approximately 10,000 ft-lbs. Rotate the top drive at a slow speed (20 - 25 rpm is fine).
Check that the top drive is rotating in the forward (clockwise looking down) direction. While
the top drive is turning with a non-zero throttle assignment, turn the top drive on/off switch
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to 'off'. The top drive should continue rotating. Turn the throttle to zero. The top drive
should stop rotating.

Start the top drive with the 'reverse' direction selected. Set a drill torque set point of
approximately 10,000 ft-lbs. Rotate the top drive at a slow speed (20 - 25 rpm is fine).
Check that the top drive is rotating in the reverse (counterclockwise looking down)
direction. While the top drive is turning with a non-zero throttle assignment, turn the top
drive direction switch to 'forward'. The top drive should continue rotating in the reverse
direction. Turn the throttle to zero. The top drive should stop rotating. Open the throttle
again. The top drive forward assignment should now cause the top drive to rotate in the
forward direction. Turn the throttle to zero. The top drive should stop rotating.
3.1.2 TD De-assignment

The top drive will de-assign if any of the following conditions are true: 1) the assignment
switch is turned to 'off' and the TD/RT throttle is at zero throttle; 2) the position of the
direction switch is changed and the TD/RT throttle is at zero (the TD will de-assign and
then re-assign); 3) the RT/TD ready feedback from the SCR is lost; 4) power contactor K1
closed feedback is lost.

Start the top drive and the turn the assignment switch to off. Check that the contactors
drop out. Start the top drive again in the forward direction. Switch the direction switch to
'reverse' and observe that the contactors drop out and then pull in again. Start the top
drive in the forward direction. Open the driller's console and silence the resulting purge
alarm. The contactors should not drop out at this point. Now disconnect the RT/TD ready
feedback wire from the SCR. The contactors should drop out. Zero the throttle. Turn the
assignment switch to 'off' and reconnect the RT/TD ready feedback wire. Close the driller's
console. Again start the top drive in the forward direction. Open the transfer panel door
and silence the resulting purge alarm. The contactors should not drop out at this point.
Now disconnect the power contactor K1 closed feedback wire at the PLC. The contactors
should drop out. Zero the throttle. Turn the assignment switch to 'off' and reconnect the
power contactor K1 feedback wire. Close the transfer panel door.

Start the top drive. n the PLC, simulate a high temperature (> 60C) from the drill motor
RTD (you can do this in FC24 network 4). Return to zero throttle and turn off the top drive.
The blower should continue running for an additional 15 minutes. There is no need to wait
the entire 15 minutes. Once it is verified at the PLC that the extend timer is running the
blower, the simulated RTD signal can be removed and the timer reset by the PLC
programmer. The blower should turn off.


Verified_______________________________________________



Date _______________________________________________
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3.2 Rotary Table Assignment / De-assignment

3.2.1 RT Assignment

The following conditions must all be true before the rotary table can start. Verify each
condition by causing the actual condition to be false (with all the other conditions true) and
then attempting to start the rotary table. The conditions for starting are: 1) rotary table not
locked out at the transfer panel; 2) TD/RT assignment switch in the RT position; 3) RT
throttle at zero; 4) the RT or TD is not already assigned.

Once all of the start conditions have been checked start the rotary with the direction switch
in the 'forward' position. The forward contactors pull in first followed by the main power
contactor. Turn the rotary table on/off switch to 'off'. Now open the transfer panel cabinet
door to get a purge alarm. Start the rotary table. The rotary table contactors will not pull in.
Close the transfer panel door. Once the purge pressure builds up in the transfer cabinet,
the contactors will pull in. Turn the rotary table on/off switch back to 'off'.

Start the rotary table with the 'forward' direction selected. Set a drill torque set point of
approximately 5,000 ft-lbs. Rotate the rotary table at a slow speed (10 - 15 rpm is fine).
Check that the rotary table is rotating in the forward (clockwise looking down) direction.
While the rotary table is turning with a non-zero throttle assignment, turn the rotary table
on/off switch to 'off'. The rotary table should continue rotating. Turn the throttle to zero.
The rotary table should stop rotating.

Start the rotary table with the 'reverse' direction selected. Set a drill torque set point of
approximately 5,000 ft-lbs. Rotate the rotary table at a slow speed (10 - 15 rpm is fine).
Check that the rotary table is rotating in the reverse (counterclockwise looking down)
direction. While the rotary table is turning with a non-zero throttle assignment, turn the
direction switch to 'forward'. The rotary table should continue rotating in the reverse
direction. Turn the throttle to zero. The rotary table should stop rotating. Open the throttle
again. The rotary table forward assignment should now cause the rotary table to rotate in
the forward direction. Turn the throttle to zero. The rotary table should stop rotating.

3.2.2 RT De-assignment

The rotary table will de-assign if any of the following conditions are true: 1) the assignment
switch is turned to 'off' and the TD/RT throttle is at zero throttle; 2) the position of the
direction switch is changed and the TD/RT throttle is at zero (the RT will de-assign and
then re-assign); 3) the RT/TD ready feedback from the SCR is lost; 4) power contactor K10
closed feedback is lost.

Start the rotary and then turn the assignment switch to off. Check that the contactors drop
out. Start the rotary table again in the forward direction. Switch the direction switch to
'reverse' and observe that the contactors drop out and then pull in again. Start the rotary
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table in the forward direction. Open the driller's console and silence the resulting purge
alarm. The contactors should not drop out at this point. Now disconnect the RT/TD ready
feedback wire from the SCR. The contactors should drop out. Zero the throttle. Turn the
assignment switch to 'off' and reconnect the RT/TD ready feedback wire. Close the driller's
console. Again start the rotary table in the forward direction. Open the transfer panel door
and silence the resulting purge alarm. The contactors should not drop out at this point.
Now disconnect the power contactor K10 closed feedback wire at the PLC. The contactors
should drop out. Zero the throttle. Turn the assignment switch to 'off' and reconnect the
power contactor K10 feedback wire. Close the transfer panel door.




Verified_______________________________________________




Date _______________________________________________


3.3 Torque Set Points
Turn the torque set switch to the 'drill' position and rotate the drill torque set potentiometer.
The torque meter will display the drill torque set point as selected by the potentiometer.
Release the torque set switch allowing it to return to the 'actual' position. The torque meter
now displays the actual drill stem torque and not the drill torque set point. Leaving the
torque set switch in the 'actual' position, turn the drill torque set potentiometer. The torque
meter display should not change. Turn the torque set switch to the 'makeup' position and
rotate the makeup torque set potentiometer. The torque meter will display the makeup
torque set point as selected by the potentiometer. Release the torque set switch allowing it
to return to the 'actual' position. The torque meter now displays the actual torque and not
the makeup torque set point. Leaving the torque set switch in the 'actual' position, turn the
makeup torque potentiometer. The torque meter display should not change.




Verified_______________________________________________




Date _______________________________________________


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3.4 TD Transmission
n order to shift the transmission, the top drive must be assigned, the brake switch must be
in 'auto' or 'off', the top drive must be in drill mode, and there must be no mode latch. A
mode latch condition will exist whenever any of the following conditions are true: the top
drive throttle command is not at zero throttle; the drill stem speed is greater than or equal to
seven RPM; the SCR armature current is not at minimum output levels, typically less than
10 amps. To test the interlocks, set the brake switch to the "on position and then attempt
to shift the transmission. The light for the gear that the transmission is in should remain
steady while the light for the gear you are attempting to shift to should flash at 1 Hz.

Now return the brake switch to the "auto or "off positions. The transmission should now
shift. The light for the previous gear will go out and the light for the new gear will flash and
then go steady when the transmission engages in the new gear. f the light does not go
steady, but continues to flash, then the throttle can be rotated off of zero to activate the
"creep mode. The creep mode causes the drive to rotate the top drive very slowly (1
RPM) to engage the gear. f the transmission still does not engage, then the transmission
shift solenoids and gear indication proximity switches will need to be checked.

Finally, start the top drive in drill mode and rotate the throttle off of zero. Make sure that
the top drive is rotating very slowly (5 RPM or less). The mode latch light should be on.
Try to shift the gears. The light for the gear that the transmission is in should remain
steady while the light for the gear you are attempting to shift to should flash at 1 Hz.
Return the transmission switch to the gear position it was in. Rotate the throttle to zero.


Verified_______________________________________________



Date _______________________________________________

3.5 Speed and Torque
Start the top drive and set a drill torque set point of approximately 10,000 ft-lbs. Rotate the
top drive at a slow speed. Rotate the throttle clockwise to increase the speed. The top
drive speed should smoothly increase to the new throttle setting. Rotate the throttle all of
the way clockwise. The top drive speed should increase to 300 RPM (high gear) (147 RPM
for low gear) and remain steady. Rotate the throttle counter clockwise. The speed should
decrease smoothly to the new throttle setting. Rotate the throttle all of the way
counterclockwise. The top drive should stop rotating.

With the top drive not rotating, set the brake switch to the 'On' position. The brake will
engage and the brake light will turn on. Rotate the throttle slightly clockwise off of zero.
The torque should increase to the drill torque setting of approximately 10,000 ft-lbs. Do not
hold the torque longer than 5 seconds. Rotate the throttle back to zero and turn the brake
switch to the 'Auto' position. The torque reading should return to zero. Repeat this test for
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drill torque set points of 20,000 ft-lbs. (high gear), 30,000 ft-lbs. (low gear), and 48,000 ft-
lbs (low gear).


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Date _______________________________________________

3.6 Mode Latch
A mode latch condition will exist whenever any of the following conditions are true: the top
drive throttle command is not at zero throttle; the drill stem speed is greater than or equal to
seven RPM; the SCR armature current is not at minimum output levels, typically less than
10 amps. Start the top drive and set a drill torque set point of approximately 10,000 ft-lbs.
Rotate the top drive at a slow speed (about 20 RPM). The mode latch light will turn on.
Switch the mode selector switch to spin. The top drive rotation should not change. Switch
the mode selector switch to makeup. Again, the top drive rotation should not change.
Return the mode selector switch to drill and then turn the switch to breakout. Once again,
there should be no change in top drive rotation. Return the mode switch to drill and turn
the throttle to zero.


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Date _______________________________________________

4 TOP DRIVE OPERATIONAL MODES

4.1 Drill Mode
Start the top drive and set a drill torque set point of approximately 10,000 ft-lbs. Select the
forward direction and rotate the throttle off zero. The top drive should respond to the
throttle commands by rotating in the forward (clockwise) direction. Return the throttle to
zero. Select the reverse direction and rotate the throttle off zero. The top drive should
respond to the throttle commands by rotating in the reverse (counterclockwise) direction.


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Date _______________________________________________
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4.2 Spin Mode

4.2.1 Spin Speed and Torque
There are three discreet spin torques and spin speeds that are selected with the spin
torque switch. The target values are: 10 RPM, 1500 ft-lbs. in the 'low' position; 14 RPM,
3000 ft-lbs. in the 'medium' position; 18 RPM, 5000 ft-lbs. in the 'high' position. These
values, particularly the low values, will be difficult to obtain. The reason is that the throttle
and current limit references needed to obtain the lower values fall near the SCR dead
band. Also, there are almost always multiple SCRs that the top drive can be assigned to.
So the references for one SCR may produce different results when applied to another
SCR. n order to get the spin torques and speeds reasonably consistent across multiple
assignments, some tuning of the SCRs will be necessary. Setting spin torques and speeds
takes multiple adjustments of both the control references and the SCRs. Fortunately, it
does not have to be to fine. The target values are not "engraved in stone. The customer
may desire completely different values for spin in torques and speeds. So these can be
adjusted as needed to satisfy the customer. Also, the spin in operation is only applicable to
low gear. The "bottom line is that you want to have three ranges of spin torque and speed,
in low gear, that are useful to the customer and reasonably consistent across various SCR
assignments.

To adjust the references, go to the PLC program FC25, network 3. You will see headings
for each transmission and switch combination (Low gear low torque, Low gear medium
torque, etc.). Under each heading, the reference value from DB22 is loaded into the spin
speed and spin torque commands. For each combination, you will need to adjust these
references until you get the desired speed and current limit responses. Don't forget you
may need to adjust the SCRs as well. You should tune in each different SCR assignment
and then go back and retune again. When you get good results in all assignments for all
three low gear spin torque/speed settings then tuning is complete. Be sure to enter and
save all of the final reference values in DB22.

4.2.2 Spin Out
Start the top drive with the reverse direction selected. Select spin mode at the mode select
switch and select 'low' at the spin torque switch. The top drive should rotate at the low spin
speed the reverse direction. Next change the spin torque switch to 'medium'. The top
drive speed should increase to the medium spin speed. Then change the spin torque
switch to 'high'. The top drive speed should increase to the high spin speed. Return the
mode select switch to 'drill'. The top drive should stop.

4.2.3 Spin In
Start the top drive with the forward direction selected. Select spin mode at the mode select
switch and select 'low' at the spin torque switch. The top drive should rotate at the low spin
speed the forward direction. Next change the spin torque switch to 'medium'. The top
drive speed should increase to the medium spin speed. Then change the spin torque
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switch to 'high'. The top drive speed should increase to the high spin speed. Return the
mode select switch to 'drill'. The top drive should stop.

Place a pup-joint (minimum length 3 feet) into the rotary table and set the slips. Lower the
top drive so that the saver-sub makes contact with the box connection on the pup-joint.
Start the top drive in the forward direction and set a makeup torque set point of
approximately 20,000 ft-lbs. Select high spin in torque and select spin mode at the mode
select switch. The top drive should rotate at the high spin speed in the forward direction.
When the pipe "shoulders up the top drive stalls and the stalled motor light will flash at 1
Hz. Proceed to the makeup section directly.


Verified_______________________________________________



Date _______________________________________________


4.3 Makeup Mode

4.3.1 Makeup Completes
Follow the steps in the previous section for spin in. When the stalled motor light flashes at
1 Hz then the spin in is complete. Turn the mode switch to the 'makeup' position and hold
it there. The torque reading on the torque meter will increase. When it reaches the
makeup torque set point the makeup complete light will turn on steady green. Release the
mode switch and it returns to the 'spin' position. The makeup complete light should remain
illuminated. The torque should return to the spin value. Return the mode switch to the
'drill' position. Use the breakout mode to break out the pipe.

4.3.2 Makeup Completes Switch Held for Five Seconds
Follow the steps for a spin in. When the stalled motor light flashes at 1 Hz then the spin in
is complete. Turn the mode switch to the 'makeup' position and hold it there. The torque
reading on the torque meter will increase. When it reaches the makeup torque set point
the makeup complete light will turn on steady green. Continue holding the mode switch in
the 'makeup' position. After five seconds, the current limit should ramp down to zero.
Release the mode switch and it returns to the spin position. The makeup complete light
should remain illuminated. The torque should return to the spin value. Return the mode
switch to the drill position. Use the breakout mode to break out the pipe.

4.3.3 Mode Switch to Makeup Before Spin In Complete
Follow the steps for a spin in. Before the pup joint shoulders up, turn the mode switch to
the 'makeup' position. The alarm horn should sound and the makeup complete light will
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flash at 1 Hz. The top drive will stop. Silence the horn and return the mode switch to the
spin position. The top drive will finish spin in. When the stalled motor light is flashing, then
the makeup can be completed normally. When the makeup complete light turns on,
release the mode switch allowing it to spring back to the 'spin' position. The makeup
complete light should remain illuminated. The torque should return to the spin value.
Return the mode switch to the 'drill' position. Use the breakout mode to break out the pipe.

4.3.4 Mode Switch Released from Makeup Before Makeup Completes
Follow the steps for a spin in. When the stalled motor light flashes at 1 Hz then the spin in
is complete. Turn the mode switch to the 'makeup' position and then release it
immediately. The switch spring returns to the 'spin' position, the alarm horn should sound
and the makeup complete light will flash at 1 Hz. The top drive will stop. Silence the horn
and return the mode switch to the 'drill' position. Use the breakout mode to break out the
pipe.

4.3.5 Top Drive Fails to Reach Makeup Torque
To test this alarm, reprogram timers T238 and T239 in the PLC (FC27 network 7) from 5
seconds to 250 milliseconds. Follow the steps for a spin in. When the stalled motor light
flashes at 1 Hz then the spin in is complete. Turn the mode switch to the 'makeup' position
and hold it there. The alarm horn will sound and the makeup complete light will flash at 1
Hz. The top drive will stop. Silence the horn and return the mode switch to the 'spin'
position. Return the mode switch to the 'drill' position. Reprogram the timers to 5 seconds.
Use the breakout mode to break out the pipe.
4.3.6 Top Drive Rotates During Makeup
To test this alarm, go to the PLC FC27, network 2 and find the following logic:


A "ModesVars.MakeupMode
A "ModesVars.RotationOfMotor
S "ModesVars.MakeupModeDrillRotFault


Change this to:


A "ModesVars.MakeupMode
AN "ModesVars.RotationOfMotor
S "ModesVars.MakeupModeDrillRotFault


Follow the steps for a spin in. When the stalled motor light flashes at 1 Hz then the spin in
is complete. Turn the mode switch to the make up position and hold it there. The alarm
horn will sound and the makeup complete light will flash at 2 Hz. The top drive will stop
and the top drive brake will engage. Silence the horn and return the mode switch to the
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spin position. Return the mode switch to the drill position. Restore the program to the
original logic. Use the breakout mode to break out the pipe.


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Date _______________________________________________


4.4 Breakout Mode

4.4.1 Breakout Completes
Follow the procedures for spin in and makeup to make up a pipe. Lock the handling ring
and engage the grabs. Place the mode switch in the 'breakout' position. The torque
should ramp up and the pipe should break out. The grabs should release and the grabs
pushbutton light will go out. After the pipe breaks out, it will spin out at spin speed. The
torque set point should be reduced to spin torque. Return the mode switch to the 'drill'
position. The grabs pushbutton should flash at 1 Hz. Push the grabs pushbutton to reset
the grabs.

4.4.2 Breakout Fails
To test breakout failure, reprogram timers T235 and T236 in the PLC (FC27 network 5)
from 5 seconds to 250 milliseconds. Follow the procedures for spin in and makeup to
make up a pipe. Lock the handling ring and engage the grabs. Place the mode switch in
the 'breakout' position. The torque set point should begin to ramp up to maximum for of
a second. t will then ramp back down to zero. Quickly (within 2 seconds) return the mode
switch to drill and back to breakout. No second breakout attempt should occur. Wait five
seconds. Return the mode switch to 'drill' and back to 'breakout'. The top drive should
attempt another breakout and fail again. Reprogram the timers for 5 seconds. Attempt
another breakout. The pipe should breakout. Return the mode switch to 'drill' mode.


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Date _______________________________________________




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5 BRAKE AND PIPE HANDLING EQUIPMENT

5.1 Drill Motor Brake

5.1.1 Brake Modes
Perform brake mode tests with the top drive on and in drill mode with the throttle in the zero
throttle position.

5.1.1.1 Brake Off
Place the brake mode switch in the 'off' position. The brake solenoid should be de-
energized and the brake light should be off.

5.1.1.2 Brake Auto
Place the brake mode switch in the 'auto' position. The brake solenoid should energize
and the light should illuminate. Rotate the throttle off zero. The solenoid should de-
energize and the light should turn off. Return the throttle to zero. The brake solenoid
should energize and the light should illuminate.

5.1.1.3 Brake On
Place the brake mode switch in the 'on' position. The brake solenoid should energize and
the light should illuminate. Rotate the throttle off zero. The brake should remain energized
and the brake on light remains on. Return the throttle to zero. Return the brake mode
switch to the 'auto' position.


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Date _______________________________________________


5.2 IBOP
Perform BOP tests with the top drive on and in drill mode with the throttle in the zero
throttle position.

5.2.1 IBOP Open
Place the BOP switch in the 'open' position. The BOP open solenoid should come on for
eight seconds. After the eight seconds, place the BOP switch in the 'reset' position.
Return the switch to the 'open' position. The BOP open solenoid should come on for eight
seconds. After the eight seconds, place the BOP switch in the 'reset' position.
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5.2.2 IBOP Close
With the mud pump throttles closed, place the BOP switch in the 'close' position. The
BOP close solenoid should come on for eight seconds and the BOP close light should
flash at 1 Hz for eight seconds. After the eight seconds, the BOP close light should be
steadily illuminated and the BOP close solenoid should de-energize. Now open one of the
mud pump throttles. The BOP open solenoid will energize for eight seconds and BOP
close light will flash rapidly (2 Hz). Close the mud pump throttle. The BOP close solenoid
should come on for eight seconds and the BOP close light should flash at 1 Hz for eight
seconds. After the eight seconds, the BOP close light should be steadily illuminated and
the BOP close solenoid should de-energize. Place the BOP switch in the 'reset' position.
The BOP close light remains lit. Open one of the mud pump throttles. This time the BOP
close light remains lit and no BOP open command is issued. Return the BOP switch to
the 'close' position. The BOP open solenoid will energize for eight seconds and BOP
close light will flash rapidly (2 Hz). Close the mud pump throttle. The BOP close solenoid
should come on for eight seconds and the BOP close light should flash at 1 Hz for eight
seconds. After the eight seconds, the BOP close light should be steadily illuminated and
the BOP close solenoid should de-energize.




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Date _______________________________________________



5.3 Grabs

CAUTION: t is imperative that caution be observed when working with the grabs control
circuit. f the grabs are applied without a piece of drill pipe or a pup joint threaded on to the
saver-sub pin, the grabs will crush the threads on the saver-sub pin and damage them.


Pull the handling ring unlock pushbutton to unlock the handling ring. The handling ring
pushbutton should light. Pull the grabs pushbutton. The grabs solenoid should remain de-
energized and the grabs pushbutton should not light. Push the handling ring pushbutton.
The handling ring should lock and the unlock pushbutton light should go out. The grabs
engage solenoid should energize and the grabs pushbutton should light. Rotate the throttle
off zero. The grabs release solenoid should energize and the grabs engage solenoid
should de-energize. The grabs pushbutton should flash at 2 Hz and the drill stem should
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rotate. Return the throttle to zero. When the drill stem stops rotating, the grabs should re-
engage and the grabs pushbutton light should go steady. Finally, pull the handling ring
push button. The handling ring should not unlock and the grabs pushbutton should flash at
2 Hz. Push the grabs pushbutton. The grabs should release and the pushbutton will stop
flashing. Then the handling ring should unlock and the handling ring pushbutton should
light.


Verified_______________________________________________


Date _______________________________________________


5.4 Drawworks Clutch Solenoid

When the grabs are engaged a 24 VDC signal is sent to the drawworks clutch lockout
solenoid. The signal is removed when the grabs are released. Check this signal under
both engaged and released conditions.



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5.5 Handling Ring

5.5.1 Lock/Unlock
Push the grabs pushbutton to release the grabs. Push the handling ring pushbutton in to
lock the handling ring. The handling ring lock solenoid should energize and the handling
ring pushbutton light should go out. Pull the handling ring pushbutton out. The handling
ring unlock solenoid should energize and the handling ring should unlock. The handling
ring pushbutton should illuminate.


5.5.2 Spin Left/Right
Unlock the handling ring. Turn the handling ring spin switch to the left. The handling
should rotate left. Turn the handling ring spin switch to the right. The handling ring should
rotate right. Lock the handling ring. Turning the spin switch left or right should cause the
handling ring to try to spin in the appropriate direction even though the locking pawl holds it
in place.


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Date _______________________________________________


5.6 Link Tilt
Select each position (drill down, drill, neutral, mouse hole, racking) on the link tilt selector
switch. The links should rotate to the appropriate position.


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5.7 Counterbalance
There will be a pressure switch, wired normally open, located inside the top drive solenoid
junction box. The pressure switch will provide an electric feedback signal indicating when
the counter balance is centered. The pressure switch will be calibrated so that the normally
open contact will close at 50-PS increasing pressure. The contact closure will signal that
the counter balance is at the center position and will cause the blue counter balance
centered status light to energize. n addition, an audible alarm will sound for 1 second
when the center position is reached. When the counter balance moves above or below the
center position, the pressure switch contact will open causing the counter balance centered
status light to de-energize and the one second audible alarm circuit to reset.

The pneumatic signal to the pressure switch will originate from a pneumatic limit switch
located on the counter balance. The mechanical actuating lever on the limit switch will be
adjusted so that it is actuated when the counter balance is in the center position. When the
counter balance is in the center position the limit switch will send a pneumatic signal (full rig
air pressure 100-125 PS) down a hose to the pressure switch located inside the top drive
solenoid junction box. When the counter balance moves above or below the center
position, the target that contacts the limit switch actuating lever will disengage from the
switch allowing the limit switch to return to its normal state. When the limit switch returns to
its normal state, the pneumatic signal to the pressure switch will be vented down to 0 PS.


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Date _______________________________________________



5.8 Top Drive Hour Meter
Assign the top drive and rotate at 10 RPM. Observe the top drive hour meter at the
transfer panel long enough to assure it is incrementing. Stop the top drive.



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6 SIGNAL CONDITIONERS

6.1 Potentiometer Signal Conditioners (Control Console) (Type G438)
Before adjusting a signal conditioner, lock out the top drive at the transfer cabinet. This
type (G438) is used for the drill torque and makeup torque setting potentiometers. Set the
potentiometer connected to the signal conditioner to its zero level (fully counterclockwise).
Now adjust the zero potentiometer on the signal conditioner to get a 0 VDC reading at the
signal conditioner output. Next turn the torque setting potentiometer to full scale (fully
clockwise). Adjust the span potentiometer on the signal conditioner to get a 10 VDC
reading at the signal conditioner output. Repeat this process until the zero level and full
scale readings are stable and correct. This will take repeating the process several times.

6.2 Analog Signal Conditioners (Control Console) (Type G408)
Before adjusting a signal conditioner, lock out the top drive at the transfer cabinet. This
type (G408) is used to send throttle and reference signals between the TD control console
and the SCR driller's console. Disconnect the input to the signal conditioner and connect a
calibrated DC voltage source. Now adjust the zero potentiometer on the signal conditioner
to get a 0 VDC reading at the signal conditioner output. Next apply 10VDC to the signal
conditioner input using the voltage source. Adjust the span potentiometer on the signal
conditioner to get a 10 VDC reading at the signal conditioner output. Repeat this process
until the zero level and full scale readings are stable and correct. This will take repeating
the process several times.

6.3 Analog Signal Conditioners (Transfer Cabinet) (Type G408)
Before adjusting a signal conditioner, lock out the top drive at the transfer cabinet. This
type (G408) is used to send spare torque and speed signals for logging. Do not adjust
these signal conditioners unless they are connected to a signal user. Disconnect the input
to the signal conditioner and connect a calibrated DC 4-20mA current source. Also
connect a meter capable of reading DC milliamps in series with the output load. Set the
DC current source to inject 4MA into the signal conditioner input. Now adjust the zero
potentiometer on the signal conditioner to get a 4mA reading at the signal conditioner
output. Next apply 20mA to the signal conditioner input using the current source. Adjust
the span potentiometer on the signal conditioner to get a 20mA reading at the signal
conditioner output. Repeat this process until the zero level and full scale readings are
stable and correct. This will take repeating the process several times.

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