TD350P TOP DRIVE CARE AND OPERATING MANUAL. EPL-1493 (Rev. 01) PATTERSON DRILLING. For. Serial Number: 309 & 311

Transcription

1 TD350P TOP DRIVE CARE AND OPERATING MANUAL EPL-1493 (Rev. 01) For PATTERSON DRILLING Serial Number: 309 & 311 Document Number Printed in U.S.A

2 Top Drive CARE AND OPERATING MANUAL Model TD350P Top Drive Drilling System NOTICE The information contained in this document is subject to change without notice. NATIONAL OILWELL VARCO SHALL NOT BE LIABLE FOR TECHNICAL OR EDITORIAL ERRORS OR OMISSIONS CONTAINED HEREIN, NOR FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING FROM THE FURNISHING, PERFORMANCE, OR USE OF THIS MATERIAL. This document contains proprietary information, which is protected by copyright. All rights are reserved. No part of this document may be photocopied, reproduced or translated to another language without the prior written consent of National Oilwell Varco. Product names mentioned herein may be trademarks and/or registered trademarks of their respective companies. All rights reserved. Printed in the U.S.A. Model TD350P Top Drive Drilling System Document Part Number (EPL-1493) Document Revision (01) Document Number II

3 Document number EPL-1493 Revision 01 Section 1 SECTION 1 TABLE OF CONTENTS

4 Top Drive TD350P TOP DRIVE DRILLING SYSTEM Serial Numbers: 309, 311 Section Document Number 1. Table of Contents Introduction Safety Notices General Notices 3. General Operating Procedures Start-Up Procedures After Rig Up Power unit Start-up Top Drive Function Tests Connecting Elevator Links Setting Counterbalance Valves Torque Breakout Tool (TBT) Torque Setting Setting Torque Cylinder Pressures Setting Clamp Cylinder Pressures Using the TBT to Breakout Drill Stem Using the TBT to Make Up Drill Stem 4. General Operating Procedure Start-Up Troubleshooting Guide 5. Maintenance Recommended Maintenance Schedule Grease Washpipe Packing Replace Washpipe Packing Repair of Washpipe Packing Box Assembly Inspect Motor Case Drain Change Swivel Case Lubricating Oil Inspect Hoses and Fittings Inspect Fasteners Grease Upper Assembly Bearing Grease Link Adapter Compensator Adjust Link Adapter Alignment and Spacing Adjust Link Tilt Cylinder Clamps Inspect Link Tilt Cylinders Grease Link Cylinder Pivots Inspect Backup Wrench Tong Dies Inspect Torque Cylinders Document Number III

5 Top Drive TD350P TOP DRIVE DRILLING SYSTEM Serial Numbers: 309, 311 Section Document Number 5. Maintenance (continued) Inspect Rig Interface Mounting Bolts Inspect Track Hanger Assembly Certify Cable Hanger Assembly Inspect Pivot Arm Connector Pins and Bushings Grease Lifting Lugs Inspect Connecting Pins Change Auxiliary Power Unit Fill/Drain Filter Replace Fuel Level Sight Tube Drain Condensate From Fuel Tank Inspect Gearbox Oil Level Inspect Filter Indicators Replace High Pressure Filters Replace Return Filters Replace Charge Pump Filters Steam Clean Power Unit Document Number - IV

6 Document number EPL-1493 Revision 01 Section 2 SECTION 2 INTRODUCTION

7 Top Drive TD350P Introduction

8 Introduction This manual is published as a general guide for the normal care and operation of your NATIONAL OILWELL VARCO Top Drive. Because of the many factors, which normally contribute to the proper function or malfunction of the Top Drive, and not having complete knowledge of each factor or combination of factors, we cannot detail all facets of this subject. We therefore confine the scope of this presentation, and when situations encountered are not fully encompassed by complete and understandable instructions, these situations must then be referred to NATIONAL OILWELL VARCO. When other than routine maintenance or servicing is necessary, it can be most efficiently performed if the unit or primary component is removed from service to an area of adequate space where an overhead crane, hydraulic lift, bearing pullers, impact tools, shelter, etc., are available and readily accessible. The dimensions and tolerances specified in this publication are those desirable for the most efficient operations of the Top Drive. When components become worn beyond limits specified, they should be replaced. Improvements in design, engineering, material, production methods, etc., may necessitate changes in the Top Drive and result in inconsistencies between the contents of this publication and the physical equipment. NATIONAL OILWELL VARCO reserves the right to make these changes without incurring any liability or obligation beyond that stipulated in the purchase contract. THE PICTURES, PHOTOGRAPHS, CHARTS, DIAGRAMS, DRAWINGS, WRITTEN CONTENTS AND SPECIFICATIONS CONTAINED HEREIN ARE NOT TO BE CONSTRUED AS GIVING RISE TO ANY WARRANTY ON THE PART OF NATIONAL OILWELL VARCO. NATIONAL OILWELL VARCO MAKES NO WARRANTY, EITHER EXPRESSED OF IMPLIED, BEYOND THAT STIPULATED IN THE PURCHASE CONTRACT. The drawings, pictures and photographs may be of similar equipment and may not appear exactly like your product. The function and the operating instructions should be valid for your product

9 Introduction SAFETY NOTICES The following safety notices were compiled from the Care and Operation Manual and are presented here for quick and easy reference. Carefully review the Care and Operation Manual to insure that all safety concerns are fully understood. DANGER Items that can result in personal injury are preceded by DANGER warnings. CAUTION Items that can result in equipment damage are preceded by CAUTION warnings. Although CAUTION warnings are noted for potential equipment damage, personal injury is always a possibility and must be taken into account. DANGER To avoid electric shock, only qualified electricians should connect electrical power to the Bowen TD35OP Top Drive. Keep personnel clear of extended elevators at all times as severe personal injury could result if the elevators dropped rapidly. Do not drain swivel oil after unit has been in prolonged operation. The temperature of the oil may be as much as thirty (30) degrees higher than the exterior of the swivel case and drive casing. Do not rotate the pipe handling system when greasing the upper assembly bearing as severe personal injury could result. Do not operate top drive when greasing washpipe packing as personal injury could result. CAUTION The elevators and links will move forward abruptly. Insure that the elevator has free travel beyond the mouse hole. Do not have the speed set above 25 rpm, as smaller drill pipe tool joint connections may over torque. Do not use clamp pressures greater than is required for the tool joints that are being run, as backup clamps may damage the tool joint leading to connection failure during operation. The kelly valve actuator weighs approximately 200 pounds and must not be handled without a suitable lifting device. Do not over tighten the link adapter compensator adjustment nut, or the link adapter will not seat against the load collar while loaded and severe equipment damage could result

10 Introduction GENERAL NOTICES NOTE The Bowen TD350P Top Drive requires 110 VAC, 1OA, 60 Hz electrical power to operate. The auxiliary power unit requires 440 VAC, 20A, 60 Hz, 3-phase to operate. Care must be exercised to insure that the electrical hookups are in accordance with the following wiring diagram (see figure 1). The Bowen TD35OP Top Drive requires a minimum 100 psi air supply to operate. Do not operate system when air supply is below 100 psi as pressure fluctuations can affect overall system performance. Insure all hydraulic lines are connected between the top drive and power unit. Insure that the Motor Case Drain is connected first. Insure air supply line is connected to engine starter. Controls and indicators in the following procedures are identified by Bold Faced Type and are listed as they are marked on the unit. 110 VAC IN

11 Document number EPL-1493 Revision 01 Section 3 SECTION 3 GENERAL OPERATING PROCEDURES

12 Top Drive TD350P General Operating Procedures

13 General Operating Procedures START-UP PROCEDURE FOR TD35OP AFTER COMPLETION OF RIG UP Due to the various configurations available for the Bowen Model TD35OP Top Drive, some component locations may be different from what is called out in this Stan-up and Maintenance Guide. The components still function the same; only the location is different. POWER UNIT START-UP 1. Observe Supply Air Pressure gauge on local control gauge panel (see figure 2) to verify steady 100 psi (minimum) air supply. 2. Switch Power switch to 110 VAC Line In and confirm AC supply by observing the 110 VAC Line In and the Low Charge Pressure indicator lights (see figure 3). If power is available, these lights will be lit. NOTE: The TD35OP has an uninterruptible power supply (UPS) backup that automatically kicks in if control power is ever lost to the power unit. The system is provided with an OFF switch when control power is disconnected to prevent power drain on the UPS. 3. Insure all hydraulic ball valves are in their normal operating condition as indicated by the individual valve labels. NOTE: Valves labeled N CLOSED are normally closed during operations and valves labeled N OPEN are normally opened during operations. 4. Check to be certain the air intake flapper valves on the engine are in the open position and that the AMOT control has been reset. 5. Shift the three position Engine Speed selector switch on the local junction box to Idle (see figure 3). 6. Shift the three position Local Control-Start-Remote Control (L-S-R) selection switch on the local junction box to Start

14 General Operating Procedures FIGURE 2 Local Control Box FIGURE 3 Electrical Wiring Diagram 7. Be certain all personnel are clear and then depress the engine Start button on the engine gauge panel (see figure 4) until the engine starts. Verify that the Low Charge Pressure light goes out and that charge pump pressures stabilize around 475 psi (see figure 3). NOTE: Refer to engine operator s guide if engine fails to start 8. Switch L-S-R selection switch to Local Control and verify that the indicator light is lit. 9. Reduce the throttle air regulators to 0 pressure (see figure 2). The regulators are clearly identified for 1800 RPM and 2100 RPM engine speed settings. They are located on the local control gauge panel just above the junction box. Reduce the air pressure by pulling out on the valve lock and rotating knob counter clockwise. 10. Shift the engine speed selector switch to the 1800 RPM position

15 General Operating Procedures Start Button FIGURE 4 Engine Gauge Panel 11. Return to the 1800 rpm throttle regulator and slowly increase air pressure, as indicated on the gauge directly above the pressure regulator, until the engine is at 1950 rpm as indicated on the engine tachometer located on the engine gauge panel. Push in the pressure regulator valve lock. 12. Shift engine speed selector to Idle and then back to 1800 RPM to insure that pressures are correct and engine speed maintains 1950 rpm. If engine speed is not 1950 rpm, repeat steps 11 and 12. NOTE: When initially setting the engine speed, it will be necessary to fine tune the regulator to consistently get 1950 rpm. Insure that the engine consistently reaches 1950 rpm during these steps. If the engine speed is below 1900 rpm, top drive operations will be severely affected. 13. Shift the engine speed selector switch to the PM position. 14. Repeat steps 11 and 12 for the 2100 rpm regulator, but set engine speed to 2250 rpm

16 General Operating Procedures FIGURE 5 Driller s Remote Control Console NOTE: When initially setting the engine speed, it will be necessary to fine-tune the regulator to consistently get 2250 rpm. Insure that the engine consistently reaches 2250 rpm during these steps. If the engine speed is below 2200 rpm, top drive operations will be severely affected. 15. Shift the engine speed selector switch to the Idle position. 16. Insure that the following remote console controls are in the listed position (see figure 5): Speed:... At zero and pushed in Drill Torque Limits:... 0 Engine Speed:.. Idle Makeup Torque Limits:. 0 TD Motor Brake:.... Set Emergency Stop:. Pulled out 17. Shift the mode selector switch from local control to remote control and verify that the Remote Control Enable light is lit (see figure 4). If the indicator fails to light, check the remote console to see if the Control OK light is lit (see figure 5). If Control OK is lit, then the bulb needs to be replaced on the remote control enable indicator. NOTE: If both lamps fail to light refer to troubleshooting section in this manual

17 General Operating Procedures TOP DRIVE FUNCTION TESTS 1. Raise the top drive to a position that allows the elevators to clear the floor. 2. Set the Engine Speed selector switch to 1800 and verify the engine accelerates to 1950 rpm. Switch to 2100 and verify that engine speed increases to 2250 rpm. Return the switch to Position the Motor Brake selector switch to Set. 4. Position Drilling Torque Limit to Slowly increase swivel speed by rotating the throttle control knob counter clockwise. The stem should not rotate. Return throttle to Zero. 5. Once verified the brake is functional, shift the Motor Brake switch to Release and shift engine speed to Idle. 6. Push the Emergency Stop button. After confirming the engine is stopped, repeat steps 1 through 17 for power unit start up and reset intake flappers and AMOT controller. 7. Shift the Kelly Valve switch to the Close position. The upper kelly valve should close. Physically verify the kelly valve is closed by looking inside the drill stem with a flashlight or by inserting a rod long enough to reach the valve ball. 8. Shift the Kelly Valve switch to the Open position, and observe the indicator. Physically verify the kelly valve is open by looking inside the drill stem with a flashlight or by inserting a rod long enough to reach the valve ball. 9. Shift the Reposition switch to the left. The pipe handler assembly should rotate. Allow one complete revolution

18 General Operating Procedures FIGURE 6 Mousehole Position Reflect Degree of Travel Connecting Elevator Links: 10. Attach links to link adapter and raise top drive until links are hanging free. 11. Center link cylinders by bumping link control to Center position. 12. Position link clamps onto links insuring that rod clevis pin holes are centered in the clamp slots. 13. Install clamp pins and tighten clamp bolts. 14. Shift the Reposition switch to the right. The pipe handler should rotate the opposite direction. 15. Rotate the pipe handler so that the backup wrench torque tube is towards the mouse hole, (see figure 6) and engage the Link Tilt cylinder lever to the mouse hole position by bumping the lever to the MH position

19 General Operating Procedures CAUTION The elevators and links will move forward abruptly. Insure that the elevator has free travel beyond the mouse hole. DANGER Keep personnel clear of extended elevators at all times as severe personal injury could result if the elevators dropped rapidly. Setting Counterbalance Valves: The following procedure is to be used to set the link tilt cylinder control manifold counter balance valves. A. With the elevators extended, loosen jam nuts on counterbalance valves. B. Back out counter balance valve adjustment screw until one cylinder begins to extend and elevators begin to drop. C. Screw in on the adjustment screw until the cylinder just stops extending. D. Repeat steps B and C for the second counterbalance valve. E. Tighten valve jam nuts. 16. Center elevator by bumping the Link Tilt control switch to the Center position. When the elevator has traveled approximately half way to the center position, bump the switch to the MH position. The elevator should stop movement and maintain position. 17. Bump the Link Tilt lever to the Center position. 18. Rotate the pipe handler so that the backup wrench torque tube is away from the mouse hole (see figure 7). 19. Bump the Link Tilt lever to the FB position. Once full travel has been reached, center the elevator. NOTE: The link cylinders will automatically center after the sequence completes. The sequence Is timed and centering may not be immediate

20 General Operating Procedures FIGURE 7 Fingerboard Position Reflect Degree of Travel 20. Set Make Up drill torque to 6,000 ft lb and insure that swivel throttle is at Zero and in the forward position. Set engine speed to 1800 rpm. Push the Make Up button and the stem on the top drive should rotate to the right. Verify that the rotating speed is satisfactory to the driller. If the speed needs to be changed, adjust the Swivel Make Up Speed control switch, located on the local control panel on the power unit, until a satisfactory speed is attained. NOTE: Do not have the speed set above 25 rpm as smaller drill pipe tool joint connections may over torque. 21. Verify that the backup wrench is below the saver sub pin threads and will not grip the threads

21 General Operating Procedures 22. Press and release the Break Out button. Allow the sequence to cycle completely. Verify that the following steps occur: A. The back up wrench clamps extend. B. The shifter cylinder retracts and the torque sleeve engages drill stem. C. The torque cylinders extend. The drill stem will rotate approximately 20 degrees. D. The shifter cylinder will extend and the torque sleeve will disengage from the drill stem. E. The back up wrench clamps will retract and the torque cylinders will reset. All these functions are computer controlled and are not adjustable by the operators. During this sequence, all other control functions, except Emergency Stop, are locked out and are inoperable. The Bowen TD35OP Top Drive is now ready for full operations. TORQUE BREAKOUT TOOL (TBT) TORQUE SETTING The TD35OP Top Drive can generate approximately 27,000 ft lbs of torque. This is insufficient to break out or make up the drill stem component (upper kelly valve, lower kelly valve and saver sub) connections in the event that one or more of these components must be replaced. The following procedure is to be used to use the TBT to break out or make up sections of the drill stem. CAUTION Do not use clamp pressures greater than is required for the tool joints that are being used as backup clamps may damage the tool joint leading to connection failure during operation

22 General Operating Procedures Make Up Control Gauge Clamp Control Gauge Clamp Control Valve Make Up Control Valve PRV1 DCV2 DCV1 PRV2 FIGURE 8 Auxiliary Power Unit Control Stand Setting Torque Cylinder Pressures: A. Using the Torque Pressure Graph (see figure 9), find the desired torque along the left side and read across the graph to the diagonal line. Read down from the line to the pressure setting required to achieve the desired torque. B. Close DCV1 (see figure 8) and manually actuate the make up control valve. Record the pressure measured on the Auxiliary Control Panel Make Up pressure gauge. This pressure will be used to reset the manifold when resuming operations. C. Using a 9/16" wrench, loosen the jam nut on the pressure relief valve marked PRV2. D. Actuate the make up valve lever and slowly rotate the adjustment knob on PRV2 until the desired pressure is achieved. Tighten the jam nut and actuate the lever once more to verify the setting. E. Open DCV1. The torque cylinders are now set to generate the desired torque

23 General Operating Procedures FIGURE 9 Torque Pressure Setting FIGURE 10 Clamp Pressure Setting Setting Clamp Cylinder Pressures: F. Using the Clamp Pressure Graph above (see figure 10), identify the diagonal line for the tool joint GD, then find the desired torque along the left side and read across the graph to the proper diagonal line. Read down from the line to the pressure setting required to hold the desired torque. G. Close DCV2 and manually actuate the clamp control valve. Record the pressure measured on the Auxiliary Control Panel Clamp pressure gauge this pressure will be used to reset the manifold when resuming operations. H. Using a 9/16" wrench, loosen the jam nut on the pressure relief valve marked PRV1. I. Actuate the clamp control valve lever and slowly rotate the adjustment knob on PRV1 clockwise until the desired pressure is achieved. Tighten the jam nut and actuate the lever once more to verify the setting. J. Open DCV2. The backup wrench is now set to make up or break out the desired connection

24 General Operating Procedures Using the TBT to Breakout Drill Stem: K. Insure that the Pipe Handler control (located at the power unit junction box) is set to Break. L. Set clamp cylinder pressures in accordance with steps G through J above. NOTE: The torque cylinders do not require setting as they will produce as much torque as is required (up to 60,000 ft lb) to break out the connection. M. At the drill floor, remove the stabbing bell and then position a stand under the back up wrench and lower the top drive until the back up wrench jaws can adequately engage the saver sub. N. Remove slack from carrier chain and then raise top drive until weight of the back up wrench is carried by the chain. 0. Press the breakout switch and breakout the connection. Repeat until the connection can be easily unscrewed. P. Lower the top drive until the carrier chain can be removed and then raise the top drive until the back up wrench sets on the torque tube stops. Remove the saver sub. Repeat steps M through P for each component that must be removed. NOTE: The upper kelly valve actuator must be removed before removing the upper kelly valve. CAUTION The kelly valve actuator weighs approximately 200 pounds and must not be handled without a suitable lifting device

25 General Operating Procedures Using the TBT to Make Up Drill Stem: A. Set TBT torque and clamp cylinder pressures in accordance with steps A through J of TBT torque setting procedures. B. Switch the Pipe Handler control to Make. C. Remove stabbing bell. D. Install component onto drill stem and, using a chain wrench, tighten hand tight. E. At the drill floor, position a stand under the back up wrench and lower the top drive until the back up wrench jaws can adequately engage the component. F. Remove slack from carrier chain and then raise top drive until weight of the back up wrench is carried by the chain. G. Press the Breakout switch and make up the connection. Repeat until the connection is properly torqued. If additional items must be installed, proceed with step H, otherwise skip to step J. H. Lower the top drive until the carrier chain can be removed and then raise the top drive until the back up wrench sets on the torque tube stops. I. Repeat steps D through G for each component that is to be made up. J. Lower the top drive until the carrier chain can be removed and then raise the top drive until the back up wrench jaws are at the proper height to adequately engage the stand tool joint connection. K. Repeat steps A through J of the TBT torque setting procedures to reset the TBT to the pressure settings required for the particular tool joint that will be used. L. Return the Pipe Handler control to the Break position. NOTE: The unit is not shipped with a preset torque setting. Before first connection is made, insure that the settings are correct for the size and type of tool Joint connections that will be used

26 Document number EPL-1493 Revision 01 Section 4 SECTION 4 TROUBLE SHOOTING

27 Top Drive TD350P Troubleshooting

28 TROUBLESHOOTING START UP TROUBLESHOOTING GUIDE Conditions (following start up procedure) Troubleshooting the Problem Solution HPU won t start. Check that Air Supply If it is not, turn it ON, Pressure is ON. and verify that sufficient pressure is being supplied. See System Pressure Gauges on local panel to ensure a minimum of 100 psi is available before cranking engine. Check that 3 position Shift Selector Switch START-LOCAL-REMOTE to START position. switch is in START position. Check that 110 V AC connection is okay. Check that 110 V AC switch is on 110 VAC position. Check that Air Intake Flapper Valves on the HPU engine are OPEN. Check that the Emergency Kill Button on the Driller's Remote Console is pulled out. Verify 110 V AC power cord is installed properly and is live. If it is in UPS position change it to 110 VAC. If flappers are closed, close the main air line and open dump valve on small air receiver tank. Manually reset flapper valve linkage and make sure AMOT control is RESET. If it is not, twist and pull out to RESET If any of steps do not alleviate the problem, please contact the nearest service center

29 TROUBLESHOOTING Conditions (following start up procedure) Troubleshooting the Problem Solution HPU started, If pressure differences Change all charge pump but hydraulic charge are significant, check that filters. pump pressures Charge Pump Oil show significant, Filters are not clogged. Contact the nearest differences from each other. NOTE All gauges should be within 10 psi total difference. Please contact the nearest service center for the necessary adjustments. service center. HPU started. Check for air flow Relocate the Power Charge pressure obstructions to HPU s Unit where the heat is okay, hut hydraulic heat exchanger. exchanger fans do not oil is above 150 have an obstructed air flow path. Ensure Normally OPEN valves to the heat exchanger are OPEN and NORMALLY CLOSED VALVES ARE CLOSED. Check oil level on reservoir. Level should no lower than midway of lower glass on gauge. upper sight level gauge. Reset valve positions. Increase oil level to midway of lower glass be on upper sight level way Ensure 1000 psi maximum is on the gauge at pump 5 while fans are ON. If higher, reset fan s relief to 1000 psi, If any of steps do not alleviate the problem, please contact the nearest service center. Pull relay R5 from its socket inside the control junction box on the Power Unit. If the fans come on automatically, leave the relay removed and contact a service immediately!

30 TROUBLESHOOTING Conditions (following start up procedure) Troubleshooting the Problem Solution HPU is okay, Check that controls on Set the 3-position Start but can t get power Driller s Remote Console Local-Remote switch to Driller s Remote are in neutral positions to its Remote position Console. Check that Set Throttle knob OFF 3-position Start- set speed switch to IDLE Local-Remote switch Reset Emergency is on REMOTE Kill. position. Check connections to the Verify that control cable Driller s Remote Console. is properly connected. Clean female and male If any of these step does connectors thoroughly. not alleviate the problem, please contact the nearest service center. HPU is okay. Check umbilical hose Check that the number- Driller s Remote connections. Lines could ing scheme on the hoses Console is okay, have been improperly is the same and that but cylinders on installed. numbers such as 6 and 9 PHS system are were not confused. actuating differently to each other. If the step does not alleviate the problem, please contact the nearest service center. HPU is okay. Check calibration on Loosen jam nuts on Driller s Remote counter balance valves, counter balance valves, Console is okay, retract cylinders to the but cylinders on If the step does not Mousehole position, PHS system do not alleviate the problem, and turn valves counter maintain position please contact the clockwise with an Allen when at Mousehole nearest service center. wrench until the cylinand unloaded (no ders maintain position. pipe in elevators). Tighten jam nuts

31 TROUBLESHOOTING Conditions (following start up procedure) Troubleshooting the Problem Solution HPU is okay. Check proper position Set the switch to Break Driller s Remote on Make-Break mode for breakout of connec- Console is okay. selector at HPU. tions. Set switch to Cylinders on PHS Make for make up are okay, of saver sub and kelly but breakout tool stems. makes up rather than breaks out Check umbilical hose Check that the numberhoses connections. connections. Lines could ing scheme on the have been swapped is the same and that when connecting. the Torque A hose is not swapped with the If any of stops do not Torque B hose. alleviate the problem, please contact the nearest service center. HPU is okay. Check for air in the Bleed air by actuating Driller s Remote system. the Repositioner in Console is okay. one direction for several Cylinders on PHS minutes until observing are okay. a better behavior Breakout tool is okay, Check umbilical hose Break improperly made but Repositioner connections. Look for up connections and will not go 360 improper made up quick make them up all the in both directions, couplers and improper way. Lock couplers. numbering scheme. Repositioner speed Turn speed control control valves are valves clockwise one screwed in too far. turn and retest. Continue adjusting until desired speed is achieved in both directions. Pipe handling package Readjust swivel away rubs track. from the track and recheck well center. If any of steps do not alleviate the problem, please contact the nearest service center,

32 TROUBLESHOOTING Conditions (following start up procedure) Troubleshooting the Problem Solution HPU is okay. Check that Engine Set engine speed to Driller s Remote Speed is at 1800 rpm rpm or 2100 rpm. Console is okay. Check that Drill and Set Drill Torque Limit Cylinders on PHS Make Up Torque Limits to the proper limit. Set are okay. are not zero. Make Up Torque Limit Breakout tool is okay, to the proper limit but Top Drive does not rotate the drill Check that Brake switch Set Brake switch to string. is on Release position. Release. Check that Repositioner circuit is not holding pressure. again to rotate the Top Reset throttle to zero and actuate Repositioner until it moves and try Drive. If any of steps do not alleviate the problem, please contact the nearest service center. HPU is okay. Check Drill Limit Reset Drill Limit settings Driller s Remote settings. Increase and increase Speed Console is okay. rotational Speed lightly lightly with the Throttle PHS is okay. with the Throttle knob. knob. Breakout tool is okay. Top Drive is drilling Decrease String Weight. Lift weight off string okay, reducing Torque require until torque increases If the step does not ments until swivel and the Torque Limit alleviate the problem, rotates. light comes on. please contact the nearest service center

33 TROUBLESHOOTING Conditions (following start up procedure) Troubleshooting the Problem Solution HPU is okay. Check for 110 V AC Reconnect 110 V AC line Driller s Remote supply. to 110 V AC supply. Console is okay. PHS is okay. Check Air Supply. Reconnect Air Hose or Breakout tool is okay, open Supply Valve. but engine rpm reduces considerably Check 1800 Throttle Increase pressure tightly while drilling. Air Pressure at HPU. with air regulator until rpm on HPU engine reaches about 2050 rpm without swivel rotating and throttle at zero position. Check Fuel Filters on HPU. Replace fuel filters. HPU is okay. Check engine air Disconnect Emergency Driller s Remote flappers to confirm Kill hose from cylinder Console is okay. emergency kill initiated on air flaps. Screw in PHS is okay. by overspeed kill system. slightly on the over Breakout tool is okay. speed safety device Top drive is drilling NOTE: adjustment screw. Test okay, Do not emergency kill the setting by shifting but HPU shuts down repeatedly while at the Local/Start/Remote when setting engine throttle. Damage to engine switch to Local. Set the speed at 2100rpm. will result Engine Throttle and switch to 2100 and increase the 2100 rpm regulator until the shutdown device engages by releasing air through the disconnected hose at 2400 rpm. Set the Engine Throttle switch to Idle and reconnect hose. Decrease setting on 2100 rpm Air Regulator, switch the Throttle setting to If any of steps do not 2100 rpm, and reset alleviate the problem, Engine Throttle to 2250 please contact the rpm with swivel not nearest service center rotating

34 Document number EPL-1493 Revision 01 Section 5 SECTION 5 MAINTENANCE

35 Top Drive TD350P Maintenance

36 MAINTENANCE RECOMMENDED MAINTENANCE SCHEDULE Intervals Calendar Daily Weekly Monthly Yearly Hours washpipe assembly (1) * G washpipe packing (2) R motor case drain (3) I I swivel case oil (4) I R hose and fittings (5) I I fasteners (6) I upper assembly bearing (7) G link adapter compensator (8) G link adapter (9) I link cylinders (10) G I backup wrench (11) I torque cylinder (12) I rig interface mounting bolts (13) I track hanger assembly (14) I I pivot arm pins & bushings (15) I lifting lugs (16) G connecting pins (17) I APU filter (18) AS REQUIRED fuel level sight tube (19) I fuel tank (20) I gearbox oil level I filter indicators (22) AS REQUIRED high pressure filters (23) AS REQUIRED return filters (24) AS REQUIRED charge pump filters (25) AS REQUIRED steam clean power unit (26) I engine Refer to OEM Engine Operator s Manual * Numbers in parentheses refer to items in text, pages Codes: G Grease I Inspect, service, correct, replace, if necessary R Replace

37 MAINTENANCE MAINTENANCE PROCEDURES FOR TD35OP TOP DRIVE DRILLING SYSTEM This section was developed to provide the operator with specific guidelines that are designed to maximize the performance and operational life of the unit and minimize downtime PREVENTIVE MAINTENANCE This section describes the various procedures required to insure that the Bowen TD35OP Top Drive performs to its full capabilities. This section will provide a schedule for maintenance actions based on recommended industry practices and manufacturer s requirements. Each action is fully described including the tools necessary, parts necessary and step-by-step procedures to complete the maintenance action

38 MAINTENANCE Grease Fitting Spacer Holding Screw FIGURE 1 Lower Packing Nut (1) GREASE WASHPIPE PACKING Tools Required: Hand pump grease gun Parts Required: General purpose grease NOTE: The washpipe packing can be greased without shutting down the power unit. Caution must be exercised to insure that swivel does not rotate during greasing to prevent injury to service personnel. PROCEDURE: A. Secure operations. B. Set engine speed to idle and engage swivel brake. C. Connect grease gun to lower packing nut grease fitting (see figure 1) and inject approximately 10 strokes of grease into the lower packing. D. Disconnect grease gun, release swivel brake and slowly rotate swivel for 5 revolutions to allow grease to distribute throughout packing before applying pressure. E. Resume operations

39 MAINTENANCE (2) REPLACE WASHPIPE PACKING Tools Required: Rubber mallet, packing nut wrench, Allen wrench, snap ring pliers, parts list SSS-1 sheet 67, assembly drawing /009 Parts Required: Complete washpipe packing set, washpipe 0-rings, packing lubricant and washpipe NOTE: To reduce downtime during washpipe packing replacement, the unitized washpipe packing used on the TD35OP Top Drive can be removed as a complete unit. A spare washpipe assembly can then be installed and operations can be resumed. The old washpipe can then be overhauled during normal daily operations. PROCEDURE: A. Secure top drive operations, close upper and lower kelly valves, secure power unit and engage swivel brake. B. Strike the washpipe packing nut in a clockwise direction until it turns freely. Back the washpipe packing nut completely off the upper stem. Repeat the procedure for removal of the washpipe holding nut, and back it completely off the gooseneck. The complete assembly may now be removed. CAUTION The complete washpipe packing box assembly weighs approximately 100 pounds and should not be lifted without suitable lifting devices. NOTE: The lower packing nut will slide off of the washpipe. Exercise care when removing the washpipe assembly. C. Install replacement box assembly and tighten packing nuts. D. Grease packing to insure proper seal that the packing has a proper seal on the washpipe. E. Resume operations

40 MAINTENANCE Holding Nut Washpipe Lower Packing Nut 0-Ring (2 required) Packing Holding Ring Packing Packing Spacers REPAIR OF WASHPIPE PACKING BOX ASSEMBLY (Refer to figure 2 above for component familiarization) FIGURE 2 Washpipe Packing Assembly Components A. Remove the snap ring on the washpipe and remove the washpipe holding nut from the washpipe. B. Remove the washpipe from the washpipe packing nut. Inspect the washpipe for wear. Replace the washpipe if it shows signs of wear, noted by scoring or wearing away of the surface. Failing to properly grease the washpipe packing during operation will significantly increase the chances of excessive wear of the washpipe. C. Remove the packing from the washpipe holding nut by turning the nut upside down and tapping it several times on a piece of soft wood. The washpipe holding ring will break free and allow itself to be removed with the packing attached. Remove and discard the packing from the holding ring. D. Completely back out the spacer holding screw in the washpipe packing nut and remove the grease fitting. Using the rubber mallet, tap the top of the nut to break the packing spacers free. Once free, the spacers can be easily removed from the packing nut. Remove and discard the packing from the spacers

41 MAINTENANCE E. Clean and inspect each nut. Replace if wear or thread galling is evident. F. Apply a coating of grease to the ID of the holding nut. Install one (1) piece of packing into the holding ring. Liberally apply grease to the packing and holding ring and install into holding nut. Insure that the packing facing is correct. G. Apply a coating of grease to the ID of the lower packing nut. Install one (1) piece of packing into each packing spacer. Liberally apply grease to each spacer and packing and install into packing nut in the opposite order as removed. Insure that the packing facing is correct. Install and tighten spacer holding screw and grease fitting. NOTE: Liberally greasing packing prior to installation will significantly increase the operational life of the packing. H. Insert un-slotted end of the washpipe into packing nut. Insert the slotted end of the washpipe into the holding nut. Install snap ring onto washpipe. I. Install one (1) 0-ring into the washpipe holding ring and liberally apply grease to hold it in position. J. Install one (1) 0-ring into the lower washpipe packing spacer and liberally apply grease to hold it in position. The washpipe assembly is now ready for installation onto the top drive. If the assembly is not immediately placed in service, then it should be wrapped in heavy kraft paper or a heavy plastic

42 MAINTENANCE (3) INSPECT MOTOR CASE DRAIN Tools Required: Log sheet (copies of log sheet are available from Bowen Technical Sales and Service) Parts Required: None PROCEDURE: A. With unit in operation, monitor swivel motor case pressure gauge and case drain flow meter (on HPU). Pressure should not exceed 60 psi and flow should be less than 15 gpm. B. Monitor and log pressures and flows every six (6) hours. NOTE: If pressure exceeds the recommended rating, check the motor case drain filter to verify that the filter is not bypassing and causing excessive back pressure in the motors. If flow exceeds recommended values, it is a early indication that the motors are in need of repair and should be scheduled for overhaul at the first opportunity. C. Compare present readings with previous recordings. This is the simplest method to determine if a trend is developing that may lead to unit failure. (4) CHANGE SWIVEL CASE LUBRICATING OIL (Replace after 150 hours on initial break in and every 1000 hours thereafter.) Tools Required: Wrench, lock wire pliers, lock wire (safety wire), thread sealant, funnel, 1 hose, waste oil storage tank, oil transfer pump Parts Required: 10 gallons Bowen Gear Lube or equivalent

43 MAINTENANCE FIGURE 3 Swivel Fill Plug Fill Plug FIGURE 4 Swivel Drain Plug Case Drain Plug PROCEDURE: A. Secure operations. B. Position pipe handling package so that easy access is obtained to the case drain plug. C. Secure power unit and engage swivel brake. D. Loosen and remove fill plug (see figure 3). E. Position funnel with drain hose under the drain plug (see figure 4). Insure free end of hose is secure in the storage tank. NOTE: The swivel case can hold up to ten (10) gallons of oil, allowing the oil to heat up prior to draining will reduce downtime. DANGER Do not drain oil after unit has been operating for a d extended period of time. The internal temperature of the case may be as much as thirty (30) degrees higher than the exterior of the case

44 MAINTENANCE F. Carefully remove the drain plug and allow oil to drain to the waste oil storage tank. Inspect magnetic drain plug for metal debris. NOTE: If a substantial amount of metallic debris is evident, schedule unit for complete inspection and overhaul at a qualified repair facility. Early correction of a potential problem will prevent failure during critical drilling operations. G. When oil has stopped flowing, apply a light coating of thread sealant to the drain plug and reinstall. H. Fill swivel case up to the fill plug. Due to the large quantity of oil, a small transfer pump will significantly speed up the process. I. Reinstall fill plug and safety wire both fill plug and drain plug. (5) INSPECT HOSES AND FITTINGS FOR WEAR AND TIGHTNESS Tools Required: Wrench, flash light Parts Required: None PROCEDURE: A. Visually inspect all hoses for wear. Replace any hose that exhibit excessive abrasive wear on their exterior cover (as indicated by exposed wire braid). B. Check all fittings for tightness and leaks, replace any fittings which leakage cannot be stopped by slight re-torquing

45 MAINTENANCE FIGURE 5 Proper Safety Wire Technique (6) INSPECT FASTENERS Tools Required: Lock wire pliers, diagonal cut pliers, torque wrench, safety wire Parts Required: None PROCEDURE: A. Inspect all fasteners for proper safety wiring. If any safety wire is broken, remove all loose wire. B. Re-torque bolts that have had safety wire removed. C. Install new safety wire (see figure 5). (7) GREASE UPPER ASSEMBLY BEARING Tools Required: Hand grease gun Parts Required: None PROCEDURE A. Attach grease gun to housing grease fitting and inject ten (10) strokes of grease into the bearing (see figure 6). B. Remove the grease gun and rotate pipe handling package for five (5) revolutions in each direction to distribute the grease throughout the bearing assembly. C. Repeat steps A and B one time

46 MAINTENANCE Grease Points L FIGURE 6 Upper Assembly Bearing (8) GREASE LINK ADAPTER COMPENSATOR Tools Required: Grease gun Parts Required: None PROCEDURE: The link adapter compensator assembly has twelve (12) grease location points that require greasing. Improper greasing can lead to improper link adapter operation which could lead to damage to the load collar and to the drill stem. Wear Pads: A. Attach grease gun to the wear pad and inject two (2) strokes of grease into the pad. B. Repeat step A for each of the 4 wear pads. NOTE: Do not loosen the Jam nuts on the alignment guides when greasing. Alignment Guides: A. Attach grease gun to the guide and inject two (2) strokes of grease into the guide. B. Repeat step A for each of the 8 guides

47 MAINTENANCE (9) ADJUST LINK ADAPTER ALIGNMENT AND SPACING Tools Required: Diagonal cut pliers, lock wire pliers, lock wire, 1 wrench, 9/16" wrench Parts Required: None PROCEDURE: A. Using a thickness gauge, check that the link adapter is approximately 1/8" off of the load collar (with no pipe in elevator) and visually inspect the gap between the link adapter bore and the drill stem outside diameter to insure that it is uniform along the whole circumference of the drill stem. If the link adapter is parallel to the drill stem and there is adequate clearance between the load collar and the link adapter, then no further action is required. If the link adapter is not parallel to the drill stem, or if there is inadequate clearance between the load collar and the link adapter, then continue with this procedure. Align Link Adapter to Drill Stem: B. Determine which way the link adapter must move to allow the adapter to run parallel to the drill stem: Adjustment may have to be forward/backward, side-to-side, or a combination. C. Once it is determined which way the adapter must be shifted, use the following chart to properly align the adapter (see figure 7)

48 MAINTENANCE A B Forward FIGURE 7 Link Adapter Compensator Adjust A moves top of adapter left Adjust B moves top of adapter right Adjust C moves bottom of adapter left Adjust D moves bottom of adapter right Adjust E moves top of adapter forward Adjust F moves top of adapter backward Adjust G moves bottom of adapter forward Adjust H moves bottom of adapter backward Proper alignment may require several attempts to get adequate clearances all the way around the drill stem. NOTE: To adjust in any direction, the opposite adjust must be loosened to allow for travel. After clearances are set insure that all adjustment points are tight. Recheck link adapter to load collar gap. If gap is less than 1/8" then proceed with step D

49 MAINTENANCE FIGURE 8 Thread Compensator Tension Nut Jam Nut Adjust Link Adapter Gap: D. Remove and discard cotter pin from adjustment shaft and loosen jam nut (see figure 8). E. Loosen the adjustment nut until tension is released. Tighten nut until the gap between the load collar and the link adapter is between 1/8" to ¼. NOTE: Do not over tighten the adjustment nut or the link adapter will not seat against the load collar while loaded and severe equipment damage may result F. Install new cotter pin. (10.1) ADJUST LINK TILT CYLINDER CLAMPS Tools Required: Wrench Parts Required: None PROCEDURE: Proper clamp position is required to prevent cylinder overloading and provide even lifting of the elevators when kicking out the drilling links. A. Center link tilt cylinders. B. Visually inspect that clamp pins are in the center of the clamp slots

50 MAINTENANCE C. If pins are not centered, loosen clamp bolts and reposition clamps to place the pins in the center of the slot. (10.2) INSPECT LINK TILT CYLINDERS Tools Required: Clean dry cloth Parts Required: None PROCEDURE: Clean off cylinder rods and visually inspect the cylinder rod ends for excessive leakage, nicks or pitting. During operations, periodically wipe down the cylinder rods. This will reduce the likelihood that dirt or other debris will bypass the cylinder wiper rings and damage the gland seals. If seal failure is suspected, replace seal or cylinder immediately. If the seal should fail while under load, severe personnel and equipment damage could result. Grease Points FIGURE 9 Link Cylinder Pivots (10.3) GREASE LINK CYLINDER PIVOTS Tools Required: Grease gun Parts Required: General purpose grease PROCEDURE: A. Attach grease gun to the pivot grease fitting and inject 2 strokes of grease into the pivot (see figure 9). B. Repeat step A for opposite pivot

51 MAINTENANCE (11) INSPECT BACKUP WRENCH TONG DIES Tools Required: Wrench Parts Required: Tong dies PROCEDURE: A. Position a support under the top drive and lower the top drive until all load is removed from the support chain. B. Unhook the support chain and slowly raise the top drive until the saver sub is clear of the backup wrench assembly. C. Clean and visually inspect the tong dies for excessive wear or other damage (see figure 10). Replace dies if excessive wear or any damage is noted. D. Lower top drive until saver sub is in proper position for back up wrench to securely clamp the drill pipe tool joint. E. Reconnect support chain to backup wrench and raise top drive. FIGURE 10 Backup Wrench Tong Dies, Top View

52 MAINTENANCE FIGURE 11 Torque Cylinders (12) INSPECT TORQUE CYLINDERS Tools Required: Inspection mirror, clean dry cloth Parts Required: None PROCEDURE: Clean off cylinder rods and visually inspect the cylinder rod ends for excessive leakage (see figure 11). NOTE: A slight coating of oil on the rod is acceptable and is required for proper lubrication of the cylinder rod seals. If seal failure is suspected, replace seal or cylinder immediately. If the seal should fail while under pressure, a potentially hazardous situation could develop. FIGURE 12 Rig Interface Kit Mounting Bolts

53 MAINTENANCE (13) INSPECT RIG INTERFACE KIT MOUNTING BOLTS TOOLS REQUIRED: Torque wrench Parts Required: None PROCEDURE: Using torque wrench, insure all fasteners are at the proper torque for the particular size and thread of bolt (see figure 12). Loose/over torqued fasteners will cause fatigue failure of the clamp bolts and could result in personnel injury or equipment damage in the event they should fail during operations. FIGURE 13 Track Hanger Assembly (14.1) INSPECT TRACK HANGER ASSEMBLY Tools Required: None Parts Required: None PROCEDURE: Visually inspect the track hanger assembly (see figure 13) to insure that all devises are tight and that there are no outward signs of possible fatigue or overload failure. Because the hanger assembly is the main load support for the tracks, failure of the hanger could result in severe personnel and equipment damage

54 MAINTENANCE (14.2) CERTIFY CABLE HANGER ASSEMBLY Tools Required: None Parts Required: None PROCEDURE: Send cable assembly yearly or if wear is evident to a certified testing facility for recertification for proper load capacity. FIGURE 14 Pivot Arm Connector Pins and Bushings (15) INSPECT PIVOT ARM CONNECTOR PINS AND BUSHINGS Tools Required: None Parts Required: None PROCEDURE: After rig down, visually inspect pivot arm bushings and connector pins (see figure 14) to insure serviceability. Replace any pins or bushings showing excessive signs of wear