MB03 0100
MB03 0100
MB03 0100
Client:
MAERSK
Project:
MAERSK RIG 44
Equipment: Equipment tag no.:
PTD - 500 AC
Document title:
MAINTENANCE INSTRUCTIONS
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Client: Maersk Project: Maersk Rig 44
Equipment: PTD 500 AC Date: 26-Sep-2005
Doc. no.: 100416-Z-BJ361-MB03-0100 Rev.: 0
Title: Maintenance Page: 2 of 99
TABLE OF CONTENTS:
1. MAINTENANCE ............................................................................................ 4
1.3 Cleaning.......................................................................................................................5
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Title: Maintenance Page: 3 of 99
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1. MAINTENANCE
1.1 General
The Portable Top Drive (PTD) designed to withstand the corrosive and hostile environment
in which it is located. It is however very important to follow the maintenance schedules to
ensure trouble free operation and lengthen operating time. The recommended practice for
Maritime Hydraulics maintenance chapter is based on API RP 8B Seventh Edition.
It is of great importance that the owner/user knows the top drive equipment and is familiar
with all its functions, guidelines and routines. This to ensure safe operation and maintenance
of the equipment.
Maintenance/inspection of the top drive system is divided into various categories, which is
described in maintenance instruction these are based on API RP 8B Seventh Edition.
WARNING Secure the area and the equipment prior to any maintenance
Possible Loss, of the equipment to avoid possible damage to personnel and
Injury or Death! equipment.
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Client: Maersk Project: Maersk Rig 44
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1.3 Cleaning
The PTD is designed to withstand the corrosive and hostile environment in which it is
located. However, it should be cleaned on a regular basis.
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User/owner of top drive equipment shall establish written procedures for inspection,
maintenance, repair and remanufacture of each item of equipment. Therefore these
inspections and maintenance procedures are meant as guidelines. This because the large
variation of environment and operation this equipment is used under.
WARNING Secure the area and the equipment prior to any of the guide
Possible Loss, lines and procedures are performed to avoid possible damage
Injury or Death! to personnel and equipment.
Care must be taken whenever working with PLC modules to prevent unexpected stop of the
CPU. Do not work with the PLC modules while the system is in operation. In general it is
recommended to only change components when the IC-10-0400 feed breaker S1 is switched
off.
All configuration switches and programming set points are shown on the respective loop
drawings. Refer to these drawings and specific component data sheet whenever components
are to be replaced
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Several components require special handling during replacement. This may include special
precautions in handling, setting of switches or transfer of software.
WARNING Top Drive system contain high voltages system. Care must be
Possible Loss, taken during handling, maintenance or other type of work on
Injury or Death! the equipment
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1. Check the guide rails for alignment. If guide rail is OK then continuo with alignment
checks of the top drive.
2. Set a drill pipe stand in the rotary, the box to be approx. 4 feet above the drill floor.
Check the vertical alignment of the stick-up in two directions (90q off each).
3. Lower the Top Drive down onto the stick-up. if the saver sub is off center of the
box more than 10 mm in any direction, the Top Drive has to be aligned.
4. The top drive can be adjusted side ways by adding or removing shim on the side
rollers. For adjustment in /out shim can be added or removed between the main frame
and the connection brackets. Adjust to correct alignment in both directions.
5. If the top drive needs vertically alignment, seen from the front/back the side rollers
must be shimmed with uneven amount diagonal from each other.
6. If the top drive needs vertically alignment, seen from the side. Uneven amount of
shimmed can be placed between the main frame and the connection bracket.
7. Re-Check the alignment with a single pipe screwed into the main shaft. If any
deviation, the guide rail or top drive has to be vertically aligned. The Top Drive has to
be aligned properly to avoid abnormal forces in the system and to ensure proper
functionality of the system.
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After the Top Drive has been installed and the service loops and mud hose
connected the following adjustments have to be made in the following order.
1) Connect the cylinder and chain between the traveling block and the top drive
2) The pressure adjustment for the rod side of the compensator cylinder is made
on the pressure reducing/relief valve
3) Increase the pressure until the Top Drive just starts to be lifted clear of the bail
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Adjusting procedure
Ref: Hydraulic flow diagram for pipe handler, and hydraulic flow diagram
for valve unit.
3) Open the kelly valve manually with a hex head spanner and make sure that the
valve is open. The valve has an internal stopper, which allows you to move the
spanner 90 degrees.
4) With open valve, remove the cam sleeve/crank assembly. With the crank hex.head
in upper end of slot in the cam sleeve. Ref to cam. assembly drawing.
6) With the cylinders fully extended, push the cylinders into the slot in the
suspension plate.
7) If the plastic pad on the cylinder yoke hits the top of the cam sleeve or is 3-
5mm further down, then the yoke/cylinder is correctly adjusted in open
position. If it is more than 5 mm, the yoke must be adjusted up by turning the
cylinder rod clockwise.
NOTE Release the set screw in the yoke before adjusting
Important
Take Notice
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8) Remove the cylinders and sleeve/crank assembly. Shut the kelly valve with the
spanner and make sure the valves stop on the internal stopper.
Remount the sleeve/crank assembly with the crank hex.head in the lower end
of the slot in the sleeve.
11) If the roller hit the sleeve flange O.D. the yoke/cylinders are correctly
adjusted.
12) Release pressure on the cylinders and push them completely into the slot in the
suspension plate. Lock with locking pins.
13) Operate the IBOP cylinders from drillers panel. to open. Check that the
plastic pads/cylinders retract approx. 5mm from top of sleeve flange after 2 - 4
sec.
If the distance is too small, excessive wear on pads is likely to occur when
drilling. If the retraction is too large the rollers may hit the underside of sleeve
flange and start closing the valve. This will wear out the valve. There must be
clearance both to plastic pad and roller when the valve is open.
When the valve is shut, the rollers shall always press on underside of the
sleeve flange.
Electrical:
Calibration Procedures
The calibration procedure refers to the equipment set points, located in section 2.1.
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Equipment: PTD 500 AC Date: 26-Sep-2005
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7. Use a round bar, -diameter not more than 50 mm, unscrew the thrust nut
approximately 100 mm.
8. Move the lift tool for the nut into place and support the weight of the nut on
the lift tool when unscrewing the threads completely. Do not rest the weight of
the nut on the last few threads.
9. When the nut is completely unscrewed, lower down on floor. The intermediate
sub (if applicable) , IBOP and the saver sub will guide the nut.
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2.2.5 Guide lines for replacing the dies in the torque wrench
Note! If the Torque Wrench can be removed from the PTD, all dies are available for removal
without opening the Torque Wrench as described below.
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Client: Maersk Project: Maersk Rig 44
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Remove the safety pins and pull out/knock out the pivot pins.
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Use grease and anti-corruption adhesives when mounting the jaws and pivot pins in order to
maintain an easy service.
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1. Note! When using the torque wrench for making / breaking out saver
sub, lower jaws for 6 5/8" DP & tool joint OD 7 " have to be
installed.
3. Switch the T.W. to manual mode on panel, and perform a brake out
sequence.
To remove the lower IBOP, Upper IBOP or the Intermediate Sub (if
applicable), the IBOP cam sleeve and the IBOP cylinders have to be taken out.
CAUTION Never use rig tongs without supporting the free end in the
Possible Loss, rotary table.
Use Care
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2.2.7 Guide lines for removal of IBOP cam sleeve & cylinders.
1 Remove the pins on the IBOP-cylinders and take out the cylinders.
2. Remove the cam sleeve by pulling out the two cylinder locking pins,
and open. (Ref. cam sleeve arr. drawing), pull up pin, swing out lever,
pull up pin, swing out lever / hinge, lift sleeve half no. 1 relative to half
no. 2 and open).
3. Remove the sleeve and the crank.
Prior to installation of the completely assembled Wash Pipe, the thread connections as
well as the front-side contact surfaces are to be cleaned properly and to be greased
slightly.
Dismount possibly existing cover (in the case of a stored stuffing box).
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Attention!
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Put hook wrench around the upper stuffing box, and tighten
the stuffing box by turning the hook wrench.
After the grease nipple (1 piece) has been lubricated and all tools and auxiliary means have
been removed, the Top Drive is ready for operation.
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2.2.9 Guide lines for replacing the Seals in the Wash Pipe
The seals on the wash pipe have to be lubricated (ref. lubrication schedule) when drilling.
The seals and the wash pipe are replaced as on every other conventional swivel. The wash
pipe is kept in place by two nuts. Both are left-hand threaded. Loosening and tightening of
the nuts to be by use of a hammer and a puncher.
The following pages show how to assemble a complete wash pipe, including packing, subs,
nuts, etc.
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Please pay attention to absolute cleanness of all parts, as the later lifetime essentially depends
of this.
As a rule, all parts to be installed will have to be greased slightly prior to installation.
1. Prior to assembly, the seal retainer 2. Use a rubber mallet to install the seal in
and seal must be clean and free of the seal retainer.
grease.
3. Use a brush and fill the seal with EP 2 4. Also grease the outward groove for the
grease. O-ring.
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6. Install the seal retainer with seal into the lower stuffing box. Use a wooden plate or
other soft material.
7. Install O-ring into the upper groove on the seal retainer. Use some EP2 in the groove.
Repeat actions 1 7 until all four seal retainers are installed into the
lower stuffing box.
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8. Use a clamping device to press down the four seal retainers to such an extent, that the
hex. locking bolt can be turned into the groove of the seal retainer. (See picture 9b.)
Make sure that it is engaged into the groove.
9. Insert O-ring in upper stuffing box. 10. Place the upper stuffing box on top of
the lower stuffing box.
11. Install the mud pipe through both stuffing boxes. Before installation, check mud pipe
surface. Replace if noticeable corrosion or grooves.
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12. Install the seal retainer onto the mud 13. Install the circlip on the mud pipe.
pipe.
Before storage and transportation, mount the covers 16, 17, and secure with hex. nut 18.
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2.2.10 Guide lines for trust nut clearance check and adjustment
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2.2.11 Guide lines for General Start-Up and Maintenance of Hydraulic Systems
A long lifetime and functional security of a hydraulic system and its components,
is dependent on correct service and maintenance.
For a Safe and faultless function it is necessary to be especially aware of the following basic
but important fact:
Below is listed some basic but important knowledge regarding hydraulic system
x Check/ensure that correct oil is used and that there is oil on the tank. It is recommended
that filling of oil is performed through the filter.
x Never start up a hydraulic pump before filling the pump house. Use the filling plug on top
the tank and fill the pump with clean oil.
x Always check the direction of rotation by giving the electrical motor a short start pulse in
manual mode and check the direction upon the HPU unit.
x After rig move, startup after long storage or major repair always start the system with a
short start pulse in manual mode and check for abnormal noise.
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x Closing shut of ball valve during operation must be done in correct order
1. Pressure
2. Load sensing
3. Drain/return
x Opening shut of ball valve during operation must be done in correct order
1. Drain/return
2. Load sensing
3. Pressure
x Do not use sealing compound or hemp as a seal medium. This could give considerable
pollution disturbance in the system.
x If new components or old that has been repaired is to be installed, make sure that its
installed correctly and that correct setting (if applicable) is set. Also make sure that all
hoses or connections are correct installed and tightened up properly afterwards.
x Personnel, who are not involved in the function test, have to keep away from the testing
area
x Check all function manually from the Danfoss control valve. Check the pressures on the
gauges.
x Check oil level, temperature and for leakages constantly during start-up.
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2. - General requirements
3.2 Electrode: type E 7016 acc. to AWS: ASME II/C e.g.: FOX EV 50-A,
Messrs. Bhler, or equivalent DnV-certification approval is required.
4. - Regulations of execution
4.1 The extent of defect has to be ascertained by use of visual control acc. to
QA-10/70, dye penetrant inspection acc. to QA-10/74, magnetic particle
inspection acc. to QA-10/75 or ultrasonic inspection acc. to QA-10/76.
4.2 Prior to any repair the following criteria for repairs have to be
documented:
- Location of defect
- Defect type
- Defect size limits
- Definition of major/minor repairs
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4.3 The removal of weld metal or portions of the base metal has to be done
by machining, grinding, chipping, or gouging. It has to be done in such a
manner that the adjacent weld metal or base metal is not nicked or
gouged. Unacceptable portions of the weld have to be removed without
substantial removal of the base metal.
4.4 All excavations for weld repairs have to be examined by the magnetic
particle inspection acc. to QA-10/75 and the same quality assurance
criteria have to be applied.
4.5 Before welding all surfaces, weld and adjacent base metal, have to be
cleaned thoroughly by brushing.
4.8 The repaired or replaced weld has to be retested by the same methods as
described under point 4.1, and the same technique and quality
acceptance criteria have to be applied.
- The crack and sound metal 2 inch (50 mm) beyond each end of
the crack have to be removed and rewelded following the
instructions as described under points 4.3. - 4.6.
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Total DFT can not be achieved with application of min DFT of each coat. Surface
temperature must be at least 3q above dew point.
Recommended over coating intervals at spec. DFT. High humidity and poor ventilation will
increase the drying time
General
Before application of any coat of material, all damage to previous coat shall be repaired. All
loose paint shall be removed to a firm edge. All surface irregularities and contaminants shall
be removed. Hard, glossy surfaces may require abrading to obtain a suitable surface for
painting.
Contaminated Surfaces
All contaminated surfaces shall be thoroughly cleaned with an alkaline detergent (DEVPREP
88 or equal) and high-pressure fresh water, prior to any blast cleaning or mechanical surface
preparation.
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Set point, which is designated in the top drive control program, can be adjusted via the use of
a personal computer equipped with suitable programming software.
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The objective of this procedure is to ensure that the integrity of the equipment is maintained
during its operational life.
The owner and user together with the manufacturer should jointly develop and
update inspection, maintenance, repair and remanufacture procedures consistent
with equipment application, loading, work environment, usage and other
operational loads.
The owner or user of the equipment should develop his own schedule of
inspections based on experience, manufacturers recommendations and
consideration of one or more of the following factors:
- environment
- load cycles
- regulatory requirements
- operating time
- testing
- repairs
- remanufacture
Prior to and/or after a critical loading the drill floor supervisor should conduct a critical load
inspection. The extent of this inspection must be required by the supervisor on the
basis of his judgement of actual impact loading severity.
The following procedure can be considered as a guideline checklist, which should be used
to form part of a detailed Risk Assessment by the top drive owner/operator and thereafter
used as a recommended practice.
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The main objective of the procedure is to determine cracks, loose fits/connections, and
elongation of parts, overloading or other signs of wear. Any equipment found to show
cracks, excessive wear etc, should be removed from service. The inspection procedure is
based on the assumption that the critical load operation was performed with the string
connected to the top drive shaft. The Link hanger and Thrust Nut, with associated parts are
therefore not considered to have been exposed to any severe loads, however require
inspection for damage due to vibration.
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DESCRIPTION Sign /
ITEM
Date
1 Check swivel lugs for cracks and deformation.
2 Check pin retainer for bail pin.
3 Check bolts and securing device for swivel cover fixing bolts.
4 Check bolts and securing device for gooseneck fixing bolts.
Inspect pin and box thread in accordance with API RP 7G for tool
5
joints.
6 Check bail (or direct link if installed) for cracks and deformation.
7 Check pin retainers and securing bolts for bail pins.
8 Check compensator link lugs (if installed) for cracks and deformation.
9 Check connection links (if installed) for cracks and deformation.
Check pin retainers and securing bolts for cylinder connection to
10
compensator link.
Check top bearing and end-float (if applicable) in accordance with
Product Bulletin PB-002.
11
Additional checks!
Check the bearing hub and connecting screws for damage and wear.
Comments :
Important Note!
Since the bearings (top bearing and main thrust bearing) are exposed to unknown and most
probably very high impact loads, Maritime Hydraulics can not take the responsibility for the
expected lifetime of the bearings after jarring.
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Comments :
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DESCRIPTION Sign /
ITEM
Date
1 Check fixing pins and retainers.
2 Check locking device for cam roller.
3 Check cylinder connection to roller assembly.
4 Check the assembly operates correctly.
5 Check for hydraulic leaks on hose connections.
Comments :
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DESCRIPTION Sign /
ITEM
Date
1 Check fixing bolts for motors.
Check lever for gear lock
2 Check pins and retainer plates for connection plate (Fig 6A).
3 Check gear lock mechanism.
4 Check fixing bolts for gearbox bottom cover.
5 Check clamp for mud pipe.
6 Check fixing screws for protection grid (Fig 6A)
7 Check hose connections on motors and manifolds.
8 Check flexible coupling (Fig 6A).
9 Check pins and retainer plates for compensator cylinders (Fig 6B).
Check fixing bolts for valves, brackets etc. are tight and still secured.
10
Check for hydraulic leakage on hose connections.
11 Drain gearbox oil and check main bull gear is in correct position.
Comments:
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DESCRIPTION Sign /
ITEM
Date
1 Check fixing bolts between suspension plate and torque wrench.
2 Check guide funnel, fixing bolts and safety wire.
3 Check jaws and fixing bolts for jaws.
Check fixing bolts for brackets etc. are tight and secure. Check for
4
hydraulic leaks on hose connections.
Comments :
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DESCRIPTION Sign /
ITEM
Date
1 Check pins, fixing bolts and retainer plates for connection to top drive.
Check bolts and retainer plates for connection between main frame and
2
dolly connection frame.
3 Check boogie fixing arrangement
4 Check side roller arrangement.
NA Check fixing bolts for brackets etc. are tight and still secure.
Check alignment of PTD with well centre in accordance with guide
NA
lines
Comments :
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Figure 8
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DESCRIPTION Sign /
ITEM
Date
1 Check fixing bolts and retainer plates for connection to traveling block.
Check bolts and retainer plates for connection between main frame and
2
traveling block connection frame.
3 Check boogie fixing arrangement
4 Check side roller arrangement.
NA Check fixing bolts for brackets etc. are tight and still secure.
Check alignment of PTD with well centre in accordance with guide
NA
lines
Comments :
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Figure 9
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Note:
** For lubrication of AC motor it is important to follow lubrication procedure in
Installation, Operation and Maintenance Manual from supplier of AC-motor.
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CPU modules may only be replaced by modules with the exact same part number.
The part number is printed on the top left corner of the module front. If another CPU
module is to be used this must be done by qualified MH personnel, as hardwire
configuration changes have to be performed.
If the CPU program is not stored in FLASH memory it is not recommended that CPU
modules are replaced by other than qualified MH personnel. If the program is stored
in FLASH memory the procedure below may be used. Note that all accumulated data
stored in the CPU module will be lost. This may include data such as motor run time,
wire usage and similar integrated information.
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Proximity sensors depend on the sensing distance from its initiating flag to give an accurate
output. This is in particular important when the sensor is used to check frequency on rotating
parts (PTD speed). Check sensor to flag distance to be 4 to 6mm at minimum.
PTD speed sensor, check all flags on flag wheel to ensure stable speed readout.
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3. MAINTENANCE INSTRUCTIONS
The Portable Top Drive (PTD) is designed to withstand the corrosive and hostile environment
in which it is located. It is however very important to follow the maintenance schedules to
ensure trouble free operation and lengthen operating time. The recommended practice for
Maritime Hydraulics maintenance chapter is based on API RP 8B Seventh Edition, March
2002.
Maintenance/inspection of the top drive system is divided into the following category:
Category I
Category II
Category IIA
Category IIB
Category III
Category IV
Non-periodic inspection
Non-periodic inspection is a inspection that should be made before (if anticipated) and after
critical jobs. (e.g., running heavy casing string, jarring, pulling on stuck pipes and/or
operating at extreme low temperatures).
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Inspection and maintenance is closely linked. Inspection and maintenance may be initiated
based on but not limited to one or more of the following criteria.
WARNING Secure the area and the equipment prior to any maintenance
Possible Loss, of the equipment to avoid possible damage to personnel and
Injury or Death! equipment.
Operators shall review safety consideration applicable to the site where the maintenance is
performed.
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This service is to ensure good daily standard on the equipment, and that operation of the
equipment can be done in a safe manner.
Category , inspection involves observing the equipment during operation for indications of
inadequate performance.
When in use, the equipment shall be visually inspected on a daily basis for cracks, loose fits
or connections, elongation of parts, and other signs for wear, corrosion or overloading.
3.2.1 General
Visual checks for any obviously damaged components on top drive system.
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Check of temperature for swivel & gearbox, HPU and AC-Motor on the OP 7 panel in the
VFD housing (during drilling operation).
The viscosity of the lubrication oil is to be chosen corresponding to the ambient temperatures.
Ref. Lubrication and consumables schedule.
If the differential pressure over the lub. Oil filters are more that 1,5 bar the filter element
must be changed.
HPU:
Check filter indicators on HPU
NOTE If the hydr. Oil temp is low, the viscosity is very high and
Important the indicator will probably indicate clogged filter. Check
Take Notice the indicator when proper operation temperature is
obtained
Check daily the power connectors for abnormal heat. (Indication of bad connection)
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This service is to ensure good standard on the equipment, and that operation of the equipment
can be done in a safe manner.
Category ,, inspection involves category , inspection plus further inspection for corrosion,
deformation, loose or missing components, deterioration, proper lubrication, visible external
cracks, and adjustment
3.3.1 General
Category , inspection
Visually check that all the hydraulic hoses, pipes and fittings are free from damage. If the
steel-cord can be seen on a hydraulic hose, the actual hose should be exchanged immediately.
Visually checks that all bolt heads are secured properly. Also check that all brackets and
ancillary items are fastened and secured.
Check that all chains are free from damages and that all shackles have double locking device
(nut + split pin).
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WARNING It is strictly important that the fixing bolts are engaged in the
Possible Loss, matching groove in the main shaft. Serious damage may occur
Injury or Death! if the thrust nut is allowed to rotate respectively to the main
shaft
Pipe Handler:
Visually check the dies in the torque wrench for wear, change if necessary.
Visually check the spring packages for the guide rods on the Pipe Handler.
HPU:
Check breather filter on the HPU
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Guide Dolly:
Check for abnormal noises from guide dolly rollers
Open operator panels and visually inspect for water ingress and loose equipment.
NOTE Never pull or lift in the loop cables, safety shroud or quick
Important connectors, only in the protection hose.
Take Notice
When handling open quick connectors use caution to
avoid pollution that may cause fault on the signals
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This service is to ensure good standard on the equipment, and that operation of the equipment
can be done in a safe manner.
Category ,,A inspection involves category ,, inspection plus further and more supplementary
inspection for corrosion, deformation, loose or missing components, deterioration, proper
lubrication, visible external cracks, and adjustment
3.4.1 General
Category ,, inspection
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Check that the pressure gauge on the gearbox lubrication Oil filter indicates zero when the
pump has stopped.
Under normal conditions it is not necessary to open the gearbox before Category ,V
inspection.
In the case of deviations, such as sudden temperature increase of the lubrication oil, leakage,
i.e. defective oil-seal rings, so that oil levels are no longer o.k, the gearbox must be checked
immediately.
Check for leakage from seal rings. After failure of sealing or bearings, new ones have to be
installed.
The routine field inspection is a visual inspection of the equipment. The equipment should be
inspected on a regular basis, min. every 30 days, for cracks, loose fits or connections,
elongation of parts, other signs of wear, corrosion or over loading.
Check saver sub pin & box thread according to API RP 7 G for tool joints. Check for
excessive wear or signs of over loading.
Check IBOP valve pin & box thread according to API RP 7 G for tool joints. Check for
cracks or other signs of over loading.
Check main shaft lower end box thread according to API RP 7G for tool joints. Check for
cracks or other signs of over loading.
Check thrust nut securing bolts and clearance between thrust nut and link hanger. Check for
cracks or other signs of over loading.
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Pipe Handler:
Check the plastic plates on end of IBOP cylinders. Replace if height of this is 25 mm or less.
(New 29 mm).
Inspect if you can operate the crank in the cam sleeve assembly by hand
Inspect hexagonal hole on IBOP valve and if you can open close the valve by hand with the
allen key
Inspect the saver sub original OD 197 mm. Min. OD 190 mm.
Open torque wrench. lower and upper half. Inspect locking pins and jaws, dies. Grease the
bolts that swing the upper & lower half of the T.W.
Inspect the torque wrench spring suspension bracket and connection pins.
The sleeve bearing and the rotation gear should be inspected once a month, and greased
according to lubrication diagram.
Blower system
Inspect, if necessary clean, filter element on blower assembly. Element can be cleaned in
mild soap water. Make sure to properly dry the element before installing
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NOTE Never pull or lift in the loop cables, safety shroud or quick
Important connectors, only in the protection hose.
Take Notice
When handling open quick connectors use caution to
avoid pollution that may cause fault on the signals
Open all junction boxes and inspect for humidity, loose parts or loose cable termination.
WARNING Never open the power junction box while energized, make
Possible Loss, sure a proper shut down procedure is performed before
Injury or Death! open
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This service is to ensure good standard on the equipment, and that operation of the equipment
can be done in a safe manner.
Category ,,B inspection involves category ,,A inspection plus further and more supplementary
inspection for corrosion, deformation, loose or missing components, deterioration, proper
lubrication, visible external cracks, and adjustment
3.5.1 General
Category ,,A inspection
Check that all bolted connections are fastened and correct secured.
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Top drive:
Inspect Top Drive system for wash out:
For the mud pipe and gooseneck is normal: ID=80 mm
For take off diameter is ID = 86 mm.
Inspect (replace if req.) the top conical bearing with sealing. If mud has entered the upper
simmering both the bearing and the simmering to be replaced. Check that the axial slack is
less then 0,1mm. Make sure that the sealing is filled with grease and that grease is forced out
of the upper simmering prior to start rotation of the Top Drive.
NOTE The frequencies for this inspection may wary allot. This
Important because the large variation of environment and operation
Take Notice this equipment is used under
Guide dolly:
Inspect the dolly wheels and side rollers for sign of wear on the outside diameter.
HPU
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This service is to ensure good standard on the equipment, and that operation of the equipment
can be done in a safe manner.
Category ,,, inspection involves category ,,B inspection plus further inspection, which should
include NDT of critical Areas and may involve some disassembly to access specific
components to identify wear that exceeds allowable tolerances.
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3.6.1 General
Category ,,B inspection
The Category III inspection aims to cover inspection of all loaded items on the Top Drive and
should be based on API RP 8 B.
The Category III inspection is a combined visual and non-destructive examination (NDE)
inspection of the equipment. The equipment should be inspected on a regular basis, for
cracks, loose fits or connections, elongation of parts, other signs of wear, corrosion or over
loading.
Inspection procedure, ref. enclosed Periodic Field Inspection and loading capacity diagram.
The drawing shows check positions and test method. It also shows wear diagram for various
parts
Saver Sub:
x Unscrew and check threads and sealing surface according to API RP 7G
x NDE of threads and body
x Check wear and tear & traces of overload
IBOP:
x Unscrew IBOP valves and check pin & box thread and sealing surface according to API
RP 7G.
x NDE of threads and body.
x Check for excessive wear or other traces of overloading.
Main Shaft:
x Check main shaft lower end box thread and sealing surface according to API RP 7 G.
x NDE of threads and body.
x Check for excessive wear or traces of overloading
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Thrust nut:
x Unscrew thrust nut and visually check internal threads and other signs of wear or over
loading.
x NDE of threads and body.
Main Shaft:
x Visually check threads for thrust nut on main shaft threads for damage.
x Check for other signs of excessive wear or over loading.
x The bail or connection link between Top Drive and Traveling. Block
x The bail pins
x The swivel housing
x The link hanger
x The elevator links (se Important note for special frequency)
x The elevator
CAUTION Use the lifting tool for the thrust nut when it is unscrewed
Possible Loss, and lowered down. Do not unscrew the nut and rest it's full
Use Care weight on the two-three last threads. Proceed carefully
when entering the threads for assembly. Lift gently with the
tool.
NOTE Lubricate threads on main shaft and thrust nut with, "dope",
Important thread protection for drill collar threads during assembly
Take Notice
Bail pins to be lubricated similarly when inserting.
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Under normal conditions the gearbox should be opened on yearly basis for inspection.
In the case of deviations from the normal, such as sudden temperature increase in the
lubrication oil, leakage, i.e. defective oil-seal rings, wrong oil level, the gearbox must be
checked immediately.
Pipe handler
Check all disk springs on the pipe handler for sign of wear or cracks. Replace if necessary
Inspect all ceramic fuses for sign of wear (burning marks). Replace if necessary.
Check calibration on all pressure transmitters and pressure switches. Recalibrate if required,
according to the manufacturer instructions.
Check all boogie rollers and side rollers for sign of wear and bearing failure. Replace if
necessary. (MH recommend to change the boogie wheel when diameter is worn down to
210mm)
HPU
It is recommended to take samples of the hydraulic oil and have it analyzed for contamination
level every 6 month. The analysis will indicate if the fluid needs to be replaced.
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3.7.1 General
This inspection should be performed on a regular basis, minimum every 5 years. The
equipment should be inspected for cracks, loose fits or connections, elongation of parts,
wobbling, other signs of wear, corrosion or over loading.
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Top Drive
Magnetic particle examination of the main shaft shoulder in the area of the axial bearing to be
performed.
Visually check for other signs of wear, mechanical damage or over loading.
Check the main shaft concerning wobbling in the areas indicated on the ref. drawing.
Visually check for other signs of wear or mechanical damage.
Visually inspect the bore through the main shaft (with relevant tools).
Check for wear and other signs of mechanical damage.
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Non-periodic inspection
A non-periodic inspection is a complete, on-job, shutdown inspection equivalent to the
periodical Category III
This inspection should be made before (if anticipated) and after critical jobs. (e.g., running
heavy casing string, jarring, pulling on stuck pipes and/or operating at extreme low
temperatures).
In addition, Maritime hydraulics recommends performing a Guide lines for critical load
inspection
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Client: Maersk Project: Maersk Rig 44
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It is hoped that the trouble-shooting hints on the next few pages will provide a useful
guide for locating and clearing running faults. They cover most common forms of
trouble.
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Title: Maintenance Page: 93 of 99
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ALIGNMENT PROBLEMS
The PTD saver sub is Top drive not adjusted. Adjust top drive according
out of centre, tilted to procedure.
forwards or
backwards.
Tilted sideways. The side rollers are worn. Adjust on the side rollers.
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The various PLC modules are equipped with LEDs that indicate normal operation as
well as fault information. This section describes the LEDs and their function for the
various modules.
Power Supply
The table below gives information on the reaction of the power supply module to the
atypical operating conditions.
If Then 24 VDC
LED
the output circuit is Voltage dip, automatic voltage Flashes.
overloaded: recovery.
x I > 6.5A (dynamic) Voltage drop, shortening of
service life
x 5A <<I 6.5A (steady
state)
the output is short- Output voltage 0V; automatic Dark.
circuited voltage recovery after short
circuit has been eliminated.
an over voltage occurs Possible destruction -
on the primary side.
there is an under voltage Automatic disconnection; Dark.
on the primary side automatic voltage recovery.
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S7 CPU
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