Operating Instructions

HPS-03 -

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

Etesco Drillship V7609 TOP DRIVE HPS
ADDITIONAL CODE SDRL CODE TOTAL PGS
5.3 53 This document contains proprietary and confidential Postboks 401, Lundsiden
information which belongs to National Oilwell Varco; it is N-4604 Kristiansand
REMARKS loaned for limited purposes only and remains the property
Part of User Manual of National Oilwell Varco. Reproduction, in whole or in Norway
MAIN TAG NUMBER DISCIPLINE part; or use of this design or distribution of this information Phone +47 38 19 20 00
to others is not permitted without the express written Fax +47 38 19 26 04
consent of National Oilwell Varco. This document is to be
CLIENT PO NUMBER 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 - 2010

CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

V7609-Z-MA-007 0
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TABLE OF CONTENTS

1 OPERATING INSTRUCTIONS ......................................................................................... 5

1.1 Important Glossary .................................................................................................. 7
1.2 Safety Summary ..................................................................................................... 8
1.3 Emergency Stop ..................................................................................................... 9
1.3.1 Restarting HPS after Emergency Stop ........................................................ 9
1.4 Description of Controls .......................................................................................... 10
1.4.1 Cyberbase Controls ................................................................................... 10
1.4.2 Top Drive Drilling ....................................................................................... 11
1.4.3 Top Drive Connection ................................................................................ 13
1.4.4 Top Drive Pipe Handling ............................................................................ 15
1.4.5 Top Drive Riser Handling ........................................................................... 17
1.5 Top Drive Screen Displays.................................................................................... 19
1.5.1 Weight Compensator ................................................................................. 22
1.5.2 Dolly ........................................................................................................... 24
1.5.3 Pipe Handler .............................................................................................. 24
1.5.4 IBOP Operation ......................................................................................... 25
1.6 Local Control Valves and Indicators ...................................................................... 26
1.7 Operations ............................................................................................................ 27
1.7.1 Start ........................................................................................................... 27
1.7.2 Stop ........................................................................................................... 27
1.7.3 TD Drilling .................................................................................................. 28
1.7.4 Parking Brake ............................................................................................ 29
1.7.5 Weight Compensator ................................................................................. 29
1.7.6 Spin In and Make-up stands. ..................................................................... 30
1.7.7 Make Up/Break out by Torque Wrench ...................................................... 31
1.7.7.1 Presetting of Makeup Torque.................................................................. 31
1.7.7.2 Presetting Number of Breakout Strokes ................................................. 31
1.7.7.3 Makeup by Torque Wrench..................................................................... 32
1.7.7.4 Breakout by Torque Wrench ................................................................... 33
1.7.8 Adjusting the Height of Torque Wrench ..................................................... 34
1.7.9 Retractable Dolly (Optional) ....................................................................... 34
1.7.9.1 Manual mode .......................................................................................... 34

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1.7.9.2 Auto Extend ............................................................................................ 34

1.7.9.3 Auto Retract ............................................................................................ 34
1.7.10 Wireline Operations ................................................................................. 35
1.7.11 Wireline Running Tool (Optional) ............................................................. 36
1.7.11.1 Using Wireline Conveyed Explosives ................................................... 37
1.7.12 Operation of IBOPs .................................................................................. 38
1.7.13 Using the Pipehandler ............................................................................. 38
1.7.13.1 Pipehandler Rotation ............................................................................ 38
1.7.13.2 Tilting Knuckle Links ............................................................................. 39
1.7.14 Elevator Operation ................................................................................... 40
1.7.15 Handling Risers (Optional) ....................................................................... 40
1.7.16 Running Riser With Shaffer RRT ............................................................. 41
1.7.16.1 Interlocks .............................................................................................. 45
1.7.17 Heavy Lifting ............................................................................................ 45
1.7.17.1 Pipehandler Rotation and Jog mode (Optional) .................................... 45
1.7.18 Changing Drillpipe/Tooljoint Size ............................................................. 46
1.7.18.1 Adjusting the Torque Wrench Clamp Pressure ..................................... 47
1.7.19 Adjusting the Weight Compensator ......................................................... 48
1.7.20 Changing Elevator Links in the Knuckle Links ......................................... 48
1.7.21 Installing Elevator Links Directly on Link Hanger ..................................... 50
1.8 Disturbance of Operation ...................................................................................... 52
1.8.1 Drilling With one Motor .............................................................................. 52
1.8.2 Releasing Trapped Back Torque in Drillstring............................................ 52
1.8.2.1 Torque and Speed Throttles ................................................................... 52
1.8.2.2 Drilling Motor Blackout ............................................................................ 52
1.8.2.3 Through The BHA ................................................................................... 52
1.8.3 Dealing with Alarms ................................................................................... 53
1.8.4 Trip of Power to the Drilling Motors ............................................................ 53
1.8.5 Drilling Motors Cooling Failure ................................................................... 53
1.9 Training Program for Operators ............................................................................ 53

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1 OPERATING INSTRUCTIONS
This document describes correct use of the National Oilwell Varco TM Top Drive HPS-03 for the drillship
stated at the document front page.

The operating instructions are based on the assumption that the equipment has been commissioned and
thus are ready for ordinary routine operation.

It is of high importance that the operator reads and fully understands these instructions before
commencing operations.

The objective of the top drive is rotating the drillstring, make-up, break out of pipes, pipehandling, and
passing drilling mud into the drillstring.

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Typical Top Drive HPS-03

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1.1 Important Glossary

Drill stem: The shaft down from the cross over sub until saver sub.
Main shaft: The shaft down from washpipe until the cross over sub.
IBOP´s: Inline blow out preventers.
Saver sub: A sub inserted between the drill collar and the drill stem.
Spin mode: Screw together/unscrew drill strings lightly before make-up and after brake-out sequence.
Triples/stands: Stack of pre assembled pipes.
Backbite: Reverse backlash of tongs, left on a pipe or collar, during the tong backup operations.
Break out: To unscrew one section of pipe from another section.
Make up: to screw a length of pipe into another length of pipe.
Make a connection: To attach a joint or stand of drill pipe onto the stickup suspended in the well bore to
permit deepening the well bore by the length of the pipe.
Bottom hole assembly (BHA): The portion of the drilling assembly below the drill pipe.
Stickup: The part of a pipe sticking up from slips
Slips: Wedge-shaped pieces of metal with teeth or other gripping elements that are used to prevent pipe
from slipping down into the hole or to hold pipe in place.
Backup tongs/rig tong: Tongs used for taking up forces in pipe during make-up/Brake-out of pipes, usually
founded in catheads by wire or chain.
Stabbing/stabbing in: Vertical line up of stickup and pipe to be connected with spin-in and make-up.
Downhole motor: A drilling tool made up in the drill string directly above the bit. It causes the bit to turn
while the drill string remains fixed.
Jar/Jarring: A percussion tool operated manually or hydraulically to deliver a heavy upward or downward
blow to fish stuck in the borehole. To apply a heavy blow to the drill stem by use of a jar or bumper sub.

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1.2 Safety Summary

The following types of safety message may appear in various sections of this chapter:

WARNING: Must be observed to prevent serious injury.

CAUTION: Must be observed to prevent damage of equipment and/or loss of

operating effectiveness.

NOTE: Must be observed for correct and efficient operation.

It is the responsibility and duty of all personnel involved in the operation and maintenance of this
equipment to fully understand the SAFETY measures, by which hazards are reduced or eliminated.
Personnel must become thoroughly familiar with all aspects of safety and operation of the equipment
before starting any operation or maintenance.

It is highly recommended that there is a JSA (Job Safety Analysis) and JSM (job safety meeting) for crew
included in the forthcoming operations to clarify hazards and minimize risk of misunderstanding leading to
accident.

 Only qualified and trained personnel are allowed to operate this equipment.
 The equipment must only be used for the prescribed purpose and in accordance with the operating
instructions.
 If the power to the AC drilling motors is tripped during drilling, the HPS will be free-wheeling and any
trapped torque will be released without control of the spin-back speed.
 In a critical situation, such as during uncontrolled reverse string rotation, the operator must be aware
of the risks of undesired break-out of connections.
 Special attention must be paid when drilling down to the floor. When the links are tilted backwards it is
of essential importance that no personnel are entering the area within the rotation radius of the
elevator/pipehandler.
 Dropped objects are potential killers! Always ensure that tools and/or equipment are not lost or
forgotten at high places. If necessary, seal the area below.
 In the case of a fire, be aware that hydraulic oil is flammable. The combustion point is ca. 200 Deg. C.
Oil fog is highly flammable!
 Do not turn the speed throttle too quickly down to zero during drilling. Rapid zeroing causes the
drilling motor moment of inertia to try stopping the rotation of the drill string, and there will be a risk of
the string tool joints backing off. (Unscrew)

 For Load Capacity, Performance Data and Technical Specification; see section Product Data
Sheet

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1.3 Emergency Stop

Emergency stop for drilling equipment may vary in layout and function.

An emergency stop causes:

Drive motors and aux. Motors stops.
All solenoids, sensors etc in the hydraulic control valve unit become de-energized.

The operator must be aware of the risks by activating the emergency stop during drilling. The drilling
motors can no longer be controlled by ordinary operating controls. For this reason the emergency stop
should only be activated when an immediate uncontrolled stop of the rotating equipment is required.
Otherwise the stop should be by the ordinary operating controls.

1.3.1 Restarting HPS after Emergency Stop

After the cause of the emergency stop has been remedied, the HPS can be restarted as follows:

 In VFD; engage the main circuit breakers for main motor and heater.
 In MCC; engage main circuit breakers for auxiliary motor.
 In Control Cabinet; Engage circuit breaker for UPS and normal supply for HPS control system.

If the emergency stop interrupted an ongoing opening of the elevator, the time needed for a
complete opening has been interrupted and the elevator may have been locked in an incorrect
position. Special attention (visual) must be paid to verify proper opened/closed position.

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1.4 Description of Controls

1.4.1 Cyberbase Controls

This section introduces the Cyberbase controls (keypads with joysticks, and screen displays) for
operation of the HPS. (HPS = Power Swivel = Top Drive = TD)

It is assumed that the operator already is familiar with the general use of the Cyberbase operator station
(in DCR), and our focus is therefore on how the operator station is used to operate the HPS. The operator
station uses different sets of keypads and screen displays for machine control, and the keypads and
displays for HPS control are described at the next pages. For further Cyberbase info, reference is made
to the Drilling Control Room user manual and to:

 Doc. S01V7690-FDS-001: DCDA HMI

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1.4.2 Top Drive Drilling TD Drilling

Drillers Mode 2 (2xx1x00), Left Keypad
TD
Description of Function Keys: Conn.
DW Menu
Button Func Description
Prev p Swap to Drawworks
Menu p Swap to Menu Esc TD
Next p Swap to Top Drive Connection Ack On
Esc Ack p Escape / Acknowledge
Up p+c Top Drive On/Off
Swap Soft TD
Left p+c Soft Speed On Speed Rev.
Down p+c Top Drive Reverse On
Right TD
F1 Set
F2 p- Top Drive Set Speed Speed
Throttle
Wheel Motor TD
F3 Torque Set
F4 p+c Motor Torque Zero Zero Torque
F5 p- Top Drive Set Torque
Throttle CMC Zero DW
Wheel Pos. WOB ROP
F6 Auto
F7 p+c Crown Mounted Compensator
Position System Auto Mode TD DW
F8 p+c Zero Weight On Bit Brake Park
F9 p+c DW Rate Of Penetration Mode On
F10
F11 p Top Drive Brake On/Off
Confirm
F12 p+c Drawworks Park Brake On/Off
Js. 
Js. 
Js.  Link Tilt Backward Top Drive
Js.  Link Tilt Forward
Js. btn. 2p Elevator Open (The command is
Top open, but the button will light up
when elevator is closed) Link Tilt Link Tilt
Js. btn. p Dead Man’s Button Bwd Fwd
Front
Elev.
Close

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TD On: Push and confirm to activate the HPS controls. The PLC for the HPS will automatically start all
auxiliary motors (blower, gear oil circulation motors, and if the gear oil temperature is above +70°C, the
gear oil cooler motor). All monitoring devices on the HPS will be activated. Re-pushing and confirming
stops the HPS.

Soft Speed On: SoftSpeed2™ analyses the drilling process and detects when stick-slip occurs and
calculate optimal control parameters. The operator activates SoftSpeed2TM when stick slip is detected.
Main speed is unaffected and smooth drilling is quickly accomplished. The auto-tuning feature causes the
speed controller to provide optimal damping of both 1st and 2nd modes stick-slip.

TD Rev: Push and confirm to change the HPS direction of rotation from clockwise to counter-clockwise
(reverse). Push and confirm return to clockwise direction. The HPS speed must be zero before this is
allowed.

TD Set Speed: push to activate the pot meter wheel for setting of Drillstem RPM.

Motor Torque zero: Push and confirm to zero the drill torque setpoint. When the button later is deselected,
the drill torque setpoint returns to the value it had before the button was selected.

Motor Torque zero can be used if back torque is caught in drillstring; Set speed to zero and push
and confirm Motor Torque Zero, it slowly ramps down the backtorque.

TD Set Torque: Push to activate the pot meter wheel for setting of drillstem torque.

TD Brake On: Select the button to activate of the drilling motor’s parking air brake. The brake should only
be used when the drill stem speed is zero or near zero, otherwise back torque in drillstring may occur and
the brakes will be subject to wear. Interlocks against using brakes are only towards brake out and make
up mode.

The brake is a static brake only, and shall not be used as a retardation brake.

Joystick, horizontal axis: Activates link tilt. The links stop where they are when the joystick is returned to
neutral.

Joystick Button: (Push and confirm) to open elevator.

Dead man´s Button: Dead man´s button must be pushed before moving the joystick to selected position.
It can be released anytime during operation, but will be reactivated when joystick is released to middle
position.

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1.4.3 Top Drive Connection

TD Connection

Description of Function Keys:

Button Func Description TD TD
Prev p Swap to Top Drive Drilling Drill. Menu PH
Menu p Swap to Menu
Next p Swap to Top Drive Pipe Handling
Esc Ack p Escape / Acknowledge Esc TD
Up p+c Top Drive On/Off Ack On
Swap
Left
Down p+c Top Drive Reverse
TD
Right
Rev.
F1 p+c Pipe Handler Break Out
F2
F3 p+c Pipe Handler Make Up
F4 p+c Motor Torque Zero PH PH
F5 p+c Motor Spin Mode B/O M/U
F6 p+c Motor Torque Mode
F7 p+c Top Drive Weight Compensator
On/Off Motor Motor Motor
F8 Torque Spin Torque
F9 Zero Mode Mode
F10
F11 p+c Link Tilt Float Weight
F12 p+c Drawworks Park Brake On/Off Comp.
Js.  Dolly Extend ( 90% to activate) On
Js.  Dolly Retract ( 90% to activate)
Js.  Link Tilt Backward
Link DW
Js.  Link Tilt Forward
Tilt Park
Js. btn. 2p Elevator Open (The command is
Top open, but the button will light up
Float
when elevator is closed)
Js. btn. p Dead Man’s Button
Front Confirm

Elevator / Dolly
Dolly Ext.

Link Tilt Link Tilt

Bwd Fwd

Elev.
Close

Dolly Ret.

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TD Rev: Select (push and confirm) the button to change the HPS direction of rotation from clockwise to
counter-clockwise (reverse). Deselect (push and confirm) the button to return to clockwise direction. The
HPS speed must be zero before this function is allowed.

PH B/O (Breakout by the Torque Wrench): Activation of the button will initiate an auto breakout sequence
by the torque wrench. The sequence goes on for the preset number of breakout steps (normally 1 or 2),
and at the maximum torque wrench torque. The sequence can be interrupted by repeating the activation
command.

 Motors speed feedback must be zero.

PH M/U (Makeup by the Torque Wrench): Activation of the button will initiate an auto makeup sequence
by the torque wrench. The sequence goes on until the makeup torque setpoint is reached. The setpoint is
the same as set for the drilling motors in torque mode. The sequence can be interrupted by repeating the
activation command.

 Motors speed feedback must be zero.

Motor Torque zero: Push and confirm to zero the drill torque setpoint. When the button later is deselected,
the drill torque setpoint returns to the value it had before the button was selected.

Motor Torque zero can be used if back torque is caught in drillstring; Set speed to zero and push
and confirm Motor Torque Zero, it slowly ramps down the backtorque.

Motor Spin Mode: Activation starts an auto spin mode with preset speed and torque. Direction, spin in or
spin out depends of the TD CCW/CW selection.

 Motors speed feedback must be zero.

Motor Torque Mode: Activation starts a make up or break out sequence with the selected RPM and
Torque. TD CW for make up or TD CCW for beak out.

 Motors speed feedback must be zero.

Weight Compensator On: Selecting this function before stabbing-in/spinning out activates the TD’s thread
compensator and reduces the weight on the pipe threads to 1-2 tons. (The weight of the TD will no longer
be on the threads during the stabbing.)

Link Tilt Float: Push and confirm this button to make the Link Tilt float. The links will slowly (by gravity)
drop to a straight-down position after the tilting.

Joystick pushbutton: (push and confirm) the button on top of the joystick to open the unloaded elevator. If
the elevator is loaded, it cannot be opened.

Joystick, horizontal axis: Manually Extend/Retract Dolly.

Joystick, vertical axis: Tilt the knuckle links (with the elevator links and elevator) forwards and backwards.

Dead man´s Button: Dead man´s button must be pushed before moving the joystick to selected position.
It can be released anytime during operation, but will be reactivated when joystick is released to middle
position.

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1.4.4 Top Drive Pipe Handling

TD Pipe Handling
Description of Function Keys:
Button Func Description
Prev p Swap to Top Drive Connection TD TD
Menu p Swap to Menu Conn. Menu RH
Next p Swap to Top Drive Riser Handling
Esc Ack p Escape / Acknowledge
Up p+c Top Drive On/Off Esc TD
Swap Ack On
Left
Down
Right
F1 p+h Pipe Handler Rotate Counter Clock
Wise
F2 p+c Pipe Handler Rotate to Preset
F3 p+h Pipe Handler Rotate Clock Wise
F4 PH PH PH
F5 p Pipe Handler Set Preset CCW Rotate CW
F6 Preset
F7 p+c Dolly Auto Retract
F8 p+c Pipe Handler Rotate to Zero PH
F9 p+c Dolly Auto Extend Set
F10 Preset
F11 p+c Link Tilt Float
F12 p+c Drawworks Park Brake On/Off Dolly PH Dolly
Js.  Dolly Extend ( 90% to activate) Auto Rotate Auto
Js.  Dolly Retract Retr. Zero Ext.
Js.  Link Tilt Backward
Js.  Link Tilt Forward
Link DW
Js. btn. 2p Elevator Open (The command is
Tilt Park
Top open, but the button will light up
when elevator is closed) Float
Js. btn. p Dead Man’s Button
Front
Confirm

Elevator / Dolly
Dolly Ext.

Link Tilt Link Tilt

Bwd Fwd

Elev.
Close

Dolly Ret.

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PH CCW: Keep the button pushed to rotate the pipehandler (with elevator) in counter-clockwise direction.

PH Rotate Preset: Push and confirm the button to make the pipehandler (with elevator) rotate the shortest
way to the previously preset position.

PH CW: Keep the button pushed to rotate the pipehandler (with elevator) in clockwise direction.

PH Set Preset: Push and confirm the button to set the pipehandler’s present rotational position as
setpoint. When the PH Rotate Preset command later is activated, the pipehandler will rotate to this preset
position.

Dolly Auto Retr: Push and confirm the button to auto retract the dolly. The dolly will then retract the HPS
to parked position. Re-push to interrupt and stop.

PH Rotate Zero: Push and confirm to rotate pipehandler to Zero position (normally towards V-Door)

Dolly Auto Ext Push and confirm the button to auto retract the dolly. The dolly will then retract the HPS to
wellcentre. Re-push to interrupt and stop.

Link Tilt Float: Push and confirm this button to make the Link Tilt float. The links will slowly (by gravity)
drop to a straight-down position after the tilting.

Joystick, horizontal axis: Tilt the knuckle links (with the elevator links and elevator) forwards and
backwards.

Joystick, vertical axis: Manually Extend/Retract Dolly

Joystick pushbutton: Doublepush the button on top of the joystick to open the unloaded elevator. If the
elevator is loaded, it cannot be opened.

Dead man´s Button: Dead man´s button must be pushed before moving the joystick to selected position.
It can be released anytime during operation, but will be reactivated when joystick is released to middle
position.

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1.4.5 Top Drive Riser Handling

TD Riser Handling

Button Func Description

Prev p Swap to Top Drive Pipe Handling TD
Menu p Swap to Menu PH Menu RST
Next p Swap to Rotary Support Table
Esc Ack p Escape / Acknowledge
Up p+c Top Drive On/Off Esc TD
Swap Ack On
Left p+h Top Drive jog Motor CCW direction
Down
Right p+h Top Drive jog Motor CW direction JOG JOG
F1 p+h Pipe Handler Rotate Counter Clock CCW CW
Wise
F2 p+c Pipe Handler Rotate to Preset
F3 p+h Pipe Handler Rotate Clock Wise PH PH PH
F4 p+c Riser Running Tool Lock CCW Rotate CW
F5 p Pipe Handler Set Preset Preset
F6 p+c Riser Running Tool Unlock
F7 RRT PH RRT
F8 p Riser Mode On/Off Lock Set Unlock
F9 Preset
F10
F11 p+c Link Tilt Float Riser
F12 p+c Drawworks Park Brake On/Off Mode
Js. 
Js. 
Js.  Link Tilt Backward Link DW
Js.  Link Tilt Forward Tilt Park
Js. btn. Float
Top
Js. btn. p Dead Man’s Button
Front
Confirm

Top Drive

Link Tilt Link Tilt

Bwd Fwd

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Jog CCW: (push and hold) Rotate string counter clockwise at selected torque, low RPM; for tool
orientation. Release button to stop rotation.

Jog CW: (push and hold) Rotate string clockwise at selected torque, low RPM; for tool orientation.
Release button to stop rotation.

PH CCW: Keep the button pushed to rotate the pipehandler (with elevator) in counter-clockwise direction.

PH Rotate Preset: Push and confirm the button to make the pipehandler (with elevator) rotate the shortest
way to the previously preset position.

PH CW: Keep the button pushed to rotate the pipehandler (with elevator) in clockwise direction.

RRT Lock: Lock the Riser Running Tool.

PH Set Preset: Push and confirm the button to set the pipehandler’s present rotational position as
setpoint. When the PH Rotate Preset command later is activated, the pipehandler will rotate to this preset
position.

RRT Unlock: Unlocks the Riser Running Tool.

RRT Down: Tilts the riser tool towards vertical position. Re-push to stop.

RRT Up: Tilts the riser tool towards horizontal position. Re-push to stop.

Riser Mode: Initializing Riser Mode, must be selected to enable RRT functions (i.e. Lock/Unlock and tilt)

Link Tilt Float: Push and confirm this button to make the Link Tilt float. The links will slowly (by gravity)
drop to a straight-down position after the tilting.

Joystick, horizontal axis: Tilt the knuckle links forwards and backwards.

Dead man´s Button: Dead man´s button must be pushed before moving the joystick to selected position.
It can be released anytime during operation, but will be reactivated when joystick is released to middle
position.

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1.5 Top Drive Screen Displays

Instrument Display with Various HPS (TD) Related Information

The torque indicator does not show back torque trapped in the drillstring!

TD Speed Indicator: The thick bar shows the actual speed of the drilling motors and the thin bar (to the
left of the thick bar) shows the speed setpoint (SP). Both values are repeated by digits below the bars.

TD Torque Indicator: The thick bar shows the applied torque (in the presently selected mode (Drill mode,
Torque mode or Spin mode) and the thin bar (to the left of the thick bar) shows the torque setpoint (SP).
Both values are repeated by digits below the bars.

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TDA motor indicator and i-button: The motor indicator (M-symbol) shows the status of drilling motor A by
the standard Cyberbase status colours: White = Stopped. Green = Running. Yellow = Undefined/warning.
Red = Failure/alarm. Red X across symbol = Not available. For further drilling motor info click the i-button
to the right of M-symbol and have the TDA pop-up appear on the screen. The pop-up’s R-button is for
resetting the drive control system after it is tripped by VSDS/VFD fault.

TDB motor indicator and i-button: See description for TDA.

Blower A M-button: Click the button to start and stop cooling blower A manually (typically for testing and
fault finding). During normal TD operation the blower starts and stops automatically. The motor’s M-
symbol shows the blower motor status by different colours in the same way as described for TDA.

Blower B M-button: See description for blower A.

Oil Circulation button: Click the button to start and stop the gearbox oil circulation pump manually
(typically for testing and fault finding). During normal TD operation the pump starts and stops
automatically. The pump (motor) status is shown by different colours on the centre part of the pump
symbol. The colours are the same as described above for TDA.

Oil Cooler button: Click the button to start and stop the cooling fan of the oil cooler manually (typically for
testing and fault finding). During normal TD operation the fan starts and stops automatically. The fan
(motor) status is shown by different colours on the centre part of the fan symbol. The colours are the
same as described above for TDA.

Slips/Elevator Interlock override checkbox: Check the checkbox to override the interlock that
prevents opening of the TD elevator before the pipe is set in the power slips. Careful – not for
normal use!

Motor (Torque Mode) and TJB Torque S-button: Click the S-button to reset the makeup torque limit
setpoint for the drilling motors in Torque mode. This setting also applies for the TJB (tooljoint breaker =
torque wrench). After the clicking a pop-up appears on the screen at which the setpoint can be reset.
After the setting the new setpoint appears to the right of the S-button.

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Motor (Torque Mode) Speed S-button: Click the S-button to reset the speed of the drilling motors (the
main shaft speed) during TD operation in Torque mode. After the clicking a pop-up appears on the screen
at which the setpoint can be reset. After the setting the new setpoint appears to the right of the S-button.

Motor (Spin Mode) Torque S-button: Click the S-button to reset the maximum torque for the drilling
motors during TD operation in Spin mode.

Motor (Spin Mode) Speed S-button: Click the S-button to reset the speed of the drilling motors (the main
shaft speed) during TD operation in Spin mode.

Breakout Steps S-button: Click the S-button to reset the number of breakout steps to be used by the
torque wrench (TJB) during auto breakout sequences. The normal number of breakout steps is 1 or 2.

Pipehandler Speed S-button: Click the S-button to reset the rotational speed to be used by the
pipehandler when the CW and CCW buttons are operated.

Weight Compensator i-button: Click the button to have a pop-up for the weight compensator (=thread
compensator) appear on the screen. The pop-up is shown and described separately below.

Dolly i Button: Click the button to have a pop-up for Dolly Position Calibration appear on the screen. The
pop-up is shown and described separately below.

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1.5.1 Weight Compensator

Weight Compensator i-button: Click the button to have a pop-up for the weight compensator (=thread
compensator) appear on the screen. The pop-up is shown and described separately below.

Pressure Setpoint High and Low + - Buttons: After changing the pipe type/mud weight it may be
necessary to adjust the compensator. This can be done by clicking this button (normal setting is 0%). If
100% is entered the compensator pressure is increased with 20 bar, and with -100% it is reduced with 20
bar.

High and Low Position Reference: Shows the reference high and low calibration point of weight
compensator.

Position: The indicator shows the compensator cylinders’ vertical position. Zero position is when the
compensator cylinders are completely extended. Normal position is zero.

Pressure: The indicator shows the actual pressure of the compensator. This pressure is measured on the
rod side of the compensator cylinders.

Back Pressure: The indicator shows the compensator’s back pressure. This pressure is measured on the
hydraulic return line.

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1.5.2 Dolly

To calibrate the Dolly´s Retracted and Extended position.

 Drive Dolly to desired extended position, Press S button.

 Drive Dolly to desired retracted position, Press S button.

1.5.3 Pipe Handler

Pipehandler Speed S-button: Click the S-button to reset the rotational speed to be used by the
pipehandler when the CW and CCW buttons are operated.

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1.5.4 IBOP Operation

The operation of remote operated upper IBOP is controlled via cyberbase, usually in the mudpump
keypads.

The lower (manual) IBOP is opened and closed manually with the belonging Allen key.

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1.6 Local Control Valves and Indicators

The local controls are mostly for service/maintenance and emergency use, such as if the electric supply
to the ordinary remote controls blacks out. The controls are the following:

Pressure gauge: For local monitoring of the gearbox oil pressure.

Level gauge: On gearbox, showing gearbox oil level.

Hydraulic filter clogging indicator: The filter with indicator indicates if the filter is clogged (unacceptable
high pressure drop across the filter).

Manual IBOP Operation: The (lower) manually operated IBOP can be opened and closed by the supplied
22 mm Allen key/wrench.

Row of hydraulic proportional control valves: The valves are installed in a row at the rear of the HPS
gearbox. Each valve has a manual control lever for local operation, as indicated in the hydraulic flow
diagram.

Emergency Stop Manifold: The emergency stop/Main shut off manifold is located on the hydraulic
pressure line (fingerboard level).

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1.7 Operations
Before starting the HPS, the operator must be familiar with the AC drive, and the trip interlocks and
shutdown conditions. He must also be aware of the hazards following a trip of the AC drive during drilling.
These hazards include uncontrolled reverse rotation upon release of back torque, and back-off
(unscrewing) of tool joints.

1.7.1 Start
 HPS is started by pressing TD ON from Cyberbase keypad.
 It is recommended to deselect the TD On button when the HPS no longer is needed. This reduces the
wear of the blower and the lube oil pump, which otherwise run continuously.

1.7.2 Stop
Normal stopping takes place as described below.

 Starting point: The HPS has been operated in normal drill mode. The drill stem is disconnected from
the drillstring, and the pipehandler is unloaded (links straight down).
 Verify that the speed is turned to zero.
 Rotate the pipehandler to the most convenient position (convenient for maintenance, or just out of the
way).
 Position the HPS at the preferred height.
 Deactivate the motors by deselecting the TD On keypad button.
 For longer term shutdown, isolate the HPS according to procedure in the Maintenance section in User
Manual. .

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1.7.3 TD Drilling
After the HPS controls are activated, the HPS automatically enters drill mode. The HPS remains in drill
mode as long as none of the following modes are activated:

Spin mode
Torque mode
PH (Pipehandler torque wrench) makeup mode
PH (Pipehandler torque wrench) breakout mode.

Before each drilling session check the alignment of torque wrench according to Verifying and
Adjusting Torque Wrench Alignment in maintenance section.

Normal drill mode operation is entered by selecting drill mode and clockwise direction of main shaft
rotation (clockwise viewed from above). After setting drill torque drill motor can be driven by the speed
throttle hand wheel. Pipehandler operations can be carried out while in Drill mode.

Drilling motors can also be operated in counter clockwise direction. The direction can only be
changed at zero speed.

When drilling, RPM should be gradually applied, to avoid fast build up of torque in the drillstring,
consequently when stopping drilling the RPM should be gradually reduced.

Always assure that mudflow is sufficient before starting drill operation. The deublin washpipe
must not be “dry-running” for more than 5 minutes; the seals are depended on mud for
“lubrication”. Remove seals if “dry-running” for more than 5 minutes.

In CCW direction torque must not be set above drillstem connection make up torque.

Never rotate the main shaft when load in link hanger exceeds 10000 kg. The spring washer
packages in the torque arrestor will compress, and the load transferred through the split collar to
the drill stem. Rotation in this condition causes significant wear. (The load in the link hanger
includes links, elevator and the load in the elevator).

Rotating mainshaft without circulating mud for 5 minutes or more will result in excessive wear on
the mechanical seals of the Deublin washpipe. Refer to maintenance chapter on how to remove
seals before rotating without mud circulating.

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1.7.4 Parking Brake

The parking brake consists of a brake unit at the non-drive end of the drilling motors. It is engaged and
disengaged manually by a keypad button, and designed for static locking of the drill stem.

It is a static brake, not intended for retardation of the drillstem. The stem speed shall be zero or
near zero when the brake is engaged, or it will be subject to wear and possible damage.

The parking brake must be off when free rotation of the main shaft is required, such as during
makeup/breakout by the torque wrench, during tripping, and during positioning of heavy loads by the
pipehandler.

There is no automatic activation of the air brake, interlocks only towards Brake Out/Make Up sequence.

In a critical situation, such as during uncontrolled reverse rotation, the operator must be aware of
the risks of applying the air brake.

The parking brake must be off during makeup and breakout of the lower connection of a stand
with rig tongs, or there is a risk of backbite.

The brake must not be used as backup when breaking out pipe connections with rig tongs

1.7.5 Weight Compensator

The object of the weight compensator is to “remove” the HPS weight on the threads during spin in and
spin out sequences.

Weight compensator is only effective while torque wrench is not activated, and should only be activated:

 Before Stab in on stickup.

 Before Spin out.

Weight compensator should be deactivated soon after use, but never deactivate weight
compensator when:

 Drillstring is connected to HPS and slips are set.

 When HPS is close to stickup.

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1.7.6 Spin In and Make-up stands.

The drill motors are controlled by the speed and torque throttles. The recommended torque throttle setting
for spinning is 6800 Nm (5000 ft-lbs), and the speed throttle setting should not be above 20 rpm (to avoid
crossing threads).

When drilling with stands, HPS can use the drilling motors for spin in and makeup lower connection.

The backup torque on the stickup must be taken up by other equipment.

 Line up connection, activate the Weight Compensator.

 Lower the HPS and stabb-in connection.
 Select and activate Spin mode. The motors starts rotating the drill stem clockwise at the preset speed
and (low) torque limit, suitable for spinning in a connection. The rotation continues until the preset
torque limit is reached. The motors are then stalled at the spin torque limit for 3 seconds, before the
torque is ramped down to zero. During the sequence, the applied speed and torque is shown at the
speed and torque indicators. The sequence can be interrupted by repeating the activation command,
or by using the air brake.
 Set makeup torque to the makeup torque recommended by the pipe manufacturer.
 Activate the torque mode. The motor starts rotating the drill stem clockwise at the preset speed and
torque limit. The rotation continues until the preset torque limit is reached. The motors are then stalled
at the torque limit for 3 seconds, before the torque is ramped down to zero.
 After removing slips, deselect Weigh Compensator.

During the sequence, the applied speed and torque is shown at the speed and torque indicators. The
sequence can be interrupted by repeating the activation command, or by activating the air brake.

Too low makeup torque may result in loose pipe connections.

If back torque is trapped in the drillstring when make up mode is activated, the torque will be
released and cause reverse rotation.

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1.7.7 Make Up/Break out by Torque Wrench

Torque Wrench is used for make up or break out.

The following pipes/pieces can be made up/broken out by the torque wrench:

 Drillstring.
 Saver sub.
 Lower (manually operated) IBOP.
 Upper (remote operated) IBOP, after disconnecting actuator.

The crossover sub is out of the reach of the wrench, and must be made up and broken out by rig tongs.
The required makeup torque for each connection is stated on the drill stem assembly drawing in drawings
and partslist section.

1.7.7.1 Presetting of Makeup Torque

Before the torque is used for makeup/breakout, verify correct makeup torque. Setting is done at the
Cyberbase screen display in DCR.

The torque wrench and the drilling motor (in torque mode) share the same makeup torque setting.

The torque wrench always breaks out at the maximum design torque. The preset pressure in upper and
lower clamp also remains constant during makeup/breakout, irrespective of the torque setting. See the
Adjusting the Torque Wrench Clamp Pressure section for clamp pressure setting info.

Too low makeup torque may result in loose pipe connections. Too high clamp pressure may
deform smaller pipes.

1.7.7.2 Presetting Number of Breakout Strokes

The number of torque wrench breakout strokes (normally 1 or 2) is set at the Cyberbase screen display.

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1.7.7.3 Makeup by Torque Wrench

Makeup by torque wrench means activation of an auto sequence makeup. Before the sequence the
following preparations must have been made:

 The makeup torque set to the recommended value for this type and size of pipe.
 Parking brake must be off and the speed and torque throttles both set to zero.

The makeup sequence is as follows:

 Lower clamp on.
 Upper clamp on.
 Upper clamp turns one stroke in the makeup direction.
 Upper clamp off.
 Upper clamp turns back to start position.
 Upper clamp on.
 Upper clamp turns one stroke in the makeup direction.
 The sequence is repeated until the turning of the upper clamp results in the preset makeup torque
being met.
 Upper clamp off.
 Lower clamp off.
 The wrench returns to start position.

Sequence can be interrupted by re-pushing the button; this returns the wrench to start position.

Do not activate torquewrench without tooljoints in both clamps. Never grip on the actuator sleeve
of the upper ibop.

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1.7.7.4 Breakout by Torque Wrench

Breakout by the torque wrench means activation of an auto breakout sequence.
The breakout sequence includes the following steps (assuming two strokes preset):

 Lower clamp on.

 Upper clamp on.
 Upper clamp is turned one stroke in the breakout direction.
 Upper clamp off.
 Upper clamp is rotated back to the start position.
 Upper clamp on.
 Upper clamp is turned one stroke in the breakout direction.
 Upper clamp off.
 Lower clamp off, and the wrench is reset to the start position.

The sequence can be interrupted by repeating the activation command, and this returns the wrench to
start position.

Do not activate sequence without tooljoints in both clamps. Never grip on the actuator sleeve of
the upper ibop.

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1.7.8 Adjusting the Height of Torque Wrench

Operating the up and down movement of torque wrench for disassembly of the drillstem, can only done
from the local control valve.

The torque wrench up/down valve handle must always stay in down position when not in use.
This is to avoid torque wrench from creeping upwards, weakening/damaging the telescopic hoist
beam/torque wrench structure during torque wrench operation.

1.7.9 Retractable Dolly (Optional)

The dolly allows the HPS to be extended to the wellcentre and retracted to an out-of-the-way position. At
the same time the HPS is stabilized against sideways movements.

The HPS can be extended and retracted in manual or auto mode, and in both cases the drill stem speed
must be zero before the operation can start.

1.7.9.1 Manual mode

In manual mode the movement goes on only as long as the activation joystick is kept pushed more than
90% deflection, and at a preset limited speed.

1.7.9.2 Auto Extend

 The HPS must be in fully retracted position.
 The dolly extends HPS to the wellcentre. The speed is ramped up and down at the beginning and end
of travel to give a smooth and quick ride.

Auto sequences can be interrupted by repeating the activation command. It will then be necessary to run
the dolly to one of the end positions in manual mode before the next auto sequence.

1.7.9.3 Auto Retract

 The HPS must be at fully extended position in wellcentre.
 The elevator is open.
 The pipehandler rotates to its “zero” position, at which the elevator opening is towards the wellcentre.
 The dolly retracts the HPS to fully retracted position. The speed is ramped up and down at the
beginning and end of travel to give a smooth and quick ride.

Auto sequences can be interrupted by repeating the activation command. It will then be necessary to run
the dolly to one of the end positions in manual mode before the next auto sequence.

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1.7.10 Wireline Operations

Wireline plug (thread saver) is used when entering wireline through gooseneck.
Wireline plug contains of 2 halves forming a bolt that fits into hole in gooseneck.

 Stop mud pumps (bleed of pressure.)

 Open upper IBOP.
 Remove bolt on top of gooseneck and enter the wireline bolt. Tighten.

It is strongly recommended not using gooseneck/washpipe to enter cement or liquid slurry, as

this may plug the hole.

Also the ceramic deublin washpipe is not designed to handle cement.

Cement or liquid slurry should be fed trough a sub entry or cement head.

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1.7.11 Wireline Running Tool (Optional)

 Stop mudflow, and vent system according to

rig procedure.
 Unscrew the top lug on the gooseneck.
 Install spool piece on gooseneck connection.
 Install keeperplate onto spool piece and HPS.
 Install wireline adapter onto spool piece.

The spool piece can be installed

permanently, but requires that the wireline
tool is dismounted and that top lug of
gooseneck is installed on the top of the
spool piece.

The two gasket rings MUST be installed

between the lug unions.

*Selecting wireline mode (optional) is normally done

from the compensating AHC keypads.

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1.7.11.1 Using Wireline Conveyed Explosives

The water course (mud circuit) includes a gooseneck with a well wireline entry. This entry can be used for
wireline conveyed explosives.

When wireline conveyed explosives are entered via an electrically driven HPS, the wireline sheaves will
be close to the electrical system of the HPS. Unless the HPS first is completely isolated electrically, there
will then be a risk of premature detonation of the explosives.

Completely isolate the HPS electrically according to procedure in the Maintenance section in User
Manual.

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1.7.12 Operation of IBOPs

The drill stem is equipped with an upper and a lower IBOP (kelly cocks/mud valves) in series. The upper
IBOP is remote operated (opened/closed) from driller’s cabin by a yoke & sleeve mechanism operated by
a cylinder. The cylinder is actuated by solenoid valves located on a manifold at the rear of the HPS. No
status feedback signal is returned from the IBOP.

The lower IBOP can only be opened/closed (marked on the valve) manually by using the supplied Allen
key (special tool) directly on the valve stem. The key is for emergency and maintenance/service use.

Note that the lower IBOP shall not be used as mud saver. During normal operation the valve shall be fully
open. If the valve is left partly open, the mud circulating through it will cause erosion of the ball or seat
after a short time. Such wear will not be covered by warranty claims!

Do not use the IBOPs as mud savers!

1.7.13 Using the Pipehandler

1.7.13.1 Pipehandler Rotation

The entire pipehandler can be rotated 360 degrees CW or CCW by its rotating head. The rotation is on a
continuous basis, and independent of the drill stem rotation. Rotating can be done stepless, auto
sequence that rotates the shortest way to a pre-selected position or return to zero position (elevator
facing wellcentre). Rotation sequences can be interrupted by repeating the activation command. To
preset or reset a pre-selected position, rotate manually to this position, and push the setting button.

When the load in the link hanger (weight of links, elevator and load in elevator) exceeds ca. 10000 kg, the
spring washer packages of the torque arrestor will be compressed, and the load is then carried by the drill
stem. Before rotating the pipehandler in this condition, the drill stem must be preset for free rotation. (The
shaft rotates freely when the speed throttle and the torque throttle of the drilling motors are set to zero,
and the parking brake is off).

When manipulating heavy loads the pipehandler should be preset in cyberbase to lower % speed.

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1.7.13.2 Tilting Knuckle Links

Knuckle links for pipehandling.

 Link tilt float selected: Links slowly return to straight-down position.

 Link tilt float deselected: Links stay in position.

Link tilt lock angles must be less than ca. 90 degrees. This to prevent inadvertently clashing with dolly
guide rails.

 Forward tilting is normally used to reach the catwalk or the mousehole.

 Backward tilting to clear elevator from drillstring during drilling and to enable drilling down further.

If the knuckle links during tilting or in locked condition are exposed to vertical downward loads exceeding
the design capacity, they will be pulled to straight-down position.

The link tilt is not designed to withstand lateral stresses or loads in upward direction when tilted
forwards or backwards. When drilling down to the floor with links tilted backwards, the upward
movement of the elevator is limited to the gap in the link eyes, before overstressing the link tilt
mechanism.

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1.7.14 Elevator Operation

The HPS is prepared for operation with hydraulic and pneumatic (air operated) elevators. Detailed
installation and operating instructions must be sought in the user manuals from the elevator suppliers.

1.7.15 Handling Risers (Optional)

Applies only to NOV delivered Riser Running Tilt Tool.
Risers can be handled by the HPS. The layout of the riser running tool can vary but the installation and
functions are the same.

 Install elevator links as described in installing elevator links directly on link hanger.
 Be sure to install the link clamp.
 Verify that the riser weight is within the lifting capacity of the hps.

Ref drawing in the drawing and partslist section.

 Install riser running tool tilt cylinder Incl. chains (Upper and lower shackles).
 Install the anti rotate clamp.
 Couple the hydraulics to the riser running tool tilt cylinder.
 Couple the hydraulics to the riser handling tool.

Before Operating the Riser Running Tool, Link Tilt Float Mode Must Be Deselected.

When handling risers the link tilt forward is used to position the riser tool.
The right horizontal position is done by tilting the riser tool.

After connection of the riser, select link tilt float while lifting.

Never use the link tilt backwards while the riser tilting tool is connected, the cylinder will then
collide with the torque wrench.

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1.7.16 Running Riser With Shaffer RRT

Ensure before commencing running riser that:

 The 3 off hydraulic hoses, via Quick Connectors, are connected to the RRT
 The locking dogs are fully retracted - are under the surface of the RRT housing
 If the locking dogs are in extended position, ensure the Manual Locking Handle is set to the
"Unlock" position, before operating the "RRT Unlock" function from Cyberbase.

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 Engage RRT into Riser Joint on Catwalk

 Operate the "RRT Lock" function from Cyberbase
 Engage the RRT Manual Lock - if RRT Dogs are not fully engaged in Riser it is not possible to
operate the Manual Lock
 Disconnect RRT Quick Connectors from ALL hydraulic supply Lines

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Raise Top Drive and align

lower end of riser over
the Spider Gimbal with
the Tail-In Arm (not
shown)

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1.7.16.1 Interlocks
 Manual Mechanical Locking of RRT - There are four Visual Indication Pins that are attached to the
Locking Dog Piston. When the piston is retracted the Indicator Pins are visible and when the piston is
extended the pins are under flush. When the manual locking system is in the LOCKED position this
prevents the piston / indicator pins from retracting.
 Disconnect Quick Connectors from ALL hydraulic supply lines (RRT LOCK, PILOT & UNLOCK)
before running Riser from Catwalk to Spider Gimbal
 When the RRT travels a pre-defined distance over the drill floor the "RRT Unlock" function on the
Cyberbase keypad is deactivated and will only be available once the RRT has come below the height
limit
 The load cells in the Top Drive will be able to check for residual weight attached to the RRT and so
will again deactivate the "RRT Unlock" function. When the weight of the Riser String is transferred
from the Top Drive to the Spider Gimbal will the "RRT Unlock " function will become active on the
Cyberbase Keypad.

1.7.17 Heavy Lifting

See the product datasheet section witch state the lifting capacity of the knuckle link system, elevator links
and machine installed.

 Lifting above knuckle link system capacity must be done with a pair of elevator links
installed directly on the link hanger. The link tilt function will then no longer be available.
 Correct elevator must be installed.

Separate procedures later in this chapter describe how to remove the knuckle links, and how to install
elevator links directly on the link hanger.

When the load on the link hanger (weight of links, elevator and load) exceeds load capacity, the
load will be transferred from the pipehandler to the drill stem via the split collar. Rotating the drill
stem during such lifting will cause severe wear, and must be avoided.

1.7.17.1 Pipehandler Rotation and Jog mode (Optional)

In Top Drive Riser Handling Cyberbase menu there is a Jog CW/CCW function, this function should be
used simultaneously with PH CW/CCW when handling loads exceeding load capacity with pipehandler.

Push and hold both PH CW and Jog CW to rotate load Clock wise.
Push and hold both PH CCW and Jog CCW to rotate load Counter Clock wise.

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1.7.18 Changing Drillpipe/Tooljoint Size

When changing drillpipe size, the operator must take in consideration:

Verify correct dies is assembled for connection.

The hard stamped range on dies and wear bushing refers to tooljoint size, not pipe size.

 Saver Sub: Verify that the existing saver sub is suitable for the new size, and change the sub if
necessary.
 Wear bushing: Verify that the correct wear bushing is installed. Consult Maintenance section.
 Dies: Verify that correct dies in lower clamp and lower backup is installed. Consult Maintenance
section for how to change die assemblies.
 Verify correct alignment of torque wrench. Consult Maintenance section.

If weaker tooljoint or small OD pipe requires less clamp force (check manufacturers’
recommendation), see section adjusting the torque wrench clamp pressure

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1.7.18.1 Adjusting the Torque Wrench Clamp Pressure

The preset torque wrench clamp is suitable for most OD drillpipes and tooljoints, however if weaker
tooljoint or small OD pipes requires less clamp force, to avoid excessive wear, the pressure can be
adjusted as follows:

 Spin in a pipe on saver sub.

 Connect a calibrated pressure gauge to the LS
port at the side of the valve row.
 Locate valve for clamp On/Off.
 The clamp pressure is the upper screw.
 Unscrew the cover nut.
 The adjusting screw can now be turned by a small
Allen key.
 Push the valve’s manual control lever in the
Clamps On direction.
 While keeping the lever pushed, adjust the clamp
pressure screw while reading the outlet pressure.
 Remove the gauge and refit the cover nut.
 Verify correct gripping and operation of torque
wrench.

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1.7.19 Adjusting the Weight Compensator

The objective of the weight (thread) compensator is protecting the pipe threads from damage when the
HPS is connected to (and disconnected from) the drill string. The compensator system achieves this by
taking up the weight of the HPS via a set of hydraulic cylinders which is installed between the HPS and
the adapter link/travelling block. The maximum weight on the threads will be approx. 1-2 ton.

Adjusting the weight compensator is done in Cyberbase in DCR.

1.7.20 Changing Elevator Links in the Knuckle Links

Install the new pair of elevator links in the knuckle links as follows:

 Slew the pipehandler to a suitable position

 Lower the HPS to suitable height above the drillfloor.
 Bring the preferred pair of elevator links to the drillfloor. The lower end of the link is the one with the
smaller hole. If the lower end is bent, the bending shall point inwards.
 Inspect the contact surfaces at both ends of the elevator links (inside the holes) for cuts or scars. All
uneven parts must be filed or grinded until the surface is all smooth. This is an important point, and
neglecting it may make it hard to (later) remove the links.
 Inspect the contact surfaces of the knuckle link shafts for cuts or scars. All uneven parts must be filed
or grinded until the surface is all smooth.
 Grease the link hanger ears and the eyes of the new pair of elevator links.

Remove Inserts When Using Blohm+Voss Elevator Links

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 Hoist and balance by utility winch and suitable slings the elevator link to a horizontal working height
position.
 Unscrew the chain bolt and the shaft locking device, use the pin hammer special tool (with tilt adapter
at the end) to pull out the knuckle link shaft.
 Lower the links onto suitable arrangement on drilfloor.
 Bring in a new pair of elevatorlinks.
 Hoist them into position and insert knuckle link shaft and locking device.

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1.7.21 Installing Elevator Links Directly on Link Hanger

The supplied HPS pipehandler is dressed with knuckle links. (See product datasheet for lifting capacity.)
Before lifting operations above knuckle link capacity, the knuckle links must be removed and suitable
elevator links installed in their place, directly on the link hanger. Link tilt function will no longer be
available.

 Unscrew and remove the 3 bolts and safety plate on backside of upper knuckle joint, and use pin
puller to remove bolt.
 If changing to riser running tool, the lowest knuckle pin must be pulled.
 Remove bolt in upper link hanger ear

Use winch to carefully lift out the complete knuckle link assembly and place them out of
workspace.

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 Bring in a pair of (stiff) elevator links, hoist them into position and enter bolt, tighten and secure nut.

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1.8 Disturbance of Operation

Reference is also made to the Fault Finding guide in the Maintenance chapter.

Following scenarios will automatically shut down the ac power supply and allow the drillstring to
reverse at uncontrolled speed, and involve risk of the string tooljoints backing off:
 The hi-hi motor temp alarm is trigged.
 The hi-hi gear oil temp alarm is trigged
 The lo-lo gear oil pressure is trigged.

Therefore, always stop the operation and eliminate the reason that trigged the alarm before
automatic shutdown occurs.

1.8.1 Drilling With one Motor

The HPS can operate with just one motor, with reduced torque but same RPM.

 Switch off the main circuit breaker in VFD for the motor not operating.
 Torque setpoint in Cyberbase will automatically be reduced to just one motor.

Drilling with one motor is not recommended as a “normal operation”, and the fault should be
rectified as soon as possible.

1.8.2 Releasing Trapped Back Torque in Drillstring

When back torque is trapped in the drillstring during drilling, the torque can be released in one of the
following ways:

1.8.2.1 Torque and Speed Throttles

Stop the string rotation by setting the speed throttle to zero.
Push and confirm Motor Torque zero; it slowly ramps down the backtorque.

1.8.2.2 Drilling Motor Blackout

Apply parking brake manually. The trapped back torque will then be locked in the drill string. If possible,
release the trapped torque via the bottomhole assembly.

Also if possible, restart the VFD and HPS, select Drill mode and clockwise direction of main shaft
direction. Check that the drill torque set point is as before the blackout, and carefully adjust the speed
throttle slightly up from zero. The torque will be re-built, and the brake can be released without the risk of
uncontrolled reverse rotation.

1.8.2.3 Through The BHA

Before stopping the rotation of the drill string, hoist the HPS up and down a few feet to clean the hole.
Adjust the speed to zero and let the torque be released at the bottom of the string.

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1.8.3 Dealing with Alarms

When an alarm is activated, the operator must evaluate the situation and act so that risk and damage is
minimized. Also see the remedies recommended after an emergency stop.

After a motor temperature high alarm, or a low gearbox oil pressure or level alarm, it is important that the
HPS is shut down soonest. If possible the shutdown should be in a normal manner, using the ordinary
operation controls. The cause must then be examined and remedied. If the operations continue with one
these alarms on, there is an increasing risk of flashover, sparks, total destruction of motor or gearbox, and
uncontrolled stop of the HPS.

1.8.4 Trip of Power to the Drilling Motors

If the power to the drilling motors is tripped during drilling, the effect on the HPS is the same as if the
emergency stop was activated. See the Emergency Stop section for recommended response.

1.8.5 Drilling Motors Cooling Failure

If drive motors are equipped with external coolers (Blowers).

The drilling motors are air cooled by a dual cooling blower (two impellers driven by the same motor). The
blower is automatically switched on/off when needed. If the blower stops due to blower motor failure, this
will only be alarmed when high temperature is detected in the drilling motor.

1.9 Training Program for Operators

Training programs are available from supplier.

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