User Manual No.: T4802-Z-MA-001, Rev.

0
Equipment: Top Drive
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CHAPTER 5

OPERATING INSTRUCTIONS

Chapter 5: Operating Instructions

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Equipment: Top Drive
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TABLE OF CONTENTS

5 OPERATING INSTRUCTIONS...................................................................................4
5.1 Safety Summary...............................................................................................4
5.2 Emergency Stop...............................................................................................6
5.2.1 Restarting HPS after Emergency Stop.................................................7
5.3 Description of Controls.....................................................................................8
5.3.1 Cyberbase Controls..............................................................................8
5.3.1.1 Top Drive Keypad..............................................................................9
5.3.1.2 Top Drive Pipehandling Keypad......................................................12
5.3.1.3 MP Control Keypad..........................................................................14
5.3.1.4 Screen Displays...............................................................................16
5.3.2 Local Control Valves and Indicators...................................................17
5.4 Normal Operation...........................................................................................18
5.4.1 Basic Starting and Stopping Procedure..............................................18
5.4.2 Stand Drilling.......................................................................................20
5.4.3 Tripping...............................................................................................21
5.4.4 Heavy Lifting.......................................................................................21
5.4.5 Support Procedures............................................................................22
5.4.5.1 Drill Mode Operation........................................................................22
5.4.5.2 Spin Mode Operation.......................................................................23
5.4.5.3 Setting the Spin Mode Parameters..................................................23
5.4.5.4 Makeup Mode Operation.................................................................24
5.4.5.5 Setting the Makeup Mode Parameters............................................24
5.4.5.6 Breakout Mode Operation................................................................25
5.4.5.7 Setting the Breakout Mode Parameters...........................................25
5.4.5.8 Using the Parking Air Brake.............................................................26
5.4.5.9 Using the Retactable Dolly...............................................................27
5.4.5.10 Releasing Trapped Back Torque in Drillstring...............................28
5.4.5.11 Gear Shifting..................................................................................29
5.4.5.12 Using Wireline Conveyed Explosives............................................29
5.4.5.13 Operation of IBOPs........................................................................30
5.4.5.14 Using the Pipehandler....................................................................31
5.4.5.15 Elevator Operation.........................................................................35

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5.4.5.16 Changing from One Drillpipe Size to Another................................35

5.4.5.17 Installing Elevator Links on Link Hanger........................................36
5.5 Disturbance of Operation................................................................................37
5.5.1 Dealing with Alarms............................................................................37
5.5.2 Trip of Power to the Drilling Motor......................................................37
5.5.3 Drilling Motor Cooling Failure..............................................................37
5.5.4 Gearbox Lubrication Failure................................................................38
5.6 Training Program for Operators......................................................................38

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5 OPERATING INSTRUCTIONS

The operating instructions of this chapter are based on the assumption that the top
drive already has been installed and prepared for ordinary routine operation.

In the different sections the top drive is frequently referred to by the HPS
abbreviation, which is a short version of the type code (see chapter 2).

5.1 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.

The following points sum up the safety aspects related to operation:

 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.
 During starting: If the speed and torque throttles have not been set to zero, or
there is trapped torque in the drillstring, the drilling motor may start rotating by
itself after activation of the motor controls.
 If the power to the drilling motor is tripped during drilling, the motor can no longer
be controlled by the ordinary controls. There is then a risk of uncontrolled
reverse rotation, which may require manual activation of the parking air brake.
 If back torque is trapped in the drillstring after a spin-in or torque-up sequence
against a rig tong, the torque will be released and cause reverse rotation of the
tong.
 In a critical situation, such as during uncontrolled reverse string rotation, the
operator must be aware of the risks of undesired breakout.
 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.

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 Never rotate the drilling motor while the load in the link hanger exceeds ca. 10
tons. The link hanger will then be resting on the drill stem’s split collar, and the
result will be excessive wear of the main load carrying components. This may, in
due course, result in a hazardous situation.
 If possible, don’t turn the speed throttle quickly down to zero during drilling.
Rapid zeroing causes the drilling motor moment of inertia to try stopping the
rotation of the drillstring, and there will be a risk of the string tooljoints backing
off.
 No interlocks or sensors monitor uncontrolled reverse string rotation. If the air
brake gets hot (look for smoke), leave it alone until the temperature is normal.
 In a critical situation, such as during uncontrolled reverse string rotation, the
operator must be aware of the risks of applying the air brake.
 The air brake must be off during makeup and breakout of the lower connection
of a stand with rig tongs, or the tongs may snap back.
 In conditions requiring free rotation of the drill stem, only the speed throttle of the
AC motor needs be set to zero. If free rotation is not allowed, there is a risk of
serious damage to the gearbox, the load carrying split collar, the link hanger and
the link tilt system.
 The parking air brake is only intended for static locking of the drill stem, and
shall not be used as backup when breaking out pipe connections with rig tongs.
Activating the brake while the drill stem is rotating will cause wear and possible
damage of the equipment.
 The speed must be very slow when rotating the pipehandler with load in the
elevator.
 The link tilt is not designed to withstand lateral stresses or loads in upward
direction when tilted forwards or backwards.
 Too low makeup torque may result in loose pipe connections.
 Always ensure that the pipe is properly gripped or secured by other equipment
before opening the elevator!
 The HPS must be completely isolated from the electric supply before using
wireline conveyed explosives in the well. Otherwise there is a risk of premature
detonation when the wireline sheaves are near the electric parts of the top drive.
 Before starting any work involving the hydraulic system, the machine must be
isolated from the hydraulic supply, and the power supply to all electric motors
must be shut off.
 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.
 The equipment is powered by high pressure hydraulic oil. Beware of the risk of
pipe/hose burst. Pipe/hose connections and filter bowls must not be unscrewed
before the hydraulic system is depressurised.
 If anyone gets hydraulic oil into the eyes or open wounds, wash at once with lots
of fresh water. Consult a doctor if necessary.
 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!

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5.2 Emergency Stop

A HPS (top drive) emergency stop button is located at driller’s operator station in
DCR. Pushing this button activates the following HPS shutdown sequence:

 The electric power supply to the AC drilling motor is shut off (VFD tripped),
regardless of the settings of the drilling motor speed and torque throttles.
 The electric power to all HPS solenoid valves, except those for operation of
the air brake valve and remote operated IBOP valve, is shut off.
 The electric power to the drilling motor heaters, the cooling blower motor, the
gear oil circulation pump motor, and the oil cooler motor is shut off.
 All active sequence-based functions are stopped.
 The air supply to any air operated power slips is shut off.
 The operation of the parking air brake is not affected.

Manufacturer’s standard is not including automatic activation of the parking air

brake in the emergency stop shutdown sequence, at uncontrolled reverse rotation,
or at power/VFD blackout. Such automatic activation may result in increased
hazard. Instead driller is supposed to evaluate the situation, and take the required
action as he deems necessary. This will normally be to activate the brake manually
(by the Brake On keypad button) when the rotation approaches zero speed.
Activating the air brake before standstill will cause wear and possible damage of the
equipment. There is also a risk of over-torque in the pipe connections.

The operator must be aware of the risks by activating the emergency stop during
drilling. The drilling motor can no longer be controlled by ordinary operating controls,
and there is a risk of uncontrolled reverse rotation of the drillstring. 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.

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5.2.1 Restarting HPS after Emergency Stop

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

 Verify that the air brake is on.

 Set both the speed throttle and the torque throttle to zero.
 Reset the emergency stop button.
 Remedy any active alarms. It is not possible to restart the VFD or run the AC
drilling motor if any of the following alarms is present:

 AC motor temp high

 Gear oil temp high
 Gear oil pressure low
 VFD tripped

 Reset the VFD.

 Reactivate the HPS controls.
 If the emergency stop interrupted an ongoing opening of the elevator, the
activation button will be flashing. If that is the case, verify that the pipe is
gripped/secured by other equipment, and complete the opening by double-
pushing the button. Verify visually that the elevator has been opened.
 Turn off/release the air brake.
 If the emergency stop was activated during rotation of the drillstring, the drill
stem (main shaft) pipe connections must be checked visually. If there are any
signs of the connections having backed off or becoming over-torqued, the
connections must be checked with respect to correct makeup torque.

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5.3 Description of Controls

5.3.1 Cyberbase Controls

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

It is assumed that the operator (driller) 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. Studying the commissioning
procedure may also be useful. For further Cyberbase info, reference is made to the
Drilling Control Room user manual, and to the following documents in that manual:

 Doc. S0100469-TDO-331: Functional Design Specification, DCDA Keypads

 Doc. S0100469-TDO-332: Technical Document, DCDA Displays

A typical Cyberbase operator station is shown in the below illustration. The following
main parts are numbered: 1: Two screens. 2: One mode switch. 3: One machinery
emergency stop button. 4: Two joysticks for machinery control. 5: Two keypads for
machinery control. 6: One trackball (mouse). 7: One numerical keyboard.

Typical Cyberbase Operator Station

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5.3.1.1 Top Drive Keypad Top Drive

Driller’s left keypad

TD
Button Func Description ESC
Swap p Swap to DW
 p Swap to RT RT Esc DW
TD
 PH
 p+c Grabber On
 p Swap to TD Pipehandling Grabber
F1 p+h Top Drive Torque Decrease On RT
F2 p+c Top Drive Reverse
F3 p+h Top Drive Torque Increase
F4 p+c Top Drive Brake Out Mode
F5 p+c Top Drive Spin Mode Torque TD Torque
F6 p+c Top Drive Make Up Mode - Rev. +
F7 p+c Auto driller Rate of Penetration
F8 p+c Zero WOB
B/O Spin M/U
F9 p+c Auto Driller Weight On Bit
Mode Mode Mode
F10 p+c Top Drive On
F11 p+c Top Drive Brake On
F12 p+c Dw Park Brake Auto Zero Auto
Js.  Top Drive Speed Increase ROP WOB WOB
Js.  Top Drive Speed Decrease
Js. 
Js.  TD TD DW
Js.btn. p+c TD Zero Speed On Brake Park
p+h Activate Speed TD On

Confirm
Using the Pushbuttons

p= Push the button (single push) Top Drive

p+c = Push and confirm (Push the Confirm
button to activate the command. Speed Inc.
Safety measure.)
p+h = Push and hold (keep the button pushed
while the command is executed)
2p = Double-push (Push twice within a Act.
second. Safety measure.)

Speed Dec.

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Grabber On button: Push and confirm the button to set the backup grabber on the
tooljoint facing the grabber (at the present grabber height). The grabber cylinders
will be extended and the dies of the grabber grip on the tooljoint. The HPS is
thereby allowed to make up or break out the grabbed pipe/sub from the drill stem
above. Most frequently used for makeup/breakout of drillstring to/from saver sub.

Torque – button (Torque Throttle): Keep the “Minus” button pushed to decrease
the drill mode torque setpoint. Observe the reduction at the torque indicator at the
screen display.

WARNING:
THE TORQUE INDICATOR DOES NOT SHOW BACK TORQUE TRAPPED IN
THE DRILLSTRING!

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.

Torque + button (Torque Throttle): Keep the “Plus” button pushed to increase the
drill mode torque setpoint. Observe the increase at the torque indicator at the
screen display.

B/O Mode (Breakout Mode) button: Selecting the button makes the HPS start
rotating counter-clockwise at 20 rpm. The output torque will be at maximum for
subject drilling motor and gear. The rotation continues as long as the function is on.
If the torque is insufficient to break out the connection (the motor is stalling), the
function will automatically be switched off within 10 seconds to prevent damage of
the motor.

Spin Mode button: Selecting the (spinning in) button makes the HPS start rotating
clockwise at 20 rpm. The torque setpoint will automatically be set to 3000 ft-lbs
(4000 Nm). When the setpoint torque is reached, combined with zero motor speed,
the Spin Mode button will automatically be deselected. The HPS speed must be
zero before this function is allowed.

M/U Mode (Makeup Mode) button: Selecting the button makes the HPS start
rotating clockwise at 20 rpm. The output torque will be as the makeup torque
setpoint (preset at the screen display). When the setpoint torque is reached,
combined with zero motor speed, the mode will automatically be switched off
(button deselected). The HPS speed must be zero before this function is allowed.
Note that if the makeup is run in combination with Grabber On, the speed setpoint
will automatically be reduced to 5 rpm.

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

TD Brake On button: 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, or it will be subject to wear and possible damage. No interlocks prevent
operation of the brake.

Joystick, vertical axis (Speed Throttle): Increase the drill mode speed setpoint (and
speed) by pushing the joystick in the Speed Inc. direction (along the vertical axis).
Observe the speed setpoint indicator and the actual speed indicator at the screen
display during the adjustment. When the joystick is returned to neutral, the speed
setpoint remains where it was set. (You can only increase, not decrease, the
setpoint in this direction.)

Decrease the drill mode speed setpoint by pushing the joystick in the Speed Dec.
direction. Observe the speed setpoint indicator and the actual speed indicator at the
screen display during the adjustment. When the joystick is returned to neutral, the
setpoint reduction stops. To stop the rotation, keep the joystick pushed in the
decrease direction until the speed setpoint is zero.

Joystick button: Push and confirm the button on top of the joystick to quickly set the
drill mode motor speed setpoint to zero (and thereby stop the motor in the fastest
normal way).

Push and hold the joystick button to return to the (drill mode) motor speed set by the
joystick (speed throttle) before the button was double-pushed. Let go the button
when the speed is back to normal.

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5.3.1.2 Top Drive Pipehandling Keypad TD Pipe Handling

Driller’s left keypad

TD
Button Funct Description
ESC
Swap p Swap to Dw RT Esc RT
 p Swap to RT
TD
 p+c PH Lock

 p Swap to TD PH DW
F1 Lock
F2 p+c PH Rotate to Zero
F3
F4 p+h PH Rotate CW PH
F5 Rotat to
F6 p+h PH Rotate CCW Zero
F7 p+c Dolly Auto Extend
F8 PH PH
Rotate Rotate
F9 p+c Dolly Auto Retract
CW CCW
F10 p+c Top Drive On
F11 p+c Link Tilt Float Dolly Dolly
F12 p+c Dw Park Brake Auto Auto
Js.  p+h Dolly Extend Ext. Retr.
(>90%)
Js.  p+h Dolly Retract TD Link DW
(>90%) On Tilt Park
Js.  Link Tilt Backwards Float
Js.  Link Tilt Forward
Js.btn. 2p Elevator Open / Close
Confirm

Dolly Ext.

Link Tilt Link Tilt

Bwd Fwd
Elev.
Close

Dolly Retr.

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PH Lock button (rotation lock): If the button is selected after the pipehandler has
been rotated to the “zero position” (elevator opening pointing forwards, see the next
button), a hydraulic cylinder will be extended and stop the pipehandler from rotating
while running makeup or breakout against the backup grabber. Repeat the
activation command to deselect the lock function.

PH Rotate to Zero button: Push and confirm the button to make the pipehandler
(with the elevator) rotate clockwise and automatically stop when the elevator
opening is pointing in the forward direction.

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

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

Dolly Auto Ext: Push and confirm the button activate an auto extend sequence by
the retractable dolly. The dolly will then extend the HPS to the wellcentre in the most
efficient and accurate way.

Dolly Auto Retr: Push and confirm the button activate an auto retract sequence by
the retractable dolly. The dolly will then retract the HPS from the wellcentre to the
fully retracted position in the most efficient and accurate way.

TD On button: See description for the Top Drive keypad.

Link Tilt Float button: Select the button to make the link tilt float freely after the tilting
commands are ended. Gravity will then slowly cause the elevator links to drop to
straight-down position. When the button is deselected, the links will be hydraulically
locked at the tilt angle they are left when the tilt controls are left alone.

Joystick, vertical axis: Extend and retract the retractable dolly (with the HPS) by
moving the joystick in the Extend and Retract direction.

Joystick, horizontal axis: Tilt the knuckle links (with the elevator links and elevator)
forward and backward by moving the joystick in the Link Tilt Backward and Link Tilt
Forward direction.

Joystick pushbutton: Doublepush the button on top of the joystick to open the
unloaded elevator. If the elevator is loaded, it normally cannot be opened. The
elevator is closed by its mechanical trigger mechanism, which is activated when a
pipe is inserted correctly into the elevator.

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Mud Pumps
5.3.1.3 MP Control Keypad

Driller’s right keypad

Button Func Description

Swap


Esc
p MP Stop/Resume
 p+c IBOP Close
 p+c MP Sync. Mode
F1 p+h MP1 Speed Set point Decrease IBOP MP
F2 p+c MP1 On/Off Close MP Sync.
F3 p+h MP1 Speed Set point Increase Stop/
F4 p+h MP2 Speed Set point Decrease Resume
F5 p+c MP2 On/Off
F6 p+h MP2 Speed Set point Increase MP1 MP1 MP1
F7 p+c MP3 Speed Set point Decrease - On +
F8 p+c MP3 On/Off
F9 p+c MP3 Speed Set point Increase MP2 MP2 MP2
F10 p+c Trip Tank Pump On/Off
- On +
F11 p+c Mix Pump 1 On/Off
F12 p+c Mix Pump 2 On/Off
Js.  DW Lower MP3 MP3 MP3
Js.  DW Hoist - On +
Js.  DW Slow Speed
Js. 
Js.btn. 2p Slips Open/Close TT Mix Mix
Pump Pump 1 Pump 2
On On On

Confirm
IBOP Close button: Select (push and confirm)
the button to close the remote operated
IBOP (kelly cock) in the drill stem. Drawworks
Repeat the command to open the IBOP.
(The button is included in other keypads Lower
as well.)
Note:
When “MP Sync” is activated, the buttons “MP2 –“, Slow
“MP2 +”, “MP3 –“ and “MP3 +”will be disabled.
Slips
Close

Hoist

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Button Func Description MP Control (AD)

Swap

 p+c MP Stop Resume
 p+c IBOP Close

F1 p+h MP1 Speed Set point Decrease
F2 p+c MP1 On/Off
F3 p+h MP1 Speed Set point Increase
F4 p+h MP2 Speed Set point Decrease Esc
F5 p+c MP2 On/Off
F6 p+h MP2 Speed Set point Increase
F7 p+h MP3 Speed Set point Decrease IBOP
F8 p+c MP3 On/Off Close Stop/
F9 p+h MP3 Speed Set point Increase Resume
F10 p+c Trip Tank Pump On/Off
F11 p+c Mix Pump 1 On/Off
F12 p+c Mix Pump 2 On/Off MP 1 MP1 MP1
Js.  Auto driller Set point Increase - On +
Js.  Auto driller Set point Decrease
Js.  p Auto Driller Deactivate (90 % to
deactivate) MP 2 MP2 MP2
Js.  - On +
Js.btn.
MP 3 MP3 MP3
- On +
Note:
When “MP Sync” is activated, the buttons “MP2 –“, TT Mix Mix
“MP2 +”, “MP3 –“ and “MP3 +”will be disabled. Pump Pump 1 Pump 2
On On On

Confirm

Auto driller Set point

Inc.

Deactivate

Dec.

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5.3.1.4 Screen Displays

Top Drive (and Rotary Table) Display

The screen displays are used for status and alarm information, and for presetting
different operating parameters. At the Top Drive field of the above display the drill
stem (main shaft) Speed indicator is shown at the upper left corner. The thick bar
shows the applied speed, and the thin bar (to the left) shows the speed setpoint.
Both values are repeated by digits below the bars. The applied and setpoint torques
are likewise shown at the adjacent Torque indicator.

Clicking the S-button makes a pop-up for resetting the belonging parameter appear
on the screen. The present setting is shown to the right of the button.

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5.3.2 Local Control Valves and Indicators

Drawing: (Hydraulic) Flow Diagram

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, which
mostly are located at the rear of the HPS, 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 by pop-up
plunger and red colour if the filter is clogged (unacceptable high pressure drop
across the filter). Filter clogging is not covered by the alarm system.

Manual IBOP Operation: Both the (upper) remote operated IBOP and the (lower)
manually operated IBOP can be opened and closed manually by a supplied 22 mm
Allen key.

Row of hydraulic proportional control valves: The valves (main valve block) 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.

Gear Shift Shafts: The gearbox has a horizontal gear shift shaft that sticks out from
two of its sides, with local gear indicators next to the shaft ends. The shaft is used to
shift between low speed gear and high speed gear. See the Gear Shifting section
for more information.

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5.4 Normal Operation

5.4.1 Basic Starting and Stopping Procedure

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 VFD during drilling. These hazards include uncontrolled reverse rotation
upon release of back torque, and back-off of tool joints.

Preparations

 Starting point: The HPS is suspended in the travelling block, and properly
aligned to wellcentre. All service loop cables are properly terminated and each
cable is individually tensioned by the service loop bracket tie rods.
 Verify proper level of gear oil in the gearbox.
 Verify that the HPS drive has been lubricated according to the daily/weekly
maintenance schedule.
 Inspect the HPS to verify that it is ready for operation (no obstructions, the
umbilicals moving freely and in good working condition, no damage caused by
collision with other equipment, no maintenance going on, etc.).
 Verify that hydraulic isolation valve on the pressure line is open.
 Verify that pneumatic isolation valve is open.
 Verify that air ventilation plug on the gear box is open.
 If the start takes place in very cold surroundings, special attention must be paid
to the gearbox lube oil system. (The oil viscosity may be too high to allow
circulation, and this may result in damages to the HPS).

Starting

 Engage the main circuit breaker.

 Prepare and preset the VFD for HPS service.
 Verify that the emergency stop is reset.
 At driller’s operator station, select and activate the HPS controls (TD On). The
following start-up sequence will automatically take place:

 The blower motor starts purging and cooling the drilling motor.
 The lube oil circulation motor starts.
 All monitoring instruments on the HPS become active.

 Check that blower has started.

 Check that lube oil motor has started.
 Acknowledge and remedy any HPS alarms.

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Operation

 The HPS is now ready to operate in ordinary drill mode. The drilling motor can
be operated by the controls of the Cyberbase keypads.
 In the case of disturbances, consult the Disturbance of Operation section later in
this chapter.
 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/motor, which
otherwise run continuously.

Stopping

Normal stopping takes place as described below.

 Verify that the drill stem (main shaft) is disconnected from the string, and the
pipehandler is unloaded (links straight down).
 Verify that the HPS is placed in ordinary drill mode, and that the speed and
torque throttles are set to zero.
 Rotate the pipehandler to the most convenient position (convenient for
maintenance, or just out of the way).
 It is recommended to leave the HPS at the wellcentre position (dolly extended),
as the dolly’s extend/retract cylinders then will be stroked in and the cylinder
rods protected against corrosion.
 Position the HPS at the preferred height (by the drawworks controls).
 Deactivate the motor by deselecting the TD On keypad button. This initiates the
following shutdown sequence:

 The blower stops (5 minutes delay)

 Motor for gear oil circulation stops.
 The drilling motor is prohibited from rotating.
 The TD On button is no longer highlighted.

 For longer term shutdown, shut down the HPS by switching off the main circuit
breaker (as described in the VFD user manual). The standstill heating of the
drilling motor windings should be left on.

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5.4.2 Stand Drilling

The HPS is designed for efficient drilling by stands, which first have been
prefabricated and stored in the fingerboard.

 Starting point: The HPS operates normally and is hoisted ca 2 meters above the
fingerboard while the pipe racker brings the next stand from the fingerboard to
the wellcentre. The makeup torque setpoint is set to the value recommended by
the pipe manufacturer. The HPS pipehandler is rotated to the forward (“Zero”)
position, the elevator is open and retracted, and link tilt lock mode is selected
(link tilt float mode deselected). CW direction of rotation is selected, and the
remote operated IBOP is closed.
 Run the iron roughneck (HydraTong) to the wellcentre, and set its lower torque
wrench clamp (backup clamp) on the tooljoint of the stickup.
 Stab in the the stand on the stickup by the racker, set the racker’s grip head to a
position that allows free rotation of the stand, and withdraw the racker’s lower
guide arm.
 Spin in and make up the lower connection with the HydraTong.
 Open the backup clamp of the HydraTong and withdraw the HydraTong.
 At the HPS, activate the spin mode, carefully lower the HPS and stab in the
saver sub on the stand. (The weight compensation system of the HPS will
function automatically, provided that the HPU is running, and will protect the pipe
threads from damage during the stabbing.)
 Spin in the saver sub on the stand, and make up the upper connection.
 Verify that the connections are made up to the recommended makeup torque.
 Open HydraRacker’s roller jaw and withdraw the HydraRacker.
 |Unload the power slips by carefully hoisting the HPS a little, and then open the
power slips.
 Open the IBOP and start the mud pumps.
 Start the drill stem rotation, and increase the speed to the selected speed
setpoint.
 Lower the travelling block and continue drilling.
 Verify that the drill torque setpoint is as preferred.
 When the stand is drilled close to the drillfloor, tilt the link tilt backwards and run
the bails (elevator links) + elevator out as far as possible.

WARNING:
MAKE SURE THAT NO PERSONNEL ARE PRESENT WITHIN THE OPERATION
RADIUS OF THE ELEVATOR WHILE DRILLING WITH THE LINK TILT IN THIS
POSITION.

 Drill down as far as possible. Stop the rotation and confirm zero speed setpoint.
 Hoist the travelling block and set the power slips so the stickup is 3-4 feet above
drillfloor.

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 Lower the elevator back and stop it just behind the stickup.
 Stop the mud pumps and close the remote operated IBOP.
 Rotate the pipehandler to the “Zero” position. In this position, activate the
pipehandler’s rotation lock (select PH Lock).
 Set the backup grabber on the pipe (select Grabber On).
 Select breakout mode and break out and spin out the drillpipe from the drill
stem. Verify that the saver sub is broken out from the drillpipe stickup.
 When the spinning out is completed, stop the spinning by deselecting the
breakout mode.
 Release the backup grabber from the stickup (deselect Grabber On).
 Hoist the travelling block until the HPS is ca 2 meters above the fingerboard, and
wait for the pipe racker to bring the next stand. Then continue at the beginning of
this procedure.

5.4.3 Tripping

Tripping in or out involves only the use of the link tilt and the elevator system of the
HPS. The following should be noted:

 The elevator is opened by the joystick button.

 The link tilt lock function must be selected (link tilt float deselected) while
backing the elevator off the pipe.
 The link tilt lock function must be deselected (Link tilt float selected) while
latching the elevator on to a pipe

5.4.4 Heavy Lifting

The lifting capacity (SWL) of the HPS is stated in the the data sheet in chapter 9.

The SWL of the supplied elevator links is lower, and probably also the SWL of the
elevator (by others). Before heavy lifting involving the HPS pipehandler it must be
checked that the strength of links and elevator is sufficient for subject load.

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5.4.5 Support Procedures

5.4.5.1 Drill Mode Operation

After the HPS controls are activated, the HPS automatically enters drill mode. Later
the HPS remains in drill mode as long as none of the following modes are activated:
Makeup mode, breakout mode, and spin mode. There is thus no separate activation
button for entering drill mode. Pipehandler operations can be carried out while in
drill mode.

In drill mode the drilling motor can then be operated by the speed throttle (for setting
main shaft speed setpoint) and the torque throttle (for setting the drill torque limit
setpoint). At start and stop both throttles are set to zero. The normal direction of
rotation is CW (clockwise) when viewed from above. The direction can be reversed
at zero speed only.

Never rotate the drill stem (main shaft) when the load in the link hanger is more than
ca. 10000 kg. The spring washer packages of the torque arrestor will then be
compressed, and the load is transferred through the split collar to the drill stem. Drill
stem rotation in this condition causes significant wear. (The load in the link hanger
includes links, elevator and the load in the elevator.)

See separate sections on how to use the parking air brake and how to release
trapped back torque in the drillstring.

Note that with an AC drilling motor, both the speed throttle and the torque throttle
must to be set to zero to allow free rotation of the drill stem. And the brake must be
off.

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5.4.5.2 Spin Mode Operation

After stabbing in, the pipe connection can be spun in by operating the drilling motor.
In this mode the motor is programmed to a fixed speed and torque of 20 rpm and
3000 ft-lbs (4000 Nm).

The backup can be obtained by the iron roughneck (for spinning in singles or stands
at drillfloor level), the rotary slips (depending on the string load) or by using the
backup grabber on the HPS.

Note that if spinning-in is done in combination with the grabber, the speed setpoint
is reduced to 5 rpm in order to reduce the inertia impact from the motor when the
shoulders meet.

After the mode is selected, the spinning continues until the mode’s setpoint torque is
reached, combined with zero speed. The mode is then automatically deselected,
and you are back in ordinary drill mode.

5.4.5.3 Setting the Spin Mode Parameters

The spin mode parameters (the torque and speed setpoints) of the HPS are set in
the PLC program.

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5.4.5.4 Makeup Mode Operation

After the pipe connection is spun in by the drilling motor (as described above), a
natural continuation is to make up the connection by the same motor. This is done
by:

 Verify that the makeup torque limit setpoint is correct (as recommended by the
pipe manufacturer), and adjust if necessary. (Adjustment described in the next
section.)
 Select makeup mode, and the drilling motor will make up the connection to the
preset makeup torque. The speed is fixed at 20 rpm. After the mode is selected,
the spinning continues until the mode’s setpoint torque is reached, combined
with zero speed. The mode is then automatically deselected, and you are back
in ordinary drill mode.

Note that if the makeup is done in combination with the grabber, the speed setpoint
is reduced to 5 rpm in order to reduce the inertia impact from the motor when the
shoulders meet.

5.4.5.5 Setting the Makeup Mode Parameters

The makeup mode torque limit (makeup torque) is set by at the Cyberbase screen
display, by clicking the belonging S (= Set) button and typing in the new makeup
torque at the appearing pop-up. The present setting is shown to the right of the
button. The preset torque limit must comply with the pipe manufacturer’s
recommended makeup torque for subject type and size of pipe. The preset torque
limit is used by the drilling motor when it operates in makeup mode only.

The speed of the makeup mode sequence is set in the PLC program.

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5.4.5.6 Breakout Mode Operation

Breakout mode is used to break out the pipe connection by the drilling motor after
having drilled down a stand. The breakout is normally done by using the grabber as
backup, and as described below. The air brake must be off.

 Rotate the pipehandler to the zero position (select PH Rotate to Zero).

 Lock the pipehandler at the zero positon (select PH Lock).
 Set the backup grabber on the stickup/upper tooljoint of the drillstring (select
grabber on).
 Activate the breakout sequence (select B/O Mode). The HPS breaks out and
spins out the connection at a preset fixed speed (20 rpm) and max breakout
torque. The breakout sequence continues until the mode button is deselected.
 When the pipe connection is spun out fully, stop the rotation by deselecting the
mode button. (If the connection was stuck and could not be broken out, the
sequence will be deselected automatically after the motor has been stalling for
10 seconds.)
 After the mode is deselected you are back in ordinary drill mode.

5.4.5.7 Setting the Breakout Mode Parameters

The breakout mode parameters (the torque and speed setpoints) of the HPS are set
in the PLC program.

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5.4.5.8 Using the Parking Air Brake

The Airflex type air brake consists of an air-actuated brake unit at the non-drive end
of the drilling motor. It is engaged (turned on) and disengaged manually by a
keypad button, and designed for static locking of the drill stem. The brake shall
however not be used as backup when breaking out pipe connections with rig tongs.
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 air brake must be off when free rotation of the drill stem is required, such as
during tripping, and during positioning of heavy loads by the pipehandler.

There is no automatic activation of the air brake, and no interlocks prevent operation
of the brake.

WARNING:
IN A CRITICAL SITUATION, SUCH AS DURING UNCONTROLLED REVERSE
ROTATION, THE OPERATOR MUST BE AWARE OF THE RISKS OF APPLYING
THE AIR BRAKE.

WARNING:
THE AIR BRAKE MUST BE OFF DURING MAKEUP AND BREAKOUT OF THE
LOWER CONNECTION OF A STAND WITH RIG TONGS, OR THERE IS A RISK
THAT THE TONGS SNAP BACK.

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5.4.5.9 Using the Retactable Dolly

The dolly is a rectangular and vertical steel frame with an upper and a lower pair of
hinged and parallel arms. The corners of the frame have bogies running in and
between two vertical derrick guide rails. Both pairs of arms are connected to the
HPS support frame. The lower pair is actuated by hydraulic cylinders that can
extend and retract the arms. This arrangement allows the HPS to be extended to
the wellentre and retracted to an out-of-the-way position. At the same time the HPS
is stabilized against sideways movements. Being able to take the HPS in and out of
the wellcentre is time-saving during tripping operations.

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. In manual mode
the movement goes on only as long as the activation joystick is kept pushed, and at
a preset limited speed. Auto mode operation means activating one of the following
auto sequences:

Auto Retract

 Starting point: The HPS is at the wellcentre.

 The elevator is opened (if not open already).
 The pipehandler rotates to its “zero” position, at which the elevator opening is
towards the wellcentre.
 The dolly retracts the HPS to the 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 Extend

 Starting point: The HPS is at the fully retracted position.

 The dolly extends the 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.

Both 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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5.4.5.10 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) Torque Release through the Bottom Hole Assembly

 Before stopping the string rotation of the drillstring, hoist the block 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 drillstring.

2) Torque Release by the Parking Air Brake

 Activate the air brake while the drillstring is at or near zero speed.
 Set the speed throttle to zero.
 Disengage the air brake for a few seconds, and then engage it again. Repeat
this several times until the trapped torque is brought down to zero by controlled
reverse rotation.

CAUTION:
NO INTERLOCKS OR SENSORS MONITOR UNCONTROLLED REVERSE
ROTATION. IF THE AIR BRAKE GETS HOT (LOOK FOR SMOKE), LEAVE IT
ALONE UNTIL THE TEMPERATURE IS NORMAL.

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5.4.5.11 Gear Shifting

The gearbox has a horizontal gear shift shaft sticking out from two of its sides, with
local gear indicators next to the shaft ends. The shaft is used to shift between low
speed gear and high speed gear. The shaft ends are six-sided, and shifting from
one gear to another is by turning one of the ends 225 degrees, i.e. from one end
position to the other. Name plates by the shaft ends tell what direction is high and
low.

The turning is by a standard six-sided wrench from user’s tool store, and done while
the HPS is shut down (power off).

NB: It is assumed that only the low speed gear will be required for normal operation.

5.4.5.12 Using Wireline Conveyed Explosives

Drawing: Water Course, Assembly

The water course (mud circuit) includes a gooseneck with a 3” well wireline entry.
This entry is used if wireline conveyed explosives have to be entered into the well.

The U-formed gooseneck is located on top of the drill stem, at the mud circuit’s
highest point. The wireline entry is normally plugged by a 2¾” BSPP plug. Before
the wireline is entered into the well, the original plug must be replaced by a supplied
thread protecting wear bushing/plug. In addition a wireline guide must be arranged
above the gooseneck.

When wireline conveyed explosives are entered via the 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.

WARNING:
ISOLATE THE HPS ELECTRICALLY BEFORE ENTERING WIRELINE
CONVEYED EXPLOSIVES.

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5.4.5.13 Operation of IBOPs

Drawings: Drill Stem & IBOP, Assembly

IBOP Actuator, Assembly

The drill stem (main shaft) 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 hydraulic cylinder.
No status feedback signal is returned from the IBOP.

The lower IBOP can only be opened manually by using a supplied 22 mm Allen key
(special tool) directly on the valve stem. The torque required for closing the valve is
ca. 50 Nm. The key is for emergency and maintenance/service use. If necessary the
upper IBOP can also be opened and closed by the Allen key.

Note that the IBOPs shall not be used as mud savers. During normal operation the
valves shall be fully open. If the valves are left partly open, the mud circulating
through them will cause erosion of the ball or seat after a short time. Such wear will
not be covered by warranty claims!

NOTE:
DO NOT USE THE IBOPS AS MUD SAVERS!

If the upper IBOP or the above crossover sub need to be broken out, it will be
necessary to dismantle the upper IBOP actuator for access by the backup grabber.
Before such removal the IBOPs should be closed. Removal and reinstallation of the
actuator is described in the maintenance instructions.

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5.4.5.14 Using the Pipehandler

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 (main
shaft) rotation. You can rotate manually to an arbitrary position, or activate a
sequence that rotates to the zero position (elevator opening pointing forward). The
sequence can be interrupted by repeating the activation command. The rotation lock
can be activated at the zero position.

Free rotation of the pipehandler is allowed if it is subject to external forces or torque,

and hydraulically actuated rotation is not being performed.

When the load in the link hanger (weight of links, elevator and load in elevator)
exceeds ca. 10 tonnes, 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 ba allowed to rotate freely. This is
done by setting speed setpoint to zero, and releasing the parking air brake.

Tilting the Elevator Links

The elevator links can be tilted forward or backward by the manual link tilt controls.
The link tilt can be operated in floating or locked mode. In the floating mode, the
links will slowly (by gravity) return to vertical straight-down position after the tilt
controls are left alone. In the locked mode (locked = not floating) the links remain
hydraulically locked at the position they are left at the end of the tilting.

If the link tilt system becomes overloaded during hoisting of the travelling block with
the links tilted out of vertical, they will automatically give in and be pulled to vertical
position.

CAUTION:
THE LINK TILT IS NOT DESIGNED TO WITHSTAND LATERAL STRESSES OR
LOADS IN UPWARD DIRECTION WHEN TILTED FORWARD OR BACKWARD.

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Kick-out Clamp Position

Feet Millimeter Inches Millimeter

1 305 41 1040
2 610 43 1100
3 915 46 1160
4 1220 48 1220
5 1525 50 1280

Table Showing Elevator Clamp Positioning Relative to the Lower Link Eye for a Set
of 108” Elevator Links

1 ft Kick-out

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2 ft Kick-out

3 ft Kick-out
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4 ft Kick-out

5 ft Kick-out
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5.4.5.15 Elevator Operation

The HPS is prepared for operation with a pneumatic or a hydraulic elevator.

Elevators are normally supplied by others, and detailed instructions must be sought
in the user manuals from the elevator suppliers.

Most elevators are closed by the mechanical trigger mechanism in the elevator
when a pipe is inserted correctly. Elevator opening is by the joystick button of the
Top Drive Pipehandling keypad. See description of the keypad.

5.4.5.16 Changing from One Drillpipe Size to Another

When changing drillpipe size, the operator should be observant of the following:

Saver Sub: Verify that the existing saver sub is suitable for the new size, and
change the sub if necessary. See the drill stem (main shaft) assembly drawing for
details. Also see the Disassembling the Drill Stem section in the Maintenance
chapter.

Makeup Torque Setpoint: The makeup torque setpoint must be set to the value
recommended by the pipe manufacturer.

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5.4.5.17 Installing Elevator Links on Link Hanger

 Starting point: No links are installed on the link hanger.

 Rotate the pipehandler to a suitable position for the link installation, and lower
the HPS to the drillfloor.
 Remove upper bolt in locking arms and lower the locking arm to horizontal.
 Select and bring the preferred pair of elevator links. The minimum length of the
elevator links to be installed is 96”.
 Grease frequently the contact surfaces of elevator links and link hanger.
 Hoist the first elevator link in a balanced horizontal position to link hanger level,
using a utility winch and a suitable sling.
 Manoeuvre the hole of the elevator link onto the link hanger.
 Secure the elevator link to the link hanger by closing the locking arm, and re-
install the bolt.
 Lower the sling until the elevator link hangs freely (straight-down) from the link
hanger, and remove the sling.
 Install the second elevator link in the same way as the first one.

Typical Catalogue Extract from Elevator Link Manufacturer

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5.5 Disturbance of Operation

If the equipment does not function as intended, consult the below sub-sections.
Reference is also made to the Fault Finding guide in the Maintenance chapter.

5.5.1 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 (at the beginning of this chapter).

After a motor temperature high alarm, or a low gearbox oil pressure or level alarm, it
is important that the HPS be 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.

For more details reference is made to the Cyberbase and control system user
manual.

5.5.2 Trip of Power to the Drilling Motor

If the power to the drilling motor 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.

5.5.3 Drilling Motor Cooling Failure

The drilling motor is air cooled by two parallel blowers, each driven by an electric
motor. The blowers automatically start running when the HPS is switched on (see
the Basic Starting and Stopping Procedure), and run until the HPS is shut down
(plus delay). If the blowers stop due to blower motor failure, this will only be alarmed
if high temperature is detected inside the drilling motor.

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5.5.4 Gearbox Lubrication Failure

The conditions under which a gearbox oil/lubrication alarm will be activated are
specified in the Alarm and Setpoint Schedule (in chapter 2). If an oil temperature or
oil pressure alarm is activated, the following insight will help the operator to remedy
the fault correctly:

The gearbox is lubricated by a combination of oil bath and forced lubrication. The
main trust bearing, lower bearings on the drill stem and pinion shafts are placed in
the oil bath. Lubrication of the upper bearings of the drill stem and pinion shafts are
provided by an oil pump that feeds gear oil through the lube oil circuit. The circuit
includes an oil filter, pressure gauge, pressure switch, temperature transmitter and
oil cooler. The oil pump and the oil cooler fan are each driven by an electrical motor.
The pump motor starts automatically when the drilling motor controls are activated,
while the fan motor starts when oil temperature reaches 70 oC. When the
temperature drops to 60 oC; the fan stops automatically. A relief valve bypasses the
oil cooler when the pressure drop across the cooler exceeds 2.2 bar, which may
happen at a cold start and when the filter element has grown clogged. After
reaching normal operating temperature, ca. 50-60 oC, the oil pressure should be ca.
2 barg.

5.6 Training Program for Operators

Training programs are available from supplier as required, but subject to separate
agreement and described separately.

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