Canrig maintenance schedule

SECTION 4: MAINTENANCE AND SERVICE Subsection 4A: Maintenance .................................................................................................... 4-3 Subsection 4B: Inspection ...................................................................................................... 4-37 Subsection 4C: Troubleshooting............................................................................................ 4-67

Revision 05.03

4-1

Canrig Top Drive Drilling System

4-2

Revision 05.03

SUBSECTION 4A: MAINTENANCE Service and Maintenance Location Drawing Off-Driller’s Side View ........................................ 4-5 Service and Maintenance Location Drawing Driller’s Side View .............................................. 4-6 Service and Maintenance Location Drawing V-Door Side View............................................... 4-7 Maintenance Checklist ............................................................................................................. 4-8 Lubrication and Maintenance General Recommendations ...................................................... 4-9 Hydraulic Oil. ..................................................................................................................... 4-9 Gear Oil ............................................................................................................................. 4-9 Filters................................................................................................................................. 4-10 Grease............................................................................................................................... 4-11 Lubrication and Maintenance Component Recommendations............................................... 4-12 Top Drive Gearcase .......................................................................................................... 4-12 Top Drive Gearcase Oil Capacity...................................................................................... 4-12 Top Drive Guides .............................................................................................................. 4-13 Top Drive Brakes............................................................................................................... 4-13 Handler Rotate Gearbox ................................................................................................... 4-13 Rotary Torque Boost ......................................................................................................... 4-13 Viscosity Equivalents Figure 4.4 ....................................................................................... 4-14 Product Application Sheet...................................................................................................... 4-15 Synthetic Multipurpose Gear Lubricant, Api Gl-5 .............................................................. 4-15 Recommended Stacking Procedures for Long Term Storage................................................ 4-17 Stacking............................................................................................................................. 4-17 Cleaning ............................................................................................................................ 4-17 Sealing Openings .............................................................................................................. 4-17 Rust Prevention................................................................................................................. 4-18 Extended Storage – Top Drive Unit ....................................................................................... 4-19 General.............................................................................................................................. 4-19 Bearings, Housing, & Gearcase ........................................................................................ 4-19 Torque Boost & Handler Rotate Gear Boxes .................................................................... 4-19 Link Support ...................................................................................................................... 4-19 Link Tilt Cylinders .............................................................................................................. 4-19 Handler Lock ..................................................................................................................... 4-20 Pins ................................................................................................................................... 4-20 Junction Boxes .................................................................................................................. 4-20 Local Blower...................................................................................................................... 4-20 Quill ................................................................................................................................... 4-20 Top Drive Drilling Motor..................................................................................................... 4-21 Extended Storage – Torque Guide ........................................................................................ 4-22 Pins ................................................................................................................................... 4-22 Tensioning Cables............................................................................................................. 4-22 Tensioning Cylinders......................................................................................................... 4-22 Harpoon............................................................................................................................. 4-22 Junction Boxes .................................................................................................................. 4-22 Utility Lines ........................................................................................................................ 4-23 Remote Blower.................................................................................................................. 4-23 Crown Hanger ................................................................................................................... 4-23 Rails .................................................................................................................................. 4-23 Revision 05.03

4-3

Canrig Top Drive Drilling System Extended Storage – Top Drive Support Unit (TDSU) .............................................................4-24 Building ..............................................................................................................................4-24 SCR/CIP Panels ................................................................................................................4-24 Air Conditioners .................................................................................................................4-24 Grasshopper ......................................................................................................................4-24 Hydraulic System ...............................................................................................................4-24 Extended Storage – Auxiliary Equipment ...............................................................................4-25 Caterpillar Generator Sets ......................................................................................................4-26 Diesel Engine.....................................................................................................................4-26 Generators .........................................................................................................................4-27 Top Drive Re-Commissioning Procedure ...............................................................................4-29 Top Drive ...........................................................................................................................4-29 Drilling Motor......................................................................................................................4-29 Torque Guide .....................................................................................................................4-30 Top Drive Support Unit (TDSU) .........................................................................................4-30 Recommended Storage Instructions for Top Drive Drilling Motors ........................................ 4-31 Removing Top Drive Drilling Motors from Storage .................................................................4-32 Capscrew Torque Values....................................................................................................... 4-33 Recommended Tools..............................................................................................................4-34 Testing a Solenoid Coil ...........................................................................................................4-35 Failure................................................................................................................................4-35 Testing Procedure .............................................................................................................4-35

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Service and Maintenance Location Drawing Off-Driller’s Side View

TOP DRIVE DRILLING SYSTEM

Figure 4.1_1250AC-681

4

Revision 04.10

Subsection 4D: General Maintenance

Service and Maintenance Location Drawing Driller’s Side View

Figure 4.2_1250AC-681

Revision 04.10

5


Service and Maintenance Location Drawing V-Door Side View

Figure 4.3_1250AC-681

6

Revision 04.10


Maintenance Checklist Week beginning: ________________________ MAINTENANCE FUNCTION

FREQ MON

GREASE WASHPIPE PACKING GREASE UPPER SEAL RING (IF EQUIPPED) GREASE MUD SAVER VALVE (IF APPLICABLE) GREASE LWCV ACTUATOR (IF APPLICABLE)

A B E

TUE

WED

PERFORMED BY FRI SAT SUN

THU

AA

12 HRS 12 HRS 12 HRS Note 1

GREASE LINK TILT CYLINDER BUSHINGS CHECK INDICATOR ON HYDRAULIC FILTER * CHECK INDICATOR ON LUBE OIL FILTER * CHECK OIL LEVEL ON TOP DRIVE GEARBOX CHECK TOP DRIVE FOR LOOSE OR LEAKING HYDRAULIC FITTINGS OR COMPONENTS EXAMINE TOP DRIVE FOR LOOSE BOLTS, ETC. CHECK FLUID LEVEL IN BRAKE ACTUATOR(S)

C M N W X

DAILY DAILY DAILY DAILY DAILY

Z

DAILY DAILY

GREASE LINK SUPPORT GREASE BUW MAIN TUBES GREASE BUW GRIPPER CYLINDER

D G H

WEEKLY WEEKLY WEEKLY WEEKLY WEEKLY

DAY: DAY: DAY: DAY: DAY:

M M M M M

TU TU TU TU TU

W W W W W

TH TH TH TH TH

F F F F F

SA SA SA SA SA

SU SU SU SU SU

BY: BY: BY: BY: BY:

J T V Y

WEEKLY WEEKLY WEEKLY WEEKLY

DAY: DAY: DAY: DAY:

M M M M

TU TU TU TU

W W W W

TH TH TH TH

F F F F

SA SA SA SA

SU SU SU SU

BY: BY: BY: BY:

GREASE BUW GRIPPER HYD. SWIVEL FITTINGS

GREASE ROTARY MANIFOLD LIFT SPRINGS (MODEL 6027E ONLY) GREASE HANDLER LOCK CHECK & CLEAN LUBE SUCTION Y-STRAINER CHECK GEARCASE BREATHER EXAMINE BRAKE PADS FOR WEAR GREASE LUBE OIL PUMP CHECK OIL LEVEL IN HANDLER ROTATE GEARBOX CHECK OIL LEVEL IN TORQUE BOOST GEARBOX INSPECT BRUSHES ON DC MOTOR CHECK & CLEAN SPARK ARRESTOR SCREENS

F P

MNTHLY MNTHLY

DATE DUE: DATE DUE:

BY: BY:

Q

MNTHLY

DATE DUE:

BY:

K L

MNTHLY MNTHLY

DATE DUE: DATE DUE:

BY: BY:

CHANGE OIL IN TOP DRIVE GEARBOX

U

2 MTHS

DATE DUE:

BY:

CHANGE OIL IN HANDLER ROTATE GEARBOX CHANGE OIL IN TOQUE BOOST GEARBOX

R S

6 MTHS 6 MTHS

DATE DUE: DATE DUE:

BY: BY:

CHECK OIL LEVEL IN RESERVOIR CHECK INDICATOR ON PRESSURE FILTER * CHECK INDICATOR ON RETURN FILTER * CHECK & CLEAN SUCTION Y-STRAINER

HYDRAULIC POWER UNIT MAINTENANCE (IF APPLICABLE) DAILY DAILY DAILY BI-WKLY

Note 1: Refer to manufacturers literature

* Change filter if indicator shows RED. This checklist is intended to be a guide ONLY. Please refer to Subsection 4A of this manual for more detailed instructions and specifications.

NOTE: 4-8

This checklist is coded to the alphabetical labels found on the Service and Maintenance Location Drawings. Revision 05.03

Subsection 4A: Maintenance

Lubrication and Maintenance General Recommendations Hydraulic Oil Shell Tellus® or equivalent.

Ambient Temperature (°C)

ISO Grade of Oil (see attached specifications)

-10° to 15° 10° to 35° 20° to 45° 25° to 55°

22 46 68 100

Gear Oil Ambient Temperature (°C)

A.G.M.A. Number

Maximum Operating Temperature (°C)

-45° to –20°

25°

-30° to 0°

37°

-10° to +20°

2 EP

52°

10° to 40 °

3 EP

63°

30° to 60°

4 EP

74°

40° and up

5 EP

80°

CANRIG Top Drive Gear Oil

All Season All Season All Season

Shell Lubricant

ESSO* Lubricant

Geartherm® Arctic AS Geartherm® Multigrade 150

Spartan® EP 32

Omala® 68 Omala® 100 Omala® 150 Omala® 220

ELF Lubricant

CHEVRON Gear Compound EP

Spartan® EP 32 Spartan® EP 68 Spartan® EP A/S Spartan® EP 150 Spartan® EP 220

Reductelf® SP 68 Reductelf® SP 100 Reductelf® SP 150 Reductelf® SP 220

68 100

*Comparable products are available in the USA from the Exxon Corporation. Canrig Top Drives are designed to be used with ISO Industrial EP (Extreme Pressure) Gear Oils. Oils meeting AGMA specifications and grades shown in the above chart could be used in the Canrig Top Drive. See Lube and Maintenance for further information. For approval of a specific oil, contact Canrig Engineering Department.

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4-9

Canrig Top Drive Drilling System Filters Top Drive:

Hydraulic Power Unit:

Hydraulic Pressure Filter Part Element Part

#H11-1000-020 #H11-1000-02A

Lube Filter Filter Part Element Part

#H11-1003-010 #H11-1003-01A

Hydraulic Pressure Filter Part Element Part

#H11-1000-020 #H11-1000-02A

Return Filter Filter Part Element Part

#H11-1003-010 #H11-1003-01A

Check bypass indicators daily. If indicator shows RED, change the filter element. Hydraulic element should be changed every 6 months. Lube element should be changed at every oil change.

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Revision 05.03

Subsection 4A: Maintenance Grease Use multi-purpose lithium complex grease complying with N.L.G.I. classification No.1 or No.2 at the following: Ref. Location

Fittings

Frequency

Grease Quantity

A

Washpipe

1

Every 12 hours

To excess

B

Upper Seal Ring (If not equipped with self lubricating seal system)

3

Every 12 hours

3 pumps per fitting

C

Spherical Bushings – Link Tilt

4

Daily

To excess

D

Link Support

8

Weekly

10 pumps per fitting

E

Mud Saver Valve

2

Weekly

Stem: 2 pumps Ball: 4 pumps

F

Lube Pump

1

Monthly

1 pump

G

Back-up Wrench Main Tube

5

Weekly


H

Back-up Wrench Gripper Cylinder

2

Weekly


J

Handler Lock (pin-type only)

1

Weekly

1 pump

Rotary Manifold Lift Springs (Model 6027E only)

4

Weekly

To excess

Refer to Service and Maintenance Location Drawings in the Section for locations of the grease fittings.

Revision 05.03

4-11


Lubrication and Maintenance Component Recommendations Top Drive Gearcase Canrig Top Drives are designed to be used with ISO Industrial EP (Extreme Pressure) Gear Oils. EP oils are high quality, extreme pressure compounded type oils for use in all types of industrial gear sets except those with built-in variable speed type friction drive mechanisms. The use of EP ensures increased unit life under heavily loaded or shock loaded service conditions. The EP oils give superior rust protection to ferrous metal surfaces and are non-corrosive to steel, copper, brass, bronze and other common bearing materials. EP can be used in continuous service, with normal re-lubrication intervals, at temperatures up to 93°C. Above 93°C, the rate of sludging and additive depletion increases and more frequent oil changes may become necessary. Oil should be changed at planned intervals of 60 days or 1000 drilling hours or less. Oil should never be permitted to become visibly contaminated with mud or water, which will cause rapid bearing failure. If there is any doubt about the oil quality, it should be changed even though the change interval has not expired. Refer to Gearcase Capacity Chart for oil quantities. Top Drive Gearcase Oil Capacity Top Drive Model

US Gallons

Liters

Oil Level Below Gearcase Window

4017 6027E 8035E-500 1050E-500 1050E-712 1165E-712 1165E-2SP 1250AC-681 1265AC-681 1275AC-681

4-6 10 10 10 12 12 18 10 10 10

15-22 38 38 38 45 45 68 38 38 38

Check dipstick for level ½” 13 mm ½” 13 mm ½” 13 mm ½” 13 mm ½” 13 mm * NOTE * NOTE ¾” 19 mm ¾” 19 mm ¾” 19 mm

* NOTE:

This optimum oil level is approximately to the bottom of the gearcase ‘snout’ as viewed in the sight tube. The oil level should not be high enough to submerge the gears in the cluster assembly ‘snout’.

When operating a Canrig Top Drive unit in humid climates or when using corrosive drilling fluids (for example: high brine content) visually check the lubrication oil on a weekly basis for water contamination. Samples should also be taken for a visual examination. The gearcase can be drained by removing the drain plug in the bottom of the gearcase. Magnetic plugs are located on the bottom of the gearcase and in the Y-strainer to catch small metallic wear particles. An appreciable accumulation of such particles can be a clue to incipient bearing failure.

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Revision 05.03

Subsection 4A: Maintenance Check the breather (located on the bonnet) on a weekly basis to ensure that they are not plugged. Replace as required. Motor seal damage may occur if pressure is allowed to build in the gearcase. Top Drive Guides Light grease or grease mixed with oil can occasionally be applied to the Torque Guide rails to improve sliding performance. Top Drive Brakes The brake fluid reservoir should be visually checked on a daily basis. A sudden drop in oil level may indicate worn components. Be sure to use only mineral-based oil in the brake system (i.e. hydraulic oil). Also refer to the Top Drive Disc Brake inspection procedure in Subsection 4B of this Manual. Handler Rotate Gearbox Planetary Gearbox – Canrig Part # M15-1002-010 Use Spartan® EP GR68 gear oil or equivalent. Oil should be changed for the first time after 500 working hours. Subsequent changes should be done after every 2000 to 4000 hours or after 6 months. Check oil level every month.

CAUTION:

New gearbox must be filled with oil prior to use.

Rotary Torque Boost Planetary Gearbox – Canrig Part # M15-1001-010 Use Spartan® EP GR68 gear oil or equivalent. Oil should be changed for the first time after 500 working hours. Subsequent changes should be done after every 2000 to 4000 hours or after 6 months. Check oil level monthly.

CAUTION:

Revision 05.03

New gearbox must be filled with oil prior to use.

4-13


Viscosity Equivalents Figure 4.4 4-14

Revision 05.03


Product Application Sheet Canrig All-Season Gear Oil Synthetic Multipurpose Gear Lubricant, Api Gl-5 Canrig All-Season Gear Oil is a synthetic-based multipurpose, extreme pressure, API GL-5 gear lubricant. It is compounded to meet the severe lubrication requirements of equipment. It may also be used anywhere the manufacturer specifies API GL-5 gear oil. Canrig AllSeason Oil provides outstanding service over a wide temperature range and has excellent durability at elevated temperatures. It meets the requirements of API GL-5 and MT-1, as well as MIL-PRF-2105E and MIL-L-2105D. Description Canrig All-Season Gear Oil is formulated with synthetic polyalphaolefin (PAO) base oils and selected additives that provide extreme pressure properties, oxidation resistance, rust and corrosion protection, and foam resistance. The synthetic base oils have excellent thermal stability at elevated temperatures and outstanding low temperature properties. These features provide for extended drain service and superior year-round performance exceeding that of conventional hypoid gear lubricants. Canrig All-Season Gear Oil provides excellent performance in transmissions operating under varying conditions of speed, load, temperature, and torque. It is inhibited to minimize deposits and viscosity increase due to oxidation at high temperatures. It protects metal parts against rust and corrosion and is non-corrosive to steel or bronze under normal operating conditions. A foam inhibitor prevents excessive foam buildup that can interfere with proper lubrication. Typical Applications ● Conventional and limited-slip differentials in passenger cars, light trucks, and heavyduty trucks. ● Differentials, final drives, and transfer cases of heavy equipment. ● Conventional manual transmissions for which the manufacturer specifies an API GL5 gear oil. ● Hypoid gear sets. ● All parts normally lubricated by automotive gear oil, such as manual steering gears, universal joints, and rear wheel bearings. ● Industrial reduction gears where extreme pressure gear oils are specified. Outstanding Features ● ● ● ● ● ● ●

Outstanding thermal stability to minimize oxidative sludge and varnish formation High film strength and excellent shear stability Excellent load carrying capacity and protection against scuffing and wear Superior low temperature properties Good rust and corrosion protection Good foam resistance Compatible with other MIL-L-2105D quality gear lubricants (1)

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4-15


Note:

For optimum performance, the mineral oil lubricant should be drained before using Canrig All-Season Gear Oil. Mixing products may reduce the effectiveness and advantages normally gained by using Canrig AllSeason Gear Oil.

Inspection Tests (Typical): SAE Grade Density, g/cm³ @ 15°C Color, ASTM Flash Point, COC, °C (°F) Pour Point, °C (°F) Viscosity cP <150,000 (Brookfield) @ °C (°F) cSt @ 40°C cSt @ 100°C SUS @ 100°F SUS @ 210°F Viscosity Index Copper Corrosion, ASTM D130 Foam Test, ASTM D892 Non-Channeling, @ °C (°F)

4-16

75W-90 .090 8.0 205 (400) -45 (-49) -40 (-40) 125 17.0 642 87.8 149 Pass Pass < -50 (< -58)

Revision 05.03


Recommended Stacking Procedures for Long Term Storage The following data and procedures are intended to assist in properly maintaining the TopDrive if it is to be stored or “stacked” for some period of time. Proper maintenance during storage will reduce “re-start” time and assure more trouble-free operation. Stacking Enough beams should be provided to give normal support to the Top Drive/Torque Guide and TDSU and be high enough to avoid having accumulated or run off water reach the equipment. A drained location is preferable so that water will not remain under the equipment and cause abnormal dampness. Cleaning Mud, adhering dirt, and other foreign matter of a type that will hold moisture should be removed. If cleaning is done with steam or with mineral spirits, care should be taken to avoid washing lubricating oil or grease from unpainted surfaces unless it is to be replaced or a preservative compound applied. If, in cleaning, the lubricant is removed from close fitting elements, they should be rotated after new lubricant or a preservative has been applied so that it will work into the fits. Apply touch-up paint to all areas where paint has been removed. Loose paint and rust should be wire brushed away, the surface cleaned and the paint (primer) applied to a dry surface. Sealing Openings In general all openings that allow moisture to enter an area and be trapped should be sealed. Adhesive waterproof tape is convenient to use and effective. (Use Kendall No. 231 or equivalent. Do not use duct tape; it will only seal for a short length of time). It should be applied over a cleaned surface. Small openings can be covered by tape alone, or by tape and a plastic sheet, unsupported. Large openings may require support such as plywood cut to opening size, covered by plastic and/or tape.

Revision 05.03

4-17

Canrig Top Drive Drilling System Rust Prevention The most troublesome problem encountered during storage is rust and corrosion. Humid conditions associated with a top-drive system sitting idle can create considerable maintenance problems. Space heaters are provided in the traction motor. Space heaters should be on at all times, if practical. They offer the best method of stopping rust in electrical equipment and metal parts that cannot be coated. A film of lubricant can best protect gearing and other rotating components. The film can be maintained by manually coating the parts and by periodic operation. All gears and drives ride on roller or ball bearings that need regular greasing to drive out moisture and keep the rollers and races grease coated. Condensation in the gearboxes will need to be drained periodically. Finally, operation (or rotating) of the equipment for a short time helps to distribute oil and grease and re-coat all gearing for improved rust protection. All the above are covered in further detail. These measures are neither expensive nor time consuming and offer the best method of preventing problems during and after a re-start. Please contact Canrig Drilling Technology Ltd. if you have any questions or need further information.

WARNING: Cleaning solvents may be toxic and/or flammable. They can cause serious or fatal injury if used without proper precautions. For safety: 1. 2. 3. 4. 5.

Do not inhale solvent fumes. Use solvents only in adequately ventilated areas. Avoid contact of solvent with skin. Do not expose solvent to flame or sparks. Observe caution statements issued by the manufacturer of the solvent.

4-18

Revision 05.03


Extended Storage – Top Drive Unit If the Top Drive unit is to be stored (stacked) for any extended length of time before use, precautions should be taken using the following guidelines. General 1. Indoor storage is preferred whenever possible. If outside storage is necessary, ensure the Top Drive is properly supported (preferably on its torque guide), and is well away from adverse conditions, e.g. salt water spray, sand, shot blast operations, etc. 2. An all around visual inspection should be given to the exterior of the top drive. All areas where the paint has worn off or where there are signs of rust forming should be cleaned and painted or have a rust inhibitor applied. Recoat with rust inhibiting oil when necessary. Water-resistant grease should be applied to all grease nipples. Fill grease nipple openings.

Bearings, Housing, & Gearcase 1. For long term storage, use oil with strong adhesion properties (Esso Sebis K – 68 or equivalent). 2. Fill to ½ inch below the top of the gearcase sight glass with the proper oil, and run for 10 to 15 min before laying down the Top Drive. 3. If stored outside, rotate every month; if inside every three months.

Torque Boost & Handler Rotate Gear Boxes 1. After the top drive is rigged down, completely fill (through their breather ports) both gearboxes with gear oil containing a rust inhibitor additive.

Link Support 1. Bleed the pressure off while the top drive is still standing so the link support will settle to its lowest possible point. 2. Coat the upper section of the outer sleeve with rust inhibitor.

Link Tilt Cylinders 1. Fully retract the link tilt cylinders. 2. Spray pins and bushings with rust inhibitor. Revision 05.03

4-19

Canrig Top Drive Drilling System Handler Lock 1. Preferably store the top drive with the handler in the unlocked position. Pins 1. Coat all exposed areas of pins with rust inhibitor. Junction Boxes 1. Ensure that the door and strain reliefs are secured tightly. 2. Seal any other openings to provide a watertight enclosure. 3. Add moisture-absorbing pads inside each junction box.

Local Blower 1. Cover blower intake and outlet (where it mates to the drilling motor) as well as all drain holes with plastic and a wide adhesive waterproof tape. Quill 1. For extended storage it is recommended that the washpipe packing assembly be removed, cleaned, liberally coated with grease and reassembled to the Top Drive. 2. The tool joint should be cleaned, re-doped, and thread protector installed.

4-20

Revision 05.03

Subsection 4A: Maintenance Top Drive Drilling Motor Indoor storage of the drilling motor is preferred. A dry ambient temperature of 60ºF is ideal if possible. In a high humidity environment an ambient of 70ºF is recommended. Every attempt should be made to avoid widely varying temperatures and high humidity. If stored outdoors, a protective cover acting as an umbrella should be used to prevent entrance of rain, dust, etc. The drilling motor is equipped with an AC space heater (120VAC, 210W). These heaters should be energized to keep the internal machine temperature above ambient temperature, preventing condensation and sweating. All exposed machined steel parts and surfaces should be examined for rust. Rust should be removed using fine abrasive paper. Methanol should be used to remove all residues. Extreme care should be taken not to damage critical machined surfaces such as the tapered shaft surface while removing rust. The surfaces should be coated with a rust inhibitor. Brushes should be removed from their holders and clamped under the spring clips to prevent corrosion of the commutator surface as a result of moisture absorption by the carbon. Do not completely seal the motor, but cover major vent areas including the blower inlet opening with waterproof tape. Leave enough opening so the machine can breathe – i.e., moist air is not trapped. The intention is to prevent entrance of water, dust, small animals, but not to seal airtight. We do not recommend use of silica gel or dehydrating agents. Since the lubricant drains from the top half of bearings during storage, this area is subject to corrosion. The shaft should be rotated periodically to redistribute a protective film. If stored inside, rotate every three months. If outside, every month. Before placing the machine back into service after prolonged storage (1 year or more), bearings should be inspected and repacked with new grease meeting the recommended GE lubrication specification. The machine should be meggered when placed into storage and periodically while in storage (3-month intervals). Keep a record of the megger readings as a rapid decrease in insulation resistance indicates the machine condition is deteriorating and the storage conditions inadequate.

Revision 05.03

4-21


Extended Storage – Torque Guide If the Torque Guide is to be stored (stacked) for any extended length of time before use, precautions should be taken using the following guidelines. General 1. The Torque Guide should be washed and racked in a level position, properly supported with timbers high enough to avoid having accumulated or run off water reach the cylinders and cables. Ensure that it is protected from adverse conditions, e.g. salt water spray, sand, shot blast operations, etc. 2. Visually inspect all around the exterior of the torque guide. Apply touch up paint to all areas where the paint has worn off. Any places that show signs of rust forming should be cleaned, painted or have a rust inhibitor applied. Recoat with rust inhibiting oil when necessary.

Pins 1. Coat all pins with rust inhibitor. Tensioning Cables 1. Unpin the tensioning cables from the cylinders and spray the thimbles with rust inhibitor. 2. Ensure that the cables are not kinked, pinched or under tension in any way.

Tensioning Cylinders 1. Retract the tensioning cylinders fully. Coat cylinder rod eye with rust inhibitor. Harpoon 1. Coat the latching mechanism with rust inhibitor. Junction Boxes 1. Ensure that all doors and strain reliefs are secured tightly, and holes left from the grasshopper leads (444 cables) are sealed. 2. Add moisture-absorbing pads inside each junction box.

4-22

Revision 05.03

Subsection 4A: Maintenance Utility Lines 1. Cables should be free and clear of pinch points and kinks. All plugs should be tightly assembled and capped. 2. Any damaged or worn areas of the electric service loop should be repaired or covered to prevent water from entering through the outer skin.

Remote Blower 1. Cover both the intake and discharge ducts, as well as all drain holes. Crown Hanger 1. Coat all pins, bolts, and exposed metal areas with rust inhibitor. Rails 1. Coat with grease or rust inhibitor.

Revision 05.03

4-23


Extended Storage – Top Drive Support Unit (TDSU) If the TDSU is to be stored (stacked) for any extended length of time before use, precautions should be taken using the following guidelines. Building 1. Wash and store the building in a level position on timbers high enough to avoid having accumulated or run off water reach the floor of the skid and potentially enter the SCR room and/or parts storage area. Apply touch-up paint as required. The building should be protected from adverse conditions, e.g. salt water spray, sand, shot blast operations, etc. Ensure that all hydraulic and air quick-couplers, electrical plugs and receptacles are capped and securely covered. SCR/CIP Panels 1. Open all contactors. 2. Add moisture-absorbing pads inside the panels.

Air Conditioners 1. Cover the intake side to prevent dust and debris from clogging the fins. Grasshopper 1. Wrap all lugged leads. Ensure that all plugs capped tightly. Hydraulic System 1. Remove the breather from the HPU tank and replace it with a 1.5 in NPT plug. 2. Remove the drain plug from the catch tray to prevent water buildup.

4-24

Revision 05.03


Extended Storage – Auxiliary Equipment If auxiliary equipment is to be stored for any extended length of time before use, precautions should be taken using the following guidelines: 1. Before laying down the Top Drive, break off the lower well control valve and drill pipe kit if installed. 2. Thoroughly clean and re-grease the lower well control valve actuator and all manual control valves. Cycle the valves a few times to work the grease into them. 3. Thoroughly clean all tool joints. Re-dope and install thread protectors. 4. Remove the tool joint clamps, grease the bolts, and reassemble them. 5. Relocate the Top Drive control panel to the SCR room for safe storage. Clean-out any foreign debris inside the panel and put bags of desiccant inside the panel to help absorb moisture. 6. All spare parts subject to corrosion and/or damage should be wrapped for protection. Use a corrosion inhibitor paper for rust sensitive parts. 7. Thoroughly clean and apply touch-up paint as required to wireline sheave assembly, floor stabilizer, and all other components. When possible store inside the TDSU building.

Revision 05.03

4-25


Caterpillar Generator Sets If the engine/generator set is to be stored for any extended length of time before use, precautions should be taken using the following guidelines: Diesel Engine 1. Clean the outside of the engine and cover with good quality paint. 2. Remove any dirt from the air cleaner; check all seals and gaskets. 3. Put lubricant on all joints shown in the lubrication chart of the Caterpillar Engine Operations and Maintenance Guide. 4. If the cooling system is protected with clean, ethylene glycol antifreeze, make sure that it has a 50/50 mixture of ethylene glycol antifreeze and water. Be sure to completely fill the radiator up to the radiator cap with coolant mixture. Do not leave an air space. If the stored engine will never be subjected to below-freezing temperatures, completely drain the fresh water system; remove the drain plugs from the engine block, oil cooler, heat exchanger body and radiator, if so equipped. If freezing temperatures are possible, follow procedures given in item 4 above. 5. Oil filter elements do not need to be changed. If the lube oil has been used 50 hours or less, leave it in the sump and add VCI-10 at the rate of 3 to 4% by volume. If the lube oil has been used more than 50 hours, change it and add VCI-10 oil at the rate of 3 to 4%. NOTE:

If the engine crankcase is full, drain enough lubricant to add the mixture.

6. Remove the air filter elements. Turn the engine at cranking speed with throttle control in fuel OFF position, and use a sprayer to add a mixture of 50% VCI-10 oil and 50% engine oil into the air intake or turbocharger inlet. Re-install the air filter elements. Completely enclose the elements with dark plastic bags and seal them with tape. Replace the air filter covers. Put tape over all openings to seal VCL vapors in the engine. NOTE:

THIS IS CRITICAL TO PREVENT LOSS OF THE PROTECTIVE VAPORS.

7. Use a sprayer to put a mixture of 50% VCI-10 oil and 50% engine oil into the exhaust openings. Minimum application rate is 5.5 ml per liter (3 oz. Per 1000 cubic inches) of engine displacement. Seal exhaust pipe, including any drain holes in the muffler. 8. Remove the fuel from the secondary fuel filter housing or empty and re-install the fuel filter element to remove any dirt and water. Drain the fuel injection pump (sleeve 4-26

Revision 05.03

Subsection 4A: Maintenance metering only). Clean the primary fuel filter; fill with calibration oil or kerosene and operate the primary pump. This will get clean oil to the secondary fuel filter and any water or dirt from the inside of the fuel tank. Use a spray of 30 ml (1 oz.) of VCI-10 oil per each 30 L (7.50 gal) of tank capacity to prevent rust in the fuel tank. Add 15 ml (per liter of fuel) of commercial biocide (biobor JF) to the fuel. Seal all openings to the tank to prevent evaporation of the fuel and preservative. 9. Remove the fuel nozzles and put 30 ml (1 oz.) of 50% VCI-10 oil and 50% engine oil in each cylinder. Install fuel nozzles or spark plugs and tighten all fittings to the correct torque. Use a bar (or turning tool) to run the engine over slowly to put the oil on the cylinder walls. 10. Spray a thin amount of 50% VCI-10 oil and 50% engine oil on the flywheel, ring gear teeth and starter pinion. Install the covers to keep in the VCI-10 vapors. 11. Put a heavy amount of multipurpose grease on all outside parts that move, such as rod threads, ball joints, linkage, etc. Note:

Install all covers and make sure that tape has been installed over all openings, air intake, exhaust openings, flywheel housing, crankcase breathers, dipstick tubes, etc. Make sure all covers are air tight and weatherproof.

12. Under most conditions, it is best to remove the batteries and use them in another application, or put them in storage where they can be checked and electrically charged again when needed. If the batteries are not removed, wash the tops of the batteries until they are clean. Disconnect the battery terminals. Secure the cover over the batteries. 13. Loosen all fan, alternator belts, etc. 14. Attach a tag to the engine with a notation of the date that the unit was preserved. If the engine shows signs of corrosion at the check intervals repeat the protection procedure. It is not necessary to remove the preservative oil mixture before operating the engine. If a compartment under protection of VDL vapors is opened put more VCL mixture in to make up for the vapor loss.

Generators 1. When a generator is in storage, moisture condenses in the windings. To minimize condensation, when possible, store the generator in a dry storage area. Seal all openings with tape. 2. If a brush-type generator (SRCR) is to be in storage for a long time, lift the brushes off the slip ring to prevent damage to the slip ring by chemical action. Attach a tag to the generator stating that the brushes have been lifted. Note: Revision 05.03

Before start-up of a generator use a megohmeter to check insulation resistance for moisture and/or foreign material. 4-27

Canrig Top Drive Drilling System To remove moisture caused by high humidity or dampness, use one of the following methods to dry the generator. •

Put the generator in an oven at a temperature of not more than 185ºF (85ºC) for four hours. Note:

If an oven is used for drying, use a forced air-type rather than a radianttype. Radiant ovens can cause localized overheating.

•

Space heaters of the type used in the Top Drive drilling motor can be installed in the generator. These heaters heat the windings to remove moisture and should be connected at all times in high humidity conditions.

•

Use a canvas enclosure around the generator and heating lamps to increase the ambient temperature. Make an opening in the top of the canvas to release the moisture.

•

Send a low voltage current through the windings to increase the temperature of the windings to 85ºF. Note:

4-28

If there is a possibility that insulation resistance has lowered to a dangerous level, contact Canrig or your nearest Caterpillar dealer.

Revision 05.03


Top Drive Re-Commissioning Procedure Prior to putting a “preserved-stacked” Top Drive System back into service, precautions should be taken using the following guidelines: These do not preclude the need to follow the maintenance practices as outlined elsewhere in this manual. Top Drive 1. Drain stacking oil from gearbox and fill to normal operating level with Canrig specified gear oil. Run Top Drive for 10–15 min, drain and refill to normal operating level. 2. Drain and fill the torque boost and handler rotate gear boxes to appropriate level with Canrig specified gear oil. 3. Uncover intake and drain holes on local or remote blower. Test run in the down position to blow out any dust and debris before commencing with drilling activities. 4. Check all terminal blocks in junction boxes for tightness.

Drilling Motor Before placing a stored motor in use: 1. Blow dust and dirt accumulation out of windings with clean, dry air. 2. (For DC motor applications only) Re-set the brushes. Visually inspect for spring corrosion, sticking brushes in brush holders, and general defects. 3. Check winding insulation continuity to ground with a 500 volt megger. If the megger reading is less than 2 megohms, the windings should be baked or dried until the moisture content is sufficiently reduced to raise the megger reading to 2 megohms. 4. An electrical source of heat is best for drying as it can be easily regulated and is clean. Proceed as follows: •

Remove the armature from the frame and remove bearings from the armature shaft. Heat the frame and armature until dried sufficiently to obtain the 2 megohm reading.

•

Pack bearings with new grease. Refer to LUBRICATION AND MAINTENANCE RECOMMENDATIONS for the proper type and amount of grease.

•

Reassemble the motor.

•

If facilities are available, give the reassembled machine a running test to check bearings.

Revision 05.03

4-29

Canrig Top Drive Drilling System Torque Guide 1. Check that the harpoon latching mechanism is functioning correctly and freely. 2. Check all junction box terminal blocks for tightness.

Top Drive Support Unit (TDSU) 1. Remove covers from intake sides of air conditioners. 2. Open valves on inlet side of HPU pumps 3. Unwrap all lugged leads on the grasshopper and check for cleanliness or damage. 4. Ensure all valves on HPU are open. 5. Remove NPT plug from breather port of HPU tank and install Canrig breather. 6. Check all terminal blocks for tightness

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently in this text, the matter should be referred to Canrig Drilling Technology Ltd.

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Revision 05.03


Recommended Storage Instructions for Top Drive Drilling Motors WARNING:

Cleaning solvents may be toxic and/or flammable. They can cause serious or fatal injury if used without proper precautions. For safety: 1. 2. 3. 4. 5.

Do not inhale solvent fumes. Use solvents only in adequately ventilated areas. Avoid contact of solvent with skin. Do not expose solvent to flame or sparks. Observe caution statements issued by the manufacturer of the solvent.

When placing Canrig Top Drive Drilling Motors into storage, the following preparations should be undertaken to prevent damage to the equipment as a result of storage: 1. Machines should be placed on a pallet and stored indoors if possible. A clean, dry ambient temperature of 60°F is preferred. In a high humidity environment, an ambient temperature of 70°F is recommended. Every attempt should be made to avoid widely varying temperatures and high humidity. A protective cover acting as an umbrella should be used to prevent entrance of rain, dust, etc. 2. The drilling motors are equipped with AC space heaters (120VAC, 210W). These heaters should be energized to keep the internal machine temperature above ambient, preventing condensation and sweating. 3. All exposed machined steel parts and surfaces should be slushed. These areas are slushed prior to shipment from the factory, but should be examined for rust. Rust should be removed using fine abrasive paper, after the old slushing compound has been removed with mineral spirits. Methanol should be used to remove all residues. 4. Extreme care should be exercised not to damage critical machined surfaces such as the tapered shaft surface while removing rust. The surfaces should be reslushed with slush compound Kendell Grade 5, or the equivalent. 5. Brushes should be removed from their holders and clamped under the spring clips to prevent corrosion of the commutator surface as a result of moisture absorption caused by the carbon. 6. Do not completely seal the motor, but cover major vent areas with a waterproof shipping tape. Leave enough opening so that the machine can breathe – i.e., moist air is not trapped. The intention is to prevent entrance of water, rust, small animals, but not to seal airtight. We do not recommend use of silica gel or dehydrating agents. 7. Since the lubricant drains from the top half of bearings during storage, this area is subject to corrosion. The shaft should be rotated periodically to redistribute a protective film. If stored inside, rotate every three months; if outside, every month. Before placing the machine back into service after prolonged storage (1 year or more) bearings should be inspected and repacked with new grease meeting the recommended GE lubrication specification. 8. The machine should be meggered when placed into storage and periodically while in storage (3 month intervals). Keep a record of the megger readings as a rapid decrease in insulation resistance indicates the machine condition is deteriorating and the storage conditions are inadequate. Before placing a stored motor back into storage, refer to the applicable instructions: REMOVING TOP DRIVE DRILLING MOTORS FROM STORAGE. Revision 05.03

4-31


Removing Top Drive Drilling Motors from Storage It is often customary for users of Top Drive Systems to retain spare motors, which can be used for replacements. The spares might be new, rebuilt or used. Even though new or recently rebuilt, it is possible that the machine has been stored for an extended period of time and should be checked before being placed into service. Storing location and atmospheric conditions (temperature and humidity) can cause the windings to become contaminated with dirt and/or moisture. Storage conditions can help in avoiding dirt and moisture accumulation. Where possible, machines should be stored in a clean location where the temperature is kept above 60°F. In a generally high humidity climate, an even higher minimum temperature (70°F) will help keep windings dry. An accumulation of moisture or dirt causes electrical breakdown of the windings. Before placing a stored motor into service: 1. Blow dust and dirt accumulation out of windings with clean, dry air. 2. Visually inspect for spring corrosion, sticking brushes in brush holders, and general defects. 3. Check winding insulation continuity to ground with a 500 volt megger. If the megger reading is less than 2 megaohms, the windings should be baked or dried until the moisture content is sufficiently reduced to raise the megger reading to 2 megaohms. 4. An electric source of heat is best for drying as it can be easily regulated and is clean. Proceed as follows: A. Remove the armature from the frame and remove bearings from the armature shaft. B. Heat the frame and armature until dried sufficiently to obtain the 2 megaohm reading. C. Pack bearings with new grease. Refer to the Lubrication and Maintenance Recommendations in this Section for the proper type and amount of grease. D. Reassemble the motor or generator. E. If facilities are available, give the reassembled machine a running test to check bearings.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation or maintenance. Should further information be desired or should particular problems arise which are not sufficiently for the purchaser’s purposes, the matter should be referred to Canrig.

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Revision 05.03


Capscrew Torque Values All capscrews and bolts used on a Canrig Top Drive meet or exceed the SAE Gr.8 specifications. These must be torqued to the values shown on the assembly drawings or to the value charted below. In addition, the following guidelines should be followed when reinstalling capscrews or bolts:

•

All capscrews or fasteners permanently installed must be coated with Loctite 242 Threadlocker or the equivalent after insuring that the capscrew threads and mating thread are free of all dirt, oil and grease. This is a medium strength threadlocker that prevents rusting of all threads and prevents loosening due to vibration. This threadlocker can be sheared using normal hand tools.

•

All capscrews or fasteners that require periodic loosening to facilitate adjustment of components (tool joint clams, link tilt clamps, guide rails, etc.) should be coated with anti-seize thread compound 767 or the equivalent.

•

When using capscrews with locknuts, use only Grade C Stover locknuts or equivalent. These can be identified visually by eight raised dots. These are re-usable, but new nuts are recommended after repeated removal and installation.

Hex Head Capscrew Socket Head Capscrew Size 1/4 5/16 3/8 7/16 1/2 9/16 198 3/4 7/8 1 1 1/8 1 1/4

Revision 05.03

Torque ft/lb 11 23 40 65 99 159 198 350 566 848 1245 1750

Torque N/m 15 31 54 88 134 216 268 475 767 1150 1688 2373

Plated Bolts or Machined Torque ft/lb 8 17 30 49 74 119 149 263 425 636 934 1313

Torque N/m 11 23 39 64 97 156 194 343 556 833 1222 1718

Flat Head Capscrews Button Head Capscrews Torque Torque ft/lb N/m 8 11 16 21 26 34 42 55 63 82 101 133 126 165 230 292 360 472 540 707 792 1037 1114 1458

4-33


Recommended Tools FOR SERVICE AND MAINTENANCE OF A CANRIG TOP DRIVE Adjustable Wrenches: Assorted Pliers: Assorted Screwdrivers: Ball-driver Wrenches: Combination Wrenches: Dial Caliper Dial Indicator Drill Bit Set: Extractor Set Feeler Gauges Flashlight Gauge Adapter Hammer Hand Wrenches: Hex Bit Sockets: Hex Key Wrench Set: Inspection Mirror Lockwire Machinist’s File Kit Magnetic Base Magnetic Retrieval Tools: O-Ring Splicing Kit Pick Pinch Bar Pipe Wrenches: Pressure Gauge Punch and Chisel Set Seal and O-Ring Shackle, 5/8” Socket Set: Soldering Iron and Supplies Spinnaker Frame Stubs File Needle Taps, Bottoming: Taps, Pipe: T-Handle Hex Key Set: Utility Knife Wire Brush

4-34

6”, 10” and 18” Needle Nose, Pliers, Side Cutters, Electrician’s Scissors 9mm, 13mm 1/4” to 1 1/2”

1/16” to ½”

5/8”, 11/16”, 7/8”, 15/16”, 1 3/8”,Crowfoot Wrench, 15/16” 3/8”, 3/4” drive, 5/16” to 3/4” Imperial – 1/16” to 3/8”, Metric – 1.5mm to 10mm

8” pocket tool and telescoping tool

12”, 18”

3/8” & 3/4” drive, 1/4” to 1 1/2”

1/4” to 1” 1/4” to 1/2” Imperial – 1/16” to 3/8”, Metric – 2.5mm to 10mm

Revision 05.03


Testing a Solenoid Coil Failure •

The main reason for failure of a solenoid is excessive heat.

•

A sign of impending solenoid failure may be a peculiar odor, followed by the discovery of melted or cracked insulation.

•

A chattering noise could also signal solenoid failure.

Testing Procedure 1. Disconnect the power source. 2. Test the solenoid coil by attaching an ohmmeter (set to a low resistance range) across the coil terminals. •

A relatively low reading should be observed on the meter if the coil is good. Solenoid Manufacturer

Operating Voltage

Approximate Resistance

Vickers

24 VDC

19 ohms

120 VAC

32 ohms

24 VDC

35 ohms

Rexroth •

It should not read zero ohms as this is an indication that the coil windings are shorted to each other, probably the result of melted insulation.

•

If the ohmmeter reads infinity, it means that the coil is open and defective.

Revision 05.03

4-35


4-36

Revision 05.03

SUBSECTION 4B: INSPECTION Recommended Inspection Program....................................................................................... 4-38 General Inspection ............................................................................................................ 4-38 Monthly Inspection ............................................................................................................ 4-38 Inspection After Each Rig Move or 3 Months .................................................................... 4-38 Other Inspection ................................................................................................................ 4-40 1000 Day Inspection.......................................................................................................... 4-40 Inspection Following Periods of Rough Drilling or Jarring...................................................... 4-41 Inspection Indication Maps..................................................................................................... 4-42 Main Housing.................................................................................................................... 4-42 Spindle.............................................................................................................................. 4-43 Split Ring .......................................................................................................................... 4-44 Quill .................................................................................................................................. 4-45 Upper Link Support .......................................................................................................... 4-46 Outer Sleeve..................................................................................................................... 4-47 Upper Link Pin .................................................................................................................. 4-48 Upper Link ........................................................................................................................ 4-49 Bail.................................................................................................................................... 4-50 Torque Guide Skid/Section 1 ........................................................................................... 4-51 Torque Guide Live Roll..................................................................................................... 4-52 Torque Guide Section 2 ................................................................................................... 4-53 Torque Guide Section 3 ................................................................................................... 4-54 Torque Guide Section 3/Service Support Frame ............................................................. 4-55 Torque Guide Section 4 ................................................................................................... 4-56 Torque Guide Section 5 ................................................................................................... 4-57 Torque Guide Pin ............................................................................................................. 4-58 Harpoon............................................................................................................................ 4-59 Top Drive Frame .............................................................................................................. 4-60 Top Drive Guard............................................................................................................... 4-61 Blower Frame ................................................................................................................... 4-62 Main Bearing End Play.......................................................................................................... 4-63 WashPipe Inspection ............................................................................................................ 4-64 Top Drive Disc Brake Inspection .......................................................................................... 4-65 Check Brake Fluid............................................................................................................ 4-65 Check Brake Calipers ...................................................................................................... 4-65 Manual Brake Bleeding .................................................................................................... 4-65 Auto Brake Bleeding ........................................................................................................ 4-66

Revision 05.03

4-37


Recommended Inspection Program General Inspection Pressure test the circulating path from the Lower Well Control Valve (LWCV) to the Upper Well Control Valve (UWCV) to 200 psi to detect obvious leaks before testing at rated pressure. The test intervals may be specified by regulatory authorities, operator policies or contractor policies. Monthly Inspection 1. Remove the LWCV and inspect the connections (including the quill pin) using magnetic particle techniques according to API RP7G. 2. Visually inspect the following for hoisting integrity: • Bail (if applicable) • Block Interface • Upper links • Main housing • Rotary manifold outer sleeve • Upper link support • Elevator links • Elevators (if applicable) 3. Visually check the welds on the top drive frame, guard, mounts and supports for cracks or damage. 4. Visually check the Top Drive unit for loose bolts. 5. Check the drive motor according to the manufacturers publication, which is in the Electrical section of the Component Literature book. 6. Visually inspect the electrical cables on the Top Drive Unit. NOTE:

Items 2, 3, 4, 5 and 6 from the above list should also be checked after first week of operation on a new Top Drive installation.

Inspection After Each Rig Move or Every 3 months (which ever comes first) •

Visually check the complete Torque Guide for any damage (i.e. bending or cracking).

•

Visually check the integrity of all of the Torque Guide turnbuckles, pins, spherical bushings and flange connection bolts. (If applicable.)

•

Visually check all the welds on the Torque Guide System including the harpoon for cracks. If suspicious cracks were found, a full Dry Magnetic Particle inspection must be

4-38

Revision 05.03

Subsection 4B: Inspection made to all the welds included but not limited to those shown in the Torque Guide Inspection Maps. •

Check for loose bolts and mountings for the blower, mast junction box, cable trays and hydraulic tubes.

•

Visually check the service loop and service supports/mounts on the torque guide.

•

Visually check the blower and welds on Blower Frame.

•

Visually check the Grass Hopper for any damage (i.e. bending and cracking). In addition, check all the welds for cracks.

Revision 05.03

4-39

Canrig Top Drive Drilling System Other Inspection •

Check the clearance in the main Top Drive bearings and re-shim if necessary according to the schedule and instructions in this manual.

•

Check the gap between the top of the Brake Disk and the caliper. If the Disk is rubbing against the top of the caliper, this maybe an indication that the Brake Hub had spun off.

1000 Days Inspection The following major inspection is recommended every 1000 working days or at alternate intervals, which may be specified by regulatory authorities, operator policies, contractor policies or drilling conditions: 1. Disassemble the Top Drive unit. 2. Inspect all of the following hoisting load path components using magnetic particle techniques as specified on the Inspection Maps at the end of Section 4B: • Quill • Spindle • Split Ring • Upper link support • Rotary manifold outer sleeve • Housing • Upper links • Bail (if applicable) • Block Interface • Upper link pins (4) 3. Check all bearings, seals, seal running surfaces, gears and splines. Refurbish as necessary. 4. Inspect all the welds in the Torque Guide System using magnetic particle techniques as specified on the inspection maps at the end of Section 4B. 5. Inspect the end plates and lugs in the torque tubes for any damage and ensure that the lugs are properly aligned between sections. 6. Remove the motor and send to a qualified repair shop for inspection and repair if necessary. Refer to relevant Canrig and manufacturers’ literature for recommended procedures.

4-40

Revision 05.03

Subsection 4B: Inspection

Inspection Following Periods of Rough Drilling or Jarring After periods of rough drilling, especially on surface hole, various Top Drive components can loosen due to vibration. The following inspection procedure is recommended after periods of rough drilling: •

Perform a thorough visual examination of the Top Drive, looking for any signs of damage.

•

Visually inspect the mud inlet piping.

•

Check all wire-locked bolts for damaged or broken wires. If broken wires are detected, check the affected bolts for tightness and rewire. Refer to the Capscrew Torque Values information in Subsection 4A of this Manual. Replace damaged wires.

•

Check all external bolts that are not wired for tightness.

•

Check all guards, vents, and covers for tightness.

•

Ensure that all safety cables are properly and securely attached.

•

Visually check the welds on the Top Drive Guard and Frame, Blower Frame and Torque Guide System.

•

Visually examine inside the electrical junction boxes for loose components.

•

Inspect the motor armature to ensure it has not dropped: •

If the Brake Disk is approximately in the center of the Caliper, then this maybe an indication that the armature did not drop.

•

If the Brake Disk is rubbing on the bottom of the caliper, this maybe an indication that the armature did drop.

Revision 05.03

4-41


INSPECTION INDICATION MAP №: Part Name: Main Housing The following information should be supplied on the Inspection Report as a minimum: Purchase Order # Date: Inspection Report # Canrig Part # Inspector’s Signature/Stamp: Load Path/ Serial # Type of Inspection: Rated Load: Canrig Representative:

WF MPI

WF MPI

Fig. 1

Fig. 2

WF MPI

WF MPI

4-42

WF MPI

Revision 05.03


INSPECTION INDICATION MAP №: Part Name: Spindle The following information should be supplied on the Inspection Report as a minimum: Purchase Order # Date: Inspection Report # Canrig Part # Inspector’s Signature/Stamp: Load Path/ Serial # Type of Inspection: Rated Load: Canrig Representative:

Wet Fluorescent Magnetic Particle Entire Area

Wet Fluorescent Magnetic Particle Entire Area Between Arrows

Fig. 1

Fig. 2

Procedure: Perform Wet Fluorescent Magnetic Particle Inspection on areas shown in accordance with ASTM E709. Acceptance criteria are as defined in API 8C. All other areas not indicated shall be visually examined for damage and signs of fatigue. Revision 05.03

4-43


INSPECTION INDICATION MAP №: Part Name: Split Ring The following information should be supplied on the Inspection Report as a minimum: Purchase Order # Date: Inspection Report # Inspector’s Signature/Stamp:

Canrig Part # Load Path/ Serial #

Type of Inspection: Canrig Representative:

Rated Load:

WF MPI 100%

Fig. 1

WF MPI 100%

Fig. 2

Procedure: Perform Wet Fluorescent Magnetic Particle Inspection on areas shown in accordance with ASTM E709. Acceptance criteria are as defined in API 8C. All other areas not indicated shall be visually examined for damage and signs of fatigue.

4-44

Revision 05.03


INSPECTION INDICATION MAP №: Part Name: Quill The following information should be supplied on the Inspection Report as a minimum: Purchase Order # Date: Inspection Report # Canrig Part # Inspector’s Signature/Stamp: Load Path/ Serial # Type of Inspection: Rated Load: Canrig Representative: Wet Fluorescent Magnetic Particle Areas Indicated with Arrows

Wet Fluorescent Magnetic Particle Areas Indicated with Arrows Fig. 1

Fig. 2

Procedure: Perform Wet Fluorescent Magnetic Particle Inspection on areas shown in accordance with ASTM E709.Acceptance criteria are as defined in API 8C. All other areas not indicated shall be visually examined for damage and signs of fatigue.

Revision 05.03

4-45


INSPECTION INDICATION MAP №: Part Name: Upper Link Support The following information should be supplied on the Inspection Report as a minimum: Purchase Order # Date: Inspection Report # Canrig Part # Inspector’s Signature/Stamp: Load Path/ Serial # Type of Inspection: Rated Load: Canrig Representative: WF MPI AREAS SHOWN

WF MPI 100% OF RADIUS ON BOTH EARS AND SURROUNDING AREA Fig. 1

WF MPI 100% OF RADIUS ON BOTH EARS AND SURROUNDING AREA Fig. 3

Fig. 2

WF MPI AREAS SHOWN Fig. 4

Procedure: Perform Wet Fluorescent Magnetic Particle Inspection on areas shown in accordance with ASTM E709. Acceptance criteria are as defined in API 8C PSL 2. All other areas not indicated shall be visually examined for damage and signs of fatigue. 4-46

Revision 05.03


INSPECTION INDICATION MAP №: Part Name: Outer Sleeve The following information should be supplied on the Inspection Report as a minimum: Purchase Order #

Date:

Inspection Report #

Canrig Part #

Inspector’s Signature/Stamp:

Load Path/ Serial #

Type of Inspection:

Rated Load:

Canrig Representative:

WF MPI ENTIRE CIRCUMFERENCE OF COLLAR

Fig. 1

WF MPI ENTIRE AREA BETWEEN ARROWS

Fig. 2


Revision 05.03

4-47


INSPECTION INDICATION MAP №: Part Name: Upper Link Pin The following information should be supplied on the Inspection Report as a minimum: Purchase Order # Date: Inspection Report # Canrig Part # Inspector’s Signature/Stamp: Load Path/ Serial # Type of Inspection: Rated Load: Canrig Representative:

WF MPI 100% Fig.1

WF MPI 100% Fig.2

Procedure: Perform Wet Fluorescent Magnetic Particle Inspection on areas shown in accordance with ASTM E709. Acceptance criteria are as defined in API 8C.

4-48

Revision 05.03


INSPECTION INDICATION MAP №: Part Name: Upper Link The following information should be supplied on the Inspection Report as a minimum: Purchase Order # Date: Inspection Report # Inspector’s Signature/Stamp:

Canrig Part # Load Path/ Serial #

Type of Inspection: Canrig Representative:

Rated Load:

WF MPI BORE AND SURROUNDING AREA



WF MPI BORE AND SURROUNDING Fig. 2

Fig. 1 Procedure: Perform Wet Fluorescent Magnetic Particle Inspection on areas shown in accordance with ASTM E709. Acceptance criteria are as defined in API 8C. All other areas not indicated shall be visually examined for damage and signs of fatigue.

Revision 05.03

4-49


INSPECTION INDICATION MAP №: Part Name: Bail The following information should be supplied on the Inspection Report as a minimum: Purchase Order # Date: Inspection Report # Canrig Part # Inspector’s Signature/Stamp: Load Path/ Serial # Type of Inspection: Rated Load: Canrig Representative: WF MPI ENTIRE AREA BETWEEN ARROWS WF MPI 100% RADIUS


WF MPI ENTIRE AREA BETWEEN ARROWS WF MPI 100% RADIUS



4-50

Revision 05.03


INSPECTION INDICATION MAP No: Part Name: Torque Guide Skid/Section 1 The following information should be supplied on the Inspection Report as a minimum: Purchase order # Date: Inspection Report # Canrig Part # Inspector’s Signature/Stamp: Top Drive S/N: Type of Inspection: Canrig Representative:

Procedure: Perform Dry Magnetic Particle Inspection on all welds shown in accordance with ASTM E709. Acceptance criteria are as defined in E709. All other areas not indicated shall be visually examined for damage and signs of fatigue.

Revision 05.03

4-51


INSPECTION INDICATION MAP No: Part Name: Torque Guide Live Roll The following information should be supplied on the Inspection Report as a minimum: Purchase order # Date: Inspection Report # Canrig Part # Inspector’s Signature/Stamp: Top Drive S/N: Type of Inspection: Canrig Representative:

Procedure: Perform Dry Magnetic Particle Inspection on all welds shown in accordance with ASTM E709. Acceptance criteria are as defined in ASTM E709. All other areas not indicated shall be visually examined for damage and signs of fatigue.

4-52

Revision 05.03


INSPECTION INDICATION MAP No: Part Name: Torque Guide Section 2 The following information should be supplied on the Inspection Report as a minimum: Purchase order # Date: Inspection Report # Canrig Part # Inspector’s Signature/Stamp: Top Drive S/N: Type of Inspection: Canrig Representative:


Revision 05.03

4-53




4-54

Revision 05.03


INSPECTION INDICATION MAP No: Part Name: Torque Guide Section 3/Service Support Frame The following information should be supplied on the Inspection Report as a minimum: Purchase order # Date: Inspection Report # Canrig Part # Inspector’s Signature/Stamp: Top Drive S/N: Type of Inspection: Canrig Representative:


Revision 05.03

4-55




4-56

Revision 05.03




Revision 05.03

4-57


INSPECTION INDICATION MAP No: Part Name: Torque Guide Pin The following information should be supplied on the Inspection Report as a minimum: Purchase order # Date: Inspection Report # Canrig Part # Inspector’s Signature/Stamp: Top Drive S/N: Type of Inspection: Canrig Representative:

Procedure: Perform Die Penetrant Inspection on the entire pin (including the weld) in accordance with ASTM E165. Acceptance criteria are as defined in ASTM E165.

4-58

Revision 05.03


INSPECTION INDICATION MAP No: Part Name: Harpoon The following information should be supplied on the Inspection Report as a minimum: Purchase order # Date: Inspection Report # Canrig Part # Inspector’s Signature/Stamp: Top Drive S/N: Type of Inspection: Canrig Representative:


Revision 05.03

4-59


INSPECTION INDICATION MAP No: Part Name: Top Drive Frame The following information should be supplied on the Inspection Report as a minimum: Purchase order # Date: Inspection Report # Canrig Part # Inspector’s Signature/Stamp: Top Drive S/N: Type of Inspection: Canrig Representative:


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Revision 05.03


INSPECTION INDICATION MAP No: Part Name: Top Drive Guard The following information should be supplied on the Inspection Report as a minimum: Purchase order # Date: Inspection Report # Canrig Part # Inspector’s Signature/Stamp: Top Drive S/N: Type of Inspection: Canrig Representative:

Procedure: Perform Dry Magnetic Particle Inspection on all in accordance with ASTM E709. Acceptance criteria are as defined in ASTM E709. All other areas not indicated shall be visually examined for damage and signs of fatigue.

Revision 05.03

4-61


INSPECTION INDICATION MAP No: Part Name: Blower Frame The following information should be supplied on the Inspection Report as a minimum: Purchase order # Date: Inspection Report # Canrig Part # Inspector’s Signature/Stamp: Top Drive S/N: Type of Inspection: Canrig Representative:


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Revision 05.03


Main Bearing End Play Inspection Procedure 1. Remove the washpipe. 2. Place the base of the dial indicator on top of the upper seal carrier (or side of the bonnet) and the plunger on the top of the upper seal ring. 3. Load the end of the quill against the top and bottom of its free travel. (NOTE: Quill travel = 8 inches) 4. Read the end play on the dial. (Desired end play = 0.002/0.004 inches) 5. To adjust this end play, add or remove shims between the upper bearing seat and the main housing. 6. If the gear case oil becomes contaminated, the gear case should be flushed and the oil changed. The end play should be checked before resuming drilling activities. This may reveal indications of premature bearing wear.

Figure 4.5 MODEL

SHIM PART #

INSPECTION FREQUENCY

6027E

966-26-1

2 – 3 months

8035E, 1035E

681-11-1

4 – 6 months

1050E, 1250AC

681-11-1

4 – 6 months

1165E, 1265AC

681-11-1

4 – 6 months

1275AC

681-11-1

4 – 6 months

Revision 05.03

4-63


Washpipe Inspection Instructions Packing Assembly Instructions: 1. Attach magnetic indicator base or improvised holding fixture to quill or packing box. 2. Rotate sleeve 360° and record total indicator reading (TIR) indicator positions A, B, C. Recommended Tolerances: A. Maximum allowable misalignment at gooseneck support bore = 0.008’ TIR B. Maximum allowable misalignment at gooseneck pilot = 0.010” TIR C. Maximum allowable washpipe misalignment after complete assembly = 0.010” TIR Inspection may indicate misalignment exceeding recommended limits. Washpipe packing assemblies are designed to accommodate misalignments of quill to gooseneck and will operate with some excessive misalignment. However, to achieve maximum packing life, the alignment at the washpipe should be maintained within recommended limits.

A

C

B

Figure 4.6

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Revision 05.03


Top Drive Disc Brake Inspection Check Brake Fluid •

Brake fluid reservoir should be visually checked on a daily basis.

•

Sudden drop in oil level may indicate worn components. Be sure to only use mineralbased oil (i.e. hydraulic oil) in the brake system.

Check Brake Calipers •

Brake calipers should be checked weekly.

•

A function test should be done at this time.

•

There should be a minimum gap of 0.06” between the brake pads and the disc.

•

In addition to premature wear, dragging brake pads can also cause excessive heat build-up in the brake compartment.

•

If the brake pads are dragging, the system may require bleeding to eliminate any trapped air. See Brake Bleeding Procedure.

Manual Brake Bleeding 1. The brake actuator should be bled first, and then the brake calipers. 2. Clean area around reservoir covers (2 on GE 752 and GE B20 motors, 1 on 761 motors). 3. Remove covers. 4. Fill reservoirs to indicated FULL level. Use only mineral base oil (hydraulic oil) in the brake reservoirs. Do not use brake fluid. Replace reservoir cover(s) but leave loose. 5. Put the Top Drive selector switch in the AUX position and start the HPU. 6. Cycle the brakes several times by operating the Brake switch at the Top Drive Console. 7. With the brake on and the HPU running, loosen the bleed screw on the component until there is no sign of air mixed with the oil. 8. Close the bleed screw. 9. Cycle the brake off and on. 10. Repeat the process until there is no air visible in the system. 11. Top off reservoirs to indicated FULL level and replace covers tightly.

Revision 05.03

4-65

Canrig Top Drive Drilling System Auto Brake Bleeding 1. Clean area around reservoir covers (2 on GE 752 and GE B20 motors, 1 on 761 motors). 2. Remove covers. 3. Fill reservoirs to indicated FULL level. Use only mineral base oil (hydraulic oil) in the brake reservoirs. Do not use brake fluid. 4. Replace reservoir cover(s) but leave loose. If the cover is tightened the reservoir could be damaged during bleeding. 5. Open ball valve(s) (1 per reservoir) on reservoir return lines. 6. Put the Top Drive selector switch in the AUX position and start the HPU. 7. Cycle the brakes several times by operating the Brake switch at the Top Drive Console. 8. Close the ball valve(s) on the reservoir return line. 9. Top off reservoirs and replace covers tightly. Ensure there is no air visible in the system.

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Revision 05.03

SUBSECTION 4C: TROUBLESHOOTING Hydraulic Troubleshooting ..................................................................................................... 4-68 Preliminary Procedure....................................................................................................... 4-68 Mud Saver Valve Flowchart 100-1 .................................................................................... 4-69 Handler Lock Flowchart 101-1 ........................................................................................ 4-70 Back-up Wrench Flowchart 102-1 ................................................................................... 4-71 Back-up Wrench Flowchart 102-2 ................................................................................... 4-72 Handler Rotate Flowchart 103-1 ..................................................................................... 4-73 Brake System Flowchart 104-1 ...................................................................................... 4-74 Brake System Flowchart 104-2 ...................................................................................... 4-75 Torque Boost Flowchart 105-1 ...................................................................................... 4-76 Back-up Wrench Gripper Flowchart 106-1 ..................................................................... 4-77 Back-Up Wrench Gripper Flowchart 106-2 ..................................................................... 4-78 Link Tilt Flowchart 107-2 ................................................................................................. 4-79 Link Tilt (with Counterbalance Valve) Flowchart 107-3 ................................................... 4-80 Link Support Counterbalance Flowchart 108-2 ............................................................... 4-81 Lube System Troubleshooting .......................... .................................................................... 4-82 Lube System Flowchart 109-1......................................................................................... 4-82 Top Drive Blower Troubleshooting.................... .................................................................... 4-83 Top Drive Blower Flowchart 110-1 .................................................................................. 4-83 Hydraulic Pressure: Flowchart 111-1 ................................................................................ 4-84

Revision 05.03

4-67


Hydraulic Troubleshooting Preliminary Procedure 1. Ensure pump is turned on and running at system pressure 2350 psi. (see note) 2. Ensure that there is power at the console. 3. Ensure that hydraulic lines are connected to the Top Drive. 4. Ensure that there is 2350 psi (see note) system pressure on the gauge at the Top Drive. 5. Ensure that there is 0 psi on the return pressure gauge at the Top Drive. 6. Read pressures at all applicable test points.

NOTE:

4-68

Pressures on individual Top Drive systems may vary. Consult the Hydraulic Drawings in the Drawings and Parts List section for exact pressures.

Revision 05.03

Subsection 4C: Troubleshooting Mud Saver Valve: Flowchart 100-1

Problem: Valve will not open or close.

IS ACTUATOR SHAFT TURNING WHEN SWITCH IS ACTIVATED?

IS SOLENOID VALVE SHIFTING WITH SWITCH?

IS ACTUATOR FUNCTIONING BUT SHAFT NOT TURNING?

TRY MANUAL OVERRIDE, DOES ACTUATOR WORK? REPAIR MECHANICAL CONNECTION TO ACTUATOR SHAFT

REMOVE COUPLING BETWEEN VALVE AND ACTUATOR, TURN VALVE MANUALLY, IS VALVE SEIZED?

INSERT GAUGES ON TEST POINTS A & B, IS THERE 1500PSI ON GAUGE WHEN VALVE IS ACTIVATED?

REPAIR BALL VALVE

ELECTRICAL CONNECTION, WIRING / SOLENOID PROBLEM DETACH HOSE AT ACTUATOR. IS THERE FLOW WHEN VALVE IS ACTIVATED?

CONSULT CANRIG SERVICE DEPARTMENT

ADJUST PRESSURE RELIEF VALVE SO PRESSURE IS 1500 PSI WHEN ACTUATOR IS STOPPED

CHECK FOR CRIMPED LINES, BLOCKAGE,ETC. WILL VALVE ADJUST TO 1500 PSI?

ARE SEALS LEAKING ON ROTARY ACTUATOR?

CHANGE VALVE

DOES ACTUATOR WORK?

REPAIR SEAL

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PROBLEM SOLVED

Revision 05.03

Canrig Top Drive Drilling System Handler Lock: Flowchart 101-1 Problem: Lock Pin will not engage or disengage.

IS THERE A MECHANICAL PROBLEM? IS THE PIN PHYSICALLY JAMMED?

FREE PIN

IS THE SOLENOID VALVE SHIFTING WITH THE SWITCH? INSERT GAUGES ON TEST POINTS A & B IS THERE 1200 PSI ON BOTH WHEN IN LOCK POSITION AND ON B IN UNLOCK POSITION?

TRY MANUAL OVERRIDE, DOES PIN SHIFT?

ADJUST PRESSURE RELIEF VALVE SO PRESSURE IS 1200 PSI WILL VALVE ADJUST TO 1200

CHECK FOR CRIMPED LINES, BLOCKAGE, ETC.

DETACH HOSE AT CYLINDER, IS THERE FLOW FROM A & B IN LOCK AND UNLOCK POSITION?

CHANGE OUT VALVE SET PRESSURE TO 1200 PSI

DOES LOCK PIN WORK ?

ELECTRICAL CONNECTION OR WIRING/ SOLENOID PROBLEM. IS THERE POWER AT VALVE?

ARE SEALS LEAKING ON CYLINDERS? PROBLEM SOLVED

CHECK POWER AT PANEL, CONSOLE. WIRING CONNECTION OR SOLENOID PROBLEM

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REPLACE SEALS

CONSULT CANRIG SERVICE DEPARTMENT

Revision 05.03

Subsection 4C: Troubleshooting Back-up Wrench: Flowchart 102-1

Problem: Back-up wrench will not move up or down. IS THERE A MECHANICAL PROBLEM? IS THERE SOMETHING JAMMED? DID THE CYLINDER COME UNPINNED?

CORRECT PROBLEM

LEAKING SEAL IN ROTARY MANIFOLD, CONSULT CANRIG SERVICE DEPARTMENT

DO OTHER FUCNTIONS MOVE WHEN VALVE IS ACTIVATED?

IS THE SOLENOID VALVE SHIFTING WITH THE SWITCH?

INSERT GAUGES ON TEST POINTS A & B, IS THERE PRESSURE ALTERNATELY WHEN THE VALVE IS ACTIVATED UP/ DOWN?

WIRING CONNECTION OR SOLENOID PROBLEM


TRY MANUAL OVERRIDE ON DIRECTIONAL VALVE DOES CYLINDER MOVE?

TURN UP PRESSURE ON RELIEF VALVES OR CHANGE OUT FAULTY OR JAMMED RELIEF VALVE, DOES WRENCH MOVE?

PROBLEM SOLVED CHECK POWER AT PANEL, CONSOLE.

INSERT GAUGES ON TEST POINTS ON ROTARY MANIFOLD (SEE SCHEMATIC) IS THERE PRESSURE WHEN THE VALVE IS ACTIVATED?

DOES THIS PRESSURE APPROXIMATE PRESSURES ON A & B TEST POINTS (+ 50 PSI)

WITH PRESSURE @1500 PSI AND FLOW TO CYLINDER, BACK-UP WRENCH SHOULD TRAVEL UP/ DOWN. PROBLEM MAY BE A PLUGGED FITTING OR AN INTERNAL CYLINDER PROBLEM, REMOVE AND REPAIR.

4-71

CHECK FOR BLOCKED OR CRIMPED LINES TO ROTARY SEALS. DO ALL LINES HAVE FLOW?

REPAIR OR REPLACE LINES.

PLUG LINES TO HYDRAULIC CYLINDER, IS THERE PRESSURE ON TEST POINT?

LEAKING ROTARY SEAL CONSULT CANRIG SERVICE DEPARTMENT.

Revision 05.03

PROBABLY LEAKING SEAL ON CYLINDER. BACK-UP WRECH SHOULD BE FULLY EXTENDED IN THIS CASE. REPAIR PISTON SEAL.

Canrig Top Drive Drilling System Back-up Wrench: Flowchart 102-2 Problem: Back-up Wrench (BUW) moves up and down or does not hold when the BUW Joystick is in the MAINTAIN position. NOTE: A small amount of downward creeping is normal.

REVERSE HOSES TO UP/ DOWN CYLINDER. DOES CREEP STOP?

IF CYLINDER IS EXTENDING, POSTON SEALS MAY BE LEAKING. REPAIR CYLINDER.

DOES BACK-UP WRENCH MOVE IN OPPOSITE DIRECTIONS?

RELIEF VALVE MAY BE SET TOO LOW OR MAY BE DAMAGED. TRY TO SET HIGHER OR REPLACE.

POSSIBLE LEAK IN ROTARY SEAL. CONSULT CANRIG TECHNICIAN.

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Revision 05.03

Subsection 4C: Troubleshooting Handler Rotate: Flowchart 103-1 Problem: Pipe Handler assembly will not rotate. IS HANDLER UNLOCKED?

PROBLEM SOLVED

UNLOCK HANDLER.

EXAMINE GEAR ASSEMBLY. IS KEY, HUB, GEAR, ETC. IN PLACE?

REPLACE OR REPAIR PARTS AS REQUIRED. DOES HANDLER ROTATE?


CHECK DIRECTIONAL VALVE OR LINES TO MANIFOLD. INSERT GAUGES ON TEST POINTS A & B. IS THERE SYSTEM PRESSURE ON GAUGE WHEN VALVE IS ACTIVATED?

TRY MANUAL OVERRIDE ON DIRECTIONAL VALVE. DOES MOTOR ROTATE? WIRING CONNECTION OR SOLENOID PROBLEM.

DETACH HOSES AT MOTOR. IS THERE FLOW WHEN VALVE IS ACTIVATED?

OPEN UP FLOW CONTROLS. HAS FLOW INCREASED AT HOSES?

ELECTRICAL CONNECTION OR WIRING/ SOLENOID PROBLEM. IS THERE POWER AT VALVE? CHECK FOR CRIMPED LINES, BLOCKAGE, ETC.

CHANGE OUT MOTOR. DETACH 1 HOSE & CHECK LEAKAGE THRU MOTOR. IS LEAKAGE EXCESSIVE?

CHECK POWER AT PANEL CONSOLE.

RECONNECT HOSES AND ACTIVATE VALVE, DOES HANDLER ROTATE? PROBLEM SOLVED

TRY LOCKING BACK-UP WRENCH ON QUILL NAD TURNING TRACTION MOTOR. THIS MAY FREE JAMMED ROTARY SEAL. AMPS REQUIRED TO ROTATE SHOULD BE LOW. IF EXCESSIVE, MAY BE INTERNAL MACHANICAL PROBLEMS. CONSULT CANRIG SERVICE DEPARTMENT.

Revision 05.03

4-73

Canrig Top Drive Drilling System Brake System: Flowchart 104-1

Problem: Brake will not come on. WIRING CONNECTION OR SOLENOID PROBLEM.


TRY MANUAL OVERRIDE ON DIRECTIONAL VALVE. DOES BRAKE COME ON?


DOES RESERVOIR HAVE OIL? CHECK POWER AT PANEL, CONSOLE.

BLEED BRAKE SYSTEM

FILL RESERVOIR IS THERE LEAKAGE AT CALIPER?

CHECK FOR WORN PADS OR BAD SEALS.

DOES BRAKE SYSTEM BLEED?

DOES BRAKE COME OUT?

DETACH CYLINDER, IS CYLINDER FUNCTIONING WHEN ACTIVATED?

CHECK FOR WORN SEALS, (OIL BYPASSING) LINE BLOCKAGE (FLOW)

PROBLEM SOLVED

CHECK FOR LEAKING SEALS IN BRAKE ACTUATOR. LINES BLOCKED TO BRAKE.

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Revision 05.03

Subsection 4C: Troubleshooting Brake System: Flowchart 104-2 Problem: Brake will not release.

IS THE SOLENOID VALVE STAYING ON?

CHECK FOR SHORT IN THE WIRING.

IS CYLINDER RETRACTING?

CHECK PRESSURE ON LINES, CHECK FLOW, CHECK SEALS ON CYLINDER.

REMOVE CYLINDER, IS ACTUATOR PISTON RETRACTING?

REMOVE ACTUATOR AND REPAIR.

IS THERE PRESSURE AT CALIPERS?

ARE CALIPERS SEIZED?

REMOVE AND REPAIR CALIPERS.

Revision 05.03

WHEN PRESSURE IS BLED OFF, DO CALIPERS OPEN?

CHECK FOR BLOCKED OR CRIMPED LINES.

4-75

Canrig Top Drive Drilling System Torque Boost: Flowchart 105-1 Problem: No torque applied to the quill when Torque Boost is engaged. *1 To achieve these pressures, TB must be turning against resistance, i.e: against back-up wrench. Otherwise, hoses must be disconnected and plugged. *2 Consult hydraulic schematic in the parts manual, section 6 for valves and pressure settings.

IS THE CLUTCH SOLENOID VALVE SHIFTING WITH THE SWITCH?

INSTALL TEST GAUGES ON CLUTCH TEST POINTS. DO YOU HAVE 500 PSI ON “A” WHEN VALVE OF & 500 PSI ON “B” WHEN VALVE ON?

INSTALL TEST GAUGES ON TORQUE BOOST TEST POINTS. DO YOU HAVE 2300 PSI ON “B” & 1075 PSI ON “A” WHEN VALVE ACTIVATED TO BREAKOUT/ MAKE-UP? (*1)

TRY MANUAL OVERRIDE ON DIRECTIONAL VALVE. DOES CLUTCH ENGAGE?

ADJUST PRESSURE REDUCING VALVE TO 500 PSI. CAN YOU GET 500 PSI?

OPEN VIEW HOLE IN BELL HOUSEING. CAN YOU SEE CLUTCH/ JAW ROTATE WHEN ENGAGED AND WHEN TORQUE SWITCH IS ACTIVATED?

CHECK SEALS ON PISTON REPLACE PRESSURE REDUCING VALVE.

OPEN VIEW HOLE IN BELL HOUSING. CAN YOU SEE CLUTCH ENGAGE WHEN CLUTCH SWITCH IS ACTIVATED?

OPEN VIEW HOLE IN GEARCASE. CAN YOU SEE GEAR TURNING?

GEAR MAY BE SLIPPING ON SHAFT. REMOVE TORQUE BOOST ASSEMBLY AND REPAIR.

IF CLUTCH ENGAGES BUT WILL NOT ROTATE, CHECK HYDRAULIC MOTOR/ GEAR REDUCER FOR DAMAGE.

4-76

IS THE ROTATE SOLENOID VALVE SHIFTING WITH THE SWITCH?

TRY MANUAL OVERRIDE ON DIRECTIONAL VALVE. DOES THE CLUTCH ENGAGE?

WIRING CONNECTION OR SOLENOID PROBLEM.

ELECTRICAL CONNECTION OR WIRING/ SOLENOID PROBLEM. IS THERE POWER AT VALVE? ADJUST PRESSURE REDUCING /OR RELIEF VALVES TO ACHIEVE REQUIRED PRESSURES. CAN YOU GET REQUIRED PRESSURE? (*2)

CHANGE PRESSURE RELIEF/ RELIEF VALVES. CHANGE OUT HYDRAULIC MOTOR.

CHECK POWER AT PANEL CONSOLE.

Revision 05.03

Subsection 4C: Troubleshooting Back-Up Wrench Gripper: Flowchart 106-1 Problem: Back-Up Wrench Gripper will not close. *1. Pressure may vary, consult hydraulic schematic Section 6, Parts for actual pressure settings.

IS SOLENOID VALVE SHIFTING WHEN SWITCH IS ACTIVATED?

WIRING CONNECTION OR SOLENOID PROBLEM.

TRY MANUAL OVERRIDE ON DIRECTIONAL VALVE. DOES GRIPPER CLOSE?

ELECTRICAL CONNECTION OR WIRING/ SOLENOID PROBLEM. IS THERE POWER AT VALVE

INSERT GAUGES ON TEST POINTS A & B. DO YOU HAVE 1000 PSI ON EXTEND PORT “B” WITH SOLENOID SHIFTED? (*1) DO YOU HAVE 1000 PSI ON RETRACT PORT “A” WITH SOLENOID NOT SHIFTED? (*1) MAY BE INTERNAL LEAKAGE IN ROTARY SEAL. IS THERE ANY PRESSURE ON PASSAGES NEXT TO EXTEND PASSAGE WITH PRESSURE WHEN IT SHOULD BE ZERO?

CHECK POWER AT PANEL, CONSOLE.

TRY TO INCREASE PRESSURE ON PRESSURE RELIEF VALVE. WILL PRESSURE INCREASE? CHANGE OUT PRESSURE RELIEF VALVE.

OVERHAUL ROTARY SEAL.

DO YOU HAVE 1000 PSI ON TEST POINTS ON THE ROTARY SEAL?

DOES GRIPPER CLOSE?

PROBLEM SOLVED

DISCONNECT RETRACT HOSE. IS THERE FLOW FROM CYLINDER?

CHANGE OUT P.O. CHECK CARTRIDGE, DOES GRIPPER CLOSE?

PROBLEM SOLVED

Revision 05.03

SEALS MAY HAVE TO BE REPLACED ON PISTON.

MAY BE INTERNAL DAMAGE TO GRIPPER. REMOVE & REPLACE GRIPPER CYLINDER.

4-77

Canrig Top Drive Drilling System Back-Up Wrench Gripper: Flowchart 106-2 Problem: Back-up wrench gripper will not open.

REMOVE & REPLACE PISTON SEALS.

IF RETURN SIDE PRESSURE DOES NOT EQUAL 0 PSI THERE MAY BE LEAKAGE ACROSS SEALS. DISCONNECT EXTEND HOSE BETWEEN ROTARY SEAL & GRIPPER CYLINDER. IS THERE FLOW THERE WHILE CYLINDER IS STATIONARY?

IS THERE MECHANICAL JAMMING?

TAKE APPROPRIATE ACTION.

IS SOLENOID VALVE SPRING RETURNING TO PROPER POSITION?(*1)

REMOVE & REPLACE SOLENOID VALVE.

INSTALL GAUGES ON TEST POINTS ON ROTARY SEAL. DOES A=2000 PSI, B=0? (*3)

ADJUST PRESSURE RELIEF VALVE UNTIL WORKING PRESSURE = 2000 PSI. DOES PRESSURE INCREASE?

REMOVE & REPLACE PRESSURE RELIEF VALVE. MAY BE A LEAKING ROTARY SEAL. REMOVE & REPLACE (*2)

MAY BE DAMAGE INTERNAL TO GRIPPER. REMOVE & REPLACE GRIPPER CYLINDER.

INSTALL GAUGES ON TEST POINTS A & B. DOES A=2000 PSI, B=0? WITH VALVE ACTIVATED, DOES B=2000 PSI, A=0? (*3)

DOES GRIPPER OPEN?

CHANGE OUT P.O. CHECK CARTRIDGE, DOES GRIPPER OPEN?

PROBLEM SOLVED

*1 – Install test points on A & B on manifold. B should read 1800 PSI when valve is actuated, A=0. With valve returned to spring position, (solenoid OFF) A should read 1800 PSI, B=0. *2 – A temporary hose can be from valve bank to gripper cylinder to open the cylinder. Be cautious when rotating handler. *3 – Pressure may vary, consult Hydraulic Schematic in the Drawings and Parts List section for actual pressure settings.

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Revision 05.03

Subsection 4C: Troubleshooting Link Tilt: Flowchart 107-2 Problem: Link Tilt will not retract fully. (Serial Number 007 and up)

INSTALL TEST POINT “A” PORT ON MANIFOLD, INCREASE PRESSURE ON THE RELIEF VAVLE. DOES LINK TILT RETRACT FULLY?

LOAD MAY BE TOO GREAT FOR CYLINDERS. DO LINKS RETRACT FULLY WITH NO LOAD?

PROBLEM SOLVED

PROBLEM SOLVED

INSTALL TEST POINT GAUGES ON POINTS AT ROTARY MANIFOLD. DOES THE PRESSURE READ THE SAME AS AT “A” & “B”?

MAY BE LEAKING IN THE ROTARY MANIFOLD. REMOVE & REPLACE.

Revision 05.03

4-79

Canrig Top Drive Drilling System Link Tilt (with Counterbalance Valve): Flowchart 107-3 Problem: Link Tilt creeps down with the Link Tilt Joystick in the MAINTAIN position. NOTE: Minor creeping is normal.

DOES LINK TILT RETRACT FULLY?

CHECK PRESSURE ON TEST POINTS AT MANIFOLD. IS PRESSURE ABOUT 2500 PSI?

PRESSURE RELIEF VALVE SETTING IS TOO LOW, TURN UP PRESSURE. DOES LINK TILT STILL CREEP DOWN?

PROBLEM SOLVED

ARE PISTON SEALS ON CYLINDERS WORN OR LEAKING?

TURN UP SETTING ON COUNTER BALANCE VALVE. DOES LINK TILT CREEP?

PROBLEM SOLVED

SEALS IN ROTARY MANIFOLD MAY BE LEAKING, CHECK AT NEXT OVERHAUL.

LINK TILT FLOAT DIRECTIONAL VALVE MAY BE LEAKING. REPLACE OR REPAIR.

4-80

REPLACE OR REPAIR DOES LINK TILT CREEP?

PROBLEM SOLVED

Revision 05.03

Subsection 4C: Troubleshooting Link Support Counterbalance: Flowchart 108-2 Problem: Link Support will not ride up when there is no load on the elevators. INSTALL A GAUGE ON TEST POINT “A” AT THE HYDRAULIC MANIFOLD. IS THERE 1700 PSI ON THE GAUGE?

TRY TURNING IN THE PRESSURE REDUCING VALVE. DOES THE PRESSURE INCREASE?

INSTALL A GAUGE ON THE TEST POINT AT THE ROTARY MANIFOLD. IS THERE 1700 PSI ON THE GAUGE?

PROBLEM SOLVED

CHECK THE LINK SUPPORT FOR MECHANICAL JAMMING. CHECK THE CYLINDERS FOR DAMAGE.

THE RELIEF VALVE MAY BE SET TO LOW. TURN IN THE RELIEF VALVE. DOES THE PRESSURE INCREASE?

REPLACE THE PRESSURE REDUCING VALVE. DOES THE PRESSURE INCREASE?

CHECK FOR BLOCKED OR CRIMPED HYDRAULIC LINES. ARE ALL LINES OK?

SET THE PRESSURE RELIEF VAVLE @ 2100 PSI. SET THE PRESSURE REDUCING VAVLE @ 1700 PSI. DOES THE LINK SUPPORT EXTEND?

THERE MAY BE A LEAK IN THE ROTARY MANIFOLD SEALS. REPLACE THE SEALS.

PROBLEM SOLVED

PROBLEM SOLVED

REPLACE THE PRESSURE RELIEF VALVE.

Revision 05.03

4-81

Canrig Top Drive Drilling System Lube System: Flowchart 109-1 Problem: Low Lube Pressure Light (PL7) comes on.

IS THERE PRESSURE SHOWING ON THE LUBE PRESSURE GAUGE? +30 PSI

PRESSURE SWITCH MAY NEED ADJUSTING. ADJUST TILL LIGHT GOES OUT.

ADJUST PRESSURE RELIEF VALVE UNTIL WORKING PRESSURE = 2000 PSI. DOES PRESSURE INCREASE?

IS THE ELECTRIC MOTOR ON THE PUMP TURNING?

CHECK PLUG, BREAKERS & WIRING. REPLACE MOTOR.

CHECK THE COUPLING BETWEEN PUMP MOTOR. IS COUPLING OK?

ENSURE BALL VALVE IS OPEN ON THE SUCTION EXAMINE STRAINER FOR BLOCKAGE. IS OIL FLOWING TO THE PUMP?

REPAIR OR REPLACE COUPLING.

LINES MAY BE BLOCKED OR THERE IS INSUFFICIENT OIL IN GEARBOX.

PUMP MAY NEED REPLACING.

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Revision 05.03

Subsection 4C: Troubleshooting Top Drive Blower: Flowchart 110-1 Problem: Top Drive Low Air Light (PL5) comes on.

IS THERE A VISUAL OR PHYSICAL INDICATION OF AIR COMING OUT OF MOTOR?

AIR PURGE SWITCH MAY NEED ADJUSTING OR LINE TO SWITCH MAY BE BLOCKED.

IS THE AIR DUCT HOSE ATTACHED FROM BLOWER TO MOTOR?

ATTACH HOSE WHERE REQUIRED.

IS THE AIR HOSE DAMAGED (COLLAPSED OR HOLES)?

REPAIR OR REPLACE AS REQUIRED.

IS THE BLOWER TURNING?

IS THERE POWER TO THE BLOWER MOTOR?

EXAMINE BLOWER FOR PROBLEMS, BLOCKED INLET OR OUTLET, LOOSE IMPELLAR

CHECK PLUGS, BREAKER & WIRING.

BLOWER MOTOR MAY NEED REPLACING.

Revision 05.03

4-83

Subsection 4C: Troubleshooting Hydraulic Pressure: Flowchart 111-1 Problem: Low hydraulic pressure (700 PSI) on Top Drive gauge.

DOES IT HAPPEN WITH PUMP 1 AND 2?

CHECK OUT PUMP WITH LOW PRESSURE.

ISOLATE HPU FROM SYSTEM. DISCONNECT QC AT HPU.

IS SYSTEM PRESSURE 2350 PSI AT THE HPU?

CHECK HPU RELIEF VALVE.

RECONNECT HPU. DISCONNECT QC AT HPU.

IS SYSTEM PRESSURE 2350 PSI AT THE HPU?

CHECK HYDRAULIC SERVICE LOOP OR LOOK FOR DAMAGED HOSE.

RECONNECT QC ON TD PRESSURE ONLY. RETURN IS DISCONNECTED.

CHECK RELIEF VALVE ON LINK COUNTERBALANCE CIRCUIT.

Revision 05.03

IS PRESSURE AT TOP DRIVE 2350 PSI?

CHECK FOR PINCHED HOSE OR BLOCKAGE ON TD UNIT.

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Canrig maintenance schedule

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