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J:\proj\7214\do\7214-024\01.doc Wednesday, October 18, 2000 DH/gin ,1752'8&7,21 ,QWURGXFWLRQ 1.1.1 Purpose ... 2 1.1.2 Useful information... 3 1.1.3 Contact addresses... 4 4XDOLILFDWLRQDQGWUDLQLQJUHTXLUHPHQWV 1.2.1 General... 5 1.2.2 Operator-course ... 5 1.2.3 System-course... 6 +HDOWK6DIHW\DQG(QYLURQPHQW+6( 1.3.1 General... 7 1.3.2 Health... 7 1.3.3 Safety ... 7 1.3.3.1 Safety in operation ... 8 1.3.3.2 Safety in maintenance... 8 1.3.3.2.1 Hydraulics ... 8 1.3.3.2.2 Electrical... 8 1.3.3.2.3 Software... 9 1.3.4 Environment ... 9

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The purpose of this manual is to give the user and maintenance personnel knowledge regarding the following items:

- How the system works

- The purpose of the equipment - How to operate the equipment - How to maintain the system

- How to carry out corrections and make necessary adjustments - How to order spare parts

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8VHIXOLQIRUPDWLRQ Supplier information:

Manufacturer: Maritime Hydraulics A.S

Address: Serviceboks 413

4604 Kristiansand Norway

Telephone: + 47-380-57000 (Office hours)

+ 47-381-24728 (After hours telephone services)

Telefax: + 47-380-40570 (Technical dept.)

+ 47-380-46291 (Spare parts)

E-mail: [email protected]

After Sales Department: [email protected]

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If any problems should occur, requests may be directed to MH After Sales Department

Telephone (Office hours): + 47 380 57000

Telephone after office hours service: + 47 381 24728 For Your Information,

The following MH Agencies providing a 24-hour service: Maritime Hydraulics A/s

Stavanger, Norway

Stavanger Supply Division

MH-Pyramid Houston, USA

Telephone + 47 51 64 89 89 + 1 713 849 0707

Telefax + 47 51 64 89 88 + 1 713 849 0808

Maritime Hydraulics Pte. Ltd Singapore Maritime Hydraulics Pvt. Ltd., Bombay, India Telephone + 65 543 1877 + 91 22 202 4299/283 4264 Telefax + 65 542 1512 + 91 22 287 3760 Maritime Hydraulics Ltd. Aberdeen, UK Maritime Hydraulics Ltd. Calgary, Canada Telephone + 44 1224 870 091 + 1 403 569 2222 Telefax + 44 1224 874 808 + 1 403 569 2294

Maritime Hydraulics Tecnoil Ltda. Rio de Janeiro, Brazil

Maritime Hydraulics Baku, Azerbaijan

Telephone + 55 21 533 2552 + 994 12 932059

Telefax + 55 21 533 2875 + 994 12 989580

Maritime Hydraulics Ltd. Sharjah, United Arab Emirates Telephone + 971 6281 454 Telefax + 971 6285 668

Aker Maritime Asa

Maritime Hydraulics Middle East Abu Dhabi, United Arab Emirates + 971 2 463 009

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Maritime Hydraulics A.S offers operator and system courses on all MH equipment. The purpose is to educate operators and maintenance personnel in safety and reduce expensive downtime.

As the equipment has become increasingly complicated, a more “multi-disciplined” staff is required. We therefore intend to go through the system step by step; mechanically,

hydraulically and electrically. This enables us to supply a basic understanding of the complete system, and to improve the communication between the hydraulic/mechanical/ electrical and instrumentation staff.

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A system operation-course is to be held prior to the initial start-up period. The duration of an operator-course depends entirely on the amount of equipment involved. The exact fee is dependent on the duration and content of the course.

Course content recommended:

• Introduction and general description

• Technical specifications and performance data • How to operate the equipment

• Control system • Hazards • Daily checks • Exercises

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A tailor-made system-course can be arranged when the system has been in operation for 3-6 months.

The duration of a system-course depends on the amount of equipment involved. The Fee is based upon the duration and content of the course.

Course content recommended:

• General description and system philosophy • Technical specifications and performance data • How to operate the equipment

• Hydraulic system description • Hydraulic components • Hydraulic flow diagrams • Electrical system description • Electrical components • Electrical drawings • Trouble shooting • Maintenance • Exercises (LJKWSDUWLFLSDQWVLVWKHPD[LPXPQXPEHUUHFRPPHQGHGIRUHDFKFRXUVH

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The equipment has been designed in accordance with current HSE regulations and standards. To operate safely and prevent injuries to personnel and damage to the equipment and

environment, read this manual before operating the machine and comply with its contents at all times.

Observance of all the instructions set out in this manual is to be considered the full responsibility of the operator.

In addition to the instruction manuals/handbooks, observe any general legal and other mandatory regulations in force relating to accident prevention and environment protection.

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Protection of health implies that personnel are not exposed to excessive work-loads/forces. The elements taken into account are:

• Ergonomics • Noise • Vibrations

• Chemical substances and products • Illumination

• Indoor climate • Outdoor operation

The procedures/instructions/guidelines incorporated in this manual reflect the result of our studies.

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Operator shall ensure that only authorized personnel are allowed to use, operate and maintain the equipment. Such authorized personnel shall be properly trained and skilled in accordance with the relevant statutory regulations and requirements, and also Maritime Hydraulics’ requirements and recommendations for correct and safe use of the equipment or similar authorization level.

Maritime Hydraulics shall be under no liability whatsoever in respect of any damage, personnel injury, defect, delay or any consequences of such arising from incorrect use or maintenance of the equipment, or arising from unqualified personnel using or having access to the equipment.

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Only authorized personnel shall operate the equipment.

The equipment shall be used only when in proper technical condition and for its intended purpose. Functional disorders, in particular disorders that would prejudice safety, must be rectified immediately.

The operator is responsible for ensuring that no personnel are within, or in the vicinity of, the equipment operating area before starting or during operation of the equipment.

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Maintenance personnel shall be completely familiar with the equipment operation, hydraulic and electrical schematics and maintenance procedures before attempting repair or

maintenance work.

The area where the maintenance work is to be performed must be made secure as necessary. During replacement, individual parts and large and/or heavy structural components must be carefully attached to the lifting appliance and safeguarded in order to avoid a possible source of danger. Use only approved lifting equipment with sufficient carrying capacity.

Do not stay or work underneath or in the vicinity of a suspended load.

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The hydraulic circuits employed are designed for high pressure. There is a great potential for high pressure inherent at any of the hydraulic components. Maintenance personnel should therefore ensure that pressure is bled off at any circuit scheduled for inspection, maintenance or repair prior to commencing work.

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Only personnel authorized according to the electrical regulations in force, shall perform work at the electrical installations on the equipment.

If the specification for inspection, maintenance or repair requires the equipment to be voltage free, it can be achieved in one of the following ways:

For power systems:

• Switch off and lock the main circuit breaker in the MCC according to isolation procedures in force.

• Follow special procedures for the equipment in question. For instrumentation systems:

• Isolate the control panel for the equipment from the main power supply.

• Open the fuses in the control panel according to the relevant interconnection drawings. • Open the terminal strip isolation knives in the control panel according to the relevant

interconnection drawings.

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Before work proceeds verify that all circuits are voltages free.

Measures must be taken to prevent accidental activation of equipment during maintenance. This may include locking of power supply or posting of warning signs on all power

distribution, control and operator panels.

In case of malfunction in the electric supply, (voltage, frequency or other disturbances) the equipment must be switched off immediately.

To maintain the integrity of the system, it is important that all spare parts have identical or better specifications than the original equipment. This is especially important for all protective equipment such as fuses and circuit breakers. If in doubt, contact Maritime Hydraulics for recommendations.

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Only qualified MH personnel may alter the software of the system. The software delivered with the system is filed at MH. If modified software is detected in any system, it will void all warranty responsibilities with respect to the safe and normal operation of the system.

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The electrically driven Derrick Drilling Machine (DDM) is designed with a continuous shaft from the mud swivel through the gearbox and pipe handler, with the load hang-off nut at the lower end. A load rating of 650 Sh. Tons is thereby obtained through the shaft without the need for a threaded connection.

A General Electric DC top drive motor is used as driver for the gearbox. 3 types of motor cooling systems can be supplied: local cooling, remote cooling or closed cooling. Local cooling is the MH standard.

All the functions of the pipe handler including the torque wrench are remote

operated. The link tilt system is capable of parking the elevator in any position, from vertical position (tripping mode) to fully extended position (mousehole mode).

The pipe handler has a rotation facility for 360º continuous rotation (CW/CCW). This means that the elevator can be rotated for spinning in drill collars etc.

The torque wrench can be used for either make-up or breakout of the connection between the DDM and the drill pipe. In make-up mode the required torque can be pre-selected from the driller’s controls. The control system provides automatic repetition of the pre set make-up sequence until required torque is obtained when the torque wrench is operated in “auto mode”.

The DDM is designed with S-pipe (mud pipe)-, power junction box-, and service loop manifold-arrangement for installation on either LHS or RHS depending on the derrick layout. The service loops are 24,2 m (~ 79 ft.) long. This requires the service loop manifold to be installed between 22,5 m (∼ 74 ft.) and 25 m (82 ft.) above drill floor.

The DDM is type approved by DnV according to the following regulations and conditions:

− United Kingdom, S.I. No. 289 The Offshore Installation (Construction and Survey) Regulation 1974 and HSE’s Guidance on design and Construction.

− NMD’s “Regulation of 13 May 1987 concerning drilling installation and equipment etc. on mobile offshore units which are registered or will be registered in a Norwegian ship register.”

− NPD’s “Regulation relating to drilling and well activities and geological data collection in the petroleum activities”, 1994.

− API’s “Specification for Drilling and Production Hoisting Equipment (PSL 1)”, SPEC 8C, Second Edition, 1992.

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A) Utility requirements (pipe handler):

Hydraulic pressure : 180 bar (2650 psi)

Flow : 160 l/min. (42 U.S. gal./min.)

Air pressure : 7 bar (125 psi)

Flow : 3 cum/h continuous, 63 cum/h intermittent

(dried air, dew pt. -20 degrees C).

B) DDM-650L- DC characteristics:

Length (drilling), underside bail - underside torque wrench: 6700 mm (264 in) Length (tripping), underside bail - top of elevator: 7640 mm (301 in)

C) DDM-650L- DC - power characteristics, shunt motor:

GE-752 (US1) hi-torque, 843 kW (manufacturer rated) at 1185 Amps armature current and 60 Amps field current.

Torque/speed continuous (1 gear) : 68.350 Nm (50.400 ft.lb)/104 rpm Torque/speed continuous (2 gear) : 44.400 Nm (32.778 ft.lb)/161 rpm Torque/speed intermittent (1 gear) : 76.900 Nm (56.700 ft.lb)/125 rpm Torque/speed intermittent (2 gear) : 50.000 Nm (36.880 ft.lb)/193 rpm Torque/speed at max H.P. (1 gear) : 65.000 Nm (47.900 ft.lb)/121 rpm Torque/speed at max H.P. (2 gear) : 42.300 Nm (31.200 ft.lbs)/186 rpm Max speed gear 1 : 154 rpm at 36.800 Nm (27.190 ft.lbs) Max speed gear 2 : 237 rpm at 23.900 Nm (17.687 ft.lbs)

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All items painted, where relevant, with I 73 A RAL 3002. Colour red. NORSOK M – 501.

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DDM-650L-DC (less elevator) : 15 tonnes (33000 lbs) Service loop incl. manifold : 2,2 tonnes (4850 lbs)

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Consisting of a 650 Sh. tons rotary mud swivel, complete with bail and gooseneck, pressure rated at 350 bar (5000 psi) working pressure.

The gooseneck is equipped with 3" BSP threaded plug for wire line entry, and complete with "S" type pipe extension with brackets and hammer union for upper connection to gooseneck. Lower "S" end terminates in 4" API (male) threads. The wash pipe packing is cartridge type with alternate metal spacer rings and packer rings. The wash pipe is easily replaceable.

The swivel is equipped with a tapered roller type bearing to support the axial load. The lower radial bearing is a straight roller type while the upper auxiliary bearing is a tapered roller type that supports both upwards thrust and radial loads.

The swivel housing has an oil level sight gauge, and is equipped with a temperature sensor.

Swivel stem (drive shaft) has a load carrying nut for the elevator link hanger mounted at the lower end. The stem’s lower end terminates in 7 5/8" API reg. r.h. threads (female).

The gearbox is a heavy-duty type, complete with manually controlled mechanical lock, and supports for attachment to rotary/mud swivel and dolly.

The high and low range gear ratios are accomplished by shifting a splinted pinion gear wheel to either position.

A proximity switch (for rpm monitoring), that reads pulses per revolution of the main shaft, is attached to the flexible coupling on the DC-motor.

In high torque range, 1:8.58 (gear 1) the pinion gear is locked in lower position and drives the bull gear through a gear wheel mounted on a shaft, which is offset to the pinion gear.

In low torque range, 1:5.58 (gear 2) the pinion gear is locked in upper position and mesh directly with the bull gear.

The lubrication system is a forced circulation type with a gear pump mounted below the gearbox. The pump is driven by an electric motor (400VAC, 3 phase, 50Hz, 0,75Kw, EExde IIB T4) to provide lubrication to the gear wheels and all the bearings. A pressure switch is connected to the lube oil circuit in order to give an alarm if the pressure drops too low.

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The gearbox lower oil seal for the main shaft is designed so that in the event of a seal failure, there will be sufficient oil left in the gearbox to maintain proper lubrication for a period of time.

Solenoid valves with corresponding hydraulic and air distribution manifolds are mounted on the swivel/gearbox front side. Delivery includes all hard piping and hoses between solenoid valve manifold and hydraulic swivel on pipe handler. Further, all electric cabling between J-boxes for incoming cables for DC motor and solenoids are included.

The solenoid valve assembly is protected by a hinged steel grid, which can also be used as a working platform.

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The DC drilling motor is a General Electric make - type GE 752 Hi-torque - shunt wound. The motor is integrated with an air brake system and inlet/outlet duct with spark arrestors and is designed for installation in hazardous area, zone 1.

The DC motor is equipped with a 220 VAC, 60 Hz, 150 W stand still heater.

The bottom shaft end of the DC-motor is equipped with a flexible coupling for easy connection to the pinion gear.

Air brake, type Airflex 16 VC 600, provides 52000/80000 Nm (38.200/59000 ft lbs) static braking torque (respectively for gear 2/gear 1) at 7 bar (100 psi) air pressure. All monitoring equipment on the motor has electrical cable connections drawn to a common junction box.

Instrumentation on DC motor assembly includes:

- Pressure switches for monitoring of airflow through DC-motor and for monitoring pressure between outlet duct and atmospheric pressure. - Temperature sensor in the armature (high temperature alarm).

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The cooling system consists of an air inlet duct with weather louvre (for mounting at travelling block), a flexible 10 in. hose, a fan assembly directly driven by a 460 VAC, 3 phase, 60 Hz, 12,5 kW, EExde II T4 motor, and the outlet ducts with spark arrestor mounted underneath the DC-motor.

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Includes a pipe handler positioning (hydraulic) motor for rotation of the pipe handler. A proximity switch provides an auto position stop function, normally oriented so that elevator opening is towards the pipe handling system.

Swivel coupling for transfer of oil and air from the fixed part to pipe handler. Elevator link hanger, 650 sh. tons capacity, with link actuator for forward swing of elevator for mousehole pick-up or backward “swing away” drilling positioning of the elevator.

A link tilt stop system is capable of stopping the elevator in all positions when picking up drill pipes, and has remote controlled speed adjustments for the swing motion. All electric/hydraulic components are included in order to operate the system from driller’s panel.

Torque wrench complete with upper clamp jaws for 7 ¾” through 8” OD tool joint for saver sub, and lower clamp jaws for 6 3/8” through 7 ¼” OD tool joint for 5” DP. All jaws are complete with dies. Torque wrench oil requirement is 160 l/min. at 210 bar pressure. Max. make-up/break-out torque is 107.000 Nm (78.000 ft. lbs). A guide funnel is mounted at lower end of torque wrench to provide easy stab-in of pipe. A heavy-duty rubber insert provides non metallic contact of torque wrench to the drill string.

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Two hydraulic cylinders with guide rollers at the piston end for lifting/lowering of a cam sleeve, (made of aluminium for weight reduction). The cam sleeve has a hexagonal crank that mate with the IBOP-valve.

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Intermediate sub, 7 5/8” API - reg r.h. upper pin and 6 5/8” API reg. r.h. lower box connection. Length shoulder to shoulder 345 mm.

A remote operated IBOP (kelly valve), 6 5/8” reg. r.h. upper pin and 6 5/8” API-reg. r.h. lower box connection. Length shoulder to shoulder 345 mm (13 ½”). Max. working pressure is 1000 bar (15.000 psi).

A saver sub for 5” IEU - 19.50 (NC-50) drill pipe connection. The upper pin connection is 6 5/8” API-reg. r.h. length shoulder to shoulder: 220 mm (8 2/3”). Outside diameter: 197 mm (7 ¾”).

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Thread saver system with hydraulic control to provide cushioning when connecting the DDM to the drill pipe.

System comprising of 2 hydraulic cylinders with the necessary chain connections and links.

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One set of elevator links, API standard, 120” length, 350 sh. tons capacity for drill pipe elevator.

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Consist of hydraulic hoses and two sets of cables. Each set of electrical cables is bundled into a low-pressure protection hose, which terminates with flanges at both ends. The length of the loops are approx. 25 m, exact length will be decided when final derrick layout is agreed to.

A) Electrical loops: Consisting of:

− One power loop, including: 6 pcs, 750 VDC, 444 MCM (225 mm2 ), 1 pc ground 4/0 (112 mm2).

− One control loop including:

1 pc - 4 conductors - size : 8 AWG : field

2 pc - 4 conductors - size : 10 AWG: fan & lube oilmotor

7 pcs - 10 conductors - size : 14 AWG: purge contr. solenoid, sensors 1 pc - 3 conductors - size : 14 AWG: anti. cond. heaters.

Instrument control : 24 VDC Electric motor heating : 230 VAC

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B) Hydraulic and air loop:

− Two hydraulic hoses, 1.5” i.d., 2.1” o.d., supply and return for pipe handler. − One hydraulic hose, 1” i.d., 1.5” o.d., drain from pipe handler & air supply for air

flex brake and pneumatic elevator. C) Derrick termination junction boxes:

− Two junction boxes for main power cables, made of stainless steel, IP 66, each for max. 2 x 300 mm2 incoming cables.

− Two junction boxes for motor control and instrument cables, stainless steel, IP 66.

The junction boxes are certified for location in hazardous area, zone 1.

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A control valve assembly for remote controlling and monitoring all the pipe handler functions. The valve assembly is mounted on a steel rack together with the pneumatic valves and the filter for the air flex brake and elevator control.

The rack is mounted on the swivel and gearbox front side.

A hinged steel grid that can be used as a working platform protects all the equipment mounted on the rack.

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The following special tools are included in the delivery:

− 2 pcs. bolt extractors (torque wrench opening). − 1 pc lift frame for hang-off nut

− 1 pc key for IBOP

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A special cradle is provided for handling and transport of the DDM and parking the top drive for "swing-away" purpose.

A lifting sling is included for lifting and handling in horizontal position. In vertical position the DDM and cradle have to be lifted by attachment to the swivel bail. The cradle is designed also to be handled/ lifted by a forklift.

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Skids and boxed equipment should be stored in storehouse or under cover. If stored out-doors cover with tarpaulins. Derrick can be stored out-doors without cover but equipment already installed in derrick should be covered with tarpaulins. Some skids are already covered with non-flammable watertight bags when delivered.

Electronic panels/equipment or junction boxes must not be unpacked out-doors. Equipment, which is not packed in wooden cases, can not be allowed to have any items stored on top.

Check that all machined exposed surfaces are coated with Tectyl bodysafe. Any damage of initial protection shall immediately be renewed.

All electrical motor heaters to be energised.

LONG PERIOD STORAGE, MORE THAN THREE MONTHS All transport securing devices for driven equipment to be removed.

Hydraulic operated equipment to be hooked up to a hydraulic power unit (capacity 160 bar, 160 l/min.) and all functions to be hydraulically operated. Cleanliness of oil must be max. NAS 6.

Pneumatic operated equipment to be connected to instrument air supply (capacity 8 bar) and to be air operated.

All mechanical movable equipment (not driven equipment) to be moved/operated/rotated.

After operation of equipment all lube nipples to be greased, tooth racks, pinions and exposed gear racks to be lubricated. All surfaces to be checked to ensure that surface protection are intact.

This procedure to be repeated first time after 3 months of storage, then every 10 weeks for the whole storage period.

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Storage area: L x W x H (m) 5,5 x 2,1 x 2,3 m

Volume: Q = 26,5 m3

The machine is recommended to be kept in dry and clean condition.

In order to avoid damage to the bearings, the DDM should not be stored near other machines producing vibration or shocks.

The DDM must be stored on a non-electric conductive foundation. INSPECTION

All inspections to be executed by authorised personnel.

Once a month the DDM & aux. equipment to be visually inspected for damages. Every third month the main shaft to be manually turned min. one rotation. Swivel & gear box housing to be inspected every third month for lubr. oil level. Every third month all greasing points to be applied with grease.

All deviation detected during inspection to be reported and new preservation to be executed for actual item according to instruction for preservation.

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Prior to delivery the DDM 650L-DC to be:

- Coated with Tectyl 506 rust protection where machined surfaces require this treatment.

- Provided with end plastic plugs on all unprotected electric connections.

- All hydr. flange connections to be blanked with oil resistant rubber gaskets and water resistant plywood plates. Galvanised bolts to be used.

- All threaded hydr. connections to be protected by means of metallic plugs. - All grease nipples to be lubricated.

- Provided with adequate protectors on all unprotected threads in the gooseneck and main shaft.

- All electrical instruments, junction boxes and pressure gauges to be enveloped by means of aluminium sheeted glan fibre cloth.

- All junction boxes to be protected inside with vapour corrosion inhibitor or equal. - All open hydr. hoses to be plugged by means of steel plugs where applicable. Blind

flanges to be used where required.

- Prior to drain of swivel and gearbox oil reservoirs, anti corrosion admixture (FX1 or equal) to be mixed with the swivel & gearbox oil and rotated minimum 5 min. (Minimum +50°C in gear oil required.)

- When storing the DDM more than three months the above coating and protection has to be checked, and to be renewed if necessary.

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GENERAL

This procedure shall be followed by everyone who is involved in the above mentioned activities unless otherwise specified by customer.

PROCEDURE TAGGING

Each product shall be tagged in accordance with its packing list, which is to consist of the following information: the customer’s order no., MH’s order no., MH’s drawing no.,/position no. (loose items) in addition to a technical description.

Address labels are to contain the name and address of the recipient as well as the order number. Each piece is to be labelled by two pieces of address labels.

PACKING

All products/goods shall be packed securely in order to prevent damages during transport.

All loose items that are sent offshore must be packed in wooden boxes. Empty space between the items and the box must be filled with "“chips” or similar protective material depending on the size of the goods.

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SHIPMENT

The following documents are to be included in shipments: - Domestic : Packing list or waybill

- Abroad : In addition to the above mentioned documents, invoice or proforma invoice and possible export documents.

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DISPATCHING OF EQUIPMENT TO CUSTOMER GENERAL

The following procedure shall be followed when dispatching equipment to customer.

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PROCEDURE DISPATCHING

After having entered into a contractual agreement, the project manager shall see to it that a complete "Check List for Shipment" is being made as soon as possible.

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DISTRIBUTION:

- Warehouse manager, 1 copy w/relevant drawings - Shipping responsible, 1 copy

- Workshop responsible, 1 copy - Sub-supplier, 1 copy - if relevant.

In addition to the above distribution, the project manager shall see to it that all

necessary shipment information; address, tagging, packing, delivery terms, customers order no. etc., is handed over to the warehouse manager and the one responsible for shipment.

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"Check List For Shipment" - See Enclosure RETURN OF GOODS

It is the responsibility of the project manager to ensure that transport and lifting devices, not included in the delivery, are returned after use.

(33)

CLIENT: RIG:

CLIENT’S REF.: MH O. NO.: DESTINATION:

(34)

Client : Rig : Destination : Marked : Terms of delivery : Project No. : Clients ref. : Page no. 1 of Date issued: Product: Sub. vendor: Item no. No

off Description Ref.drw. no.

Colly

no LxWxH (m)

Gross kg weight

(35)

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UNPACKING

Remove all the transportation security devices like straps, bolts etc. Check the content of the cases and boxes according to the packing lists.

Do not remove the plugs in the hydraulic connections before the equipment is ready for connection to a flushed and certified clean hydraulic piping system.

Do not remove blinds in cable glands before the equipment is ready for connection of cables.

INSPECTION

Incoming material, components/equipment shall be inspected in accordance with the packing lists and the purchasing documents.

The incoming materials, components/equipment shall be inspected to ensure: - that no transport damages have occurred

- that there is conformity between prescribed quality and quantity on purchase documents and received material.

(36)

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Caution (warning)

Improper lifting operation may result in injury to personnel and damage to property. The lifting operation must conform to the national standard. Before lifting, check the equipment capacity and load on the “Certified Weight” scheme, and make sure that all covers guards and bails are securely fastened.

In order to avoid damage to other equipment during lifting, make sure that there is sufficient clearance to other equipment.

Lifting positions for the DDM:

I - horizontal in transport cradle II - vertical in transport cradle

III - vertical without transport cradle during unpacking and installation. Ref. I & II

1. Total weight approx. 15 T.

2. Use 4 pcs. of lifting eyes on the transport cradle.

3. When using rope or chain, compensate for the height difference of the lifting eyes.

Ref. III

1. Total weight approx. 14 T.

2. To lift the DDM without transport cradle during unpacking and installation use 2 lifting eyes on the gear (eye diam. ø50 mm), or bail.

The other items of the DDM’s equipment are packed on standard pallets for handling by crane and forklift.

(37)

LIFTING & HANDLING OF RETRACTABLE DOLLY CAUTION (WARNING)

1. When lifting the dolly for transport & handling from workshop to

vehicle/ship/platform etc. always lift the dolly horizontal. Connect slings to all four corners and lift vertical. Weight of dolly approx. 5 tones.

2. When lifting the dolly in or out from guide rails, connect slings to the top corners, and lift/lower. Use slings and connect to lower corners for balancing the dolly from horizontal to vertical or opposite by means of tugger winches.

(38)

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,167$//$7,21352&('85(6)25 723'5,9(Z$662&,$7('(48,30(17

REF. DRWG. DESCRIPTION REMARKS

Prior to installation the hydr. piping has to be installed, pressure tested and flushed to cleanness NAS class 6. The driller’s cabin with controls to be electrical connected to the control cubicle. All wiring between the SCR unit, the control cubicle and junction boxes in derrick to be finalized and checked. The guide rails to be checked to correct alignment, and drawworks and tugger winches to be ready for operation.

$ 0(&+$1,&$/,167$//$7,21 MH 1700-030

& MH 1722-037

1. Lift the manifold (umbilical interface plate) to the bracket in derrick. Mount bolts, torque to req. torque and secure the bolt heads/nuts by means of stainless steel wire (φ 1.0).

NA 2. Hoist the travelling block/DSC to fingerboard level.

MH 1745-024 3. Hoist the dolly to drill floor. Connect a lifting sling to the two upper lifting tugs. Connect the lifting sling to the travelling block. Connect stabilizing wires/ropes to the guide dolly (use air tugs).

MH 1745-028 4. If required, unscrew and remove upper side rollers.

MH 1745-028 5. Carefully start lifting the dolly in the way that the upper pair of bogies entering the guide rails. Lift further until lower bogies and side rollers are entered in to the guide rails.

MH 1745-028 6. Hoist the dolly approx. 10 m above drill floor. Connect the dolly to a hang-off wire. Lower the travelling block and remove the lifting sling. MH 1745-028 7. Mount the upper side rollers.

8. Lower the travelling block to drill floor. Install connection link on travelling block. Mount air inlet duct for DC-motor cooling system on the block. Hoist the travelling block.

MH 3225-08 9. Hoist the DDM and transport cradle to drill floor. Locate the DDM and cradle vertically with the DDM-main shaft on line with ¢ well.

(39)

MH 1700-030 & MH 1711-021

10. Lower the travelling block to position for connecting the hook plate connection link to the top drive bail. Insert the pivot pin, mount screws and secure the screw heads by using S.S. wire. NA 11. Hoist the travelling block until the weight of the

DDM is released from the cradle. Unscrew the clamps on the cradle until the DDM is free. NA 12. Remove the cradle from drill floor.

MH 1745-028 & MH 1705-050

13. Unscrew the hydr. hose connection from the hydr. cylinders on the dolly. (For ventilation during manual operation and handling of the dolly link arms.)

MH 1700-030 & MH 1745-028

14. Hoist the DDM to level for mounting of the dolly. Swing out the dolly link arm by means of a tugger. Remove the clamps on the link arm and manipulate the groove at the end of the link arm on to the plain spherical bearing. Mount clamps and torque to 1000 Nm.

MH 1745-028 15. Repeat for parallel arms.

MH 1705-050 16. Connect hydr. hoses (ref. pt. 13). MH 1700-030 17. Lower the DDM as low as possible.

MH 1712-036 18. Connect two hydraulic hoses (3/4”) between the manifold on the DDM, and the overcentered valve on the retractable dolly for the DDM. 19. Mount manifold to the upper dolly.

20. Connect two hydraulic hoses (3/4”) between the manifold, and the extension beam on the

retractable dolly for DDM

21. Remove old hydraulic lines on upper dolly. 22. Make new hoses between retract cylinder on

upper dolly and manifold. MH 1700-030

& MH 1722-037

23. Lift the service loop by means of a lifting strap (SWL 2,0 tones) to the manifold in derrick. 1RWH2QO\RQHKRVHWREHOLIWHGDWDWLPH MH 1722-037 24. For electrical service loop: Position the hose

flange into the manifold. Mount the clamp and secure bolts with wire. Mount safety shrouds and shackles. 1RWH_{0RXQWLQJRIWKHVHUYLFHORRSWREHGRQH} DIWHULQVWDOODWLRQRIMXQFWLRQER[HVLQGHUULFN DQGLQVWDOODWLRQRIWKHGROO\''0,WLVYHU\ LPSRUWDQWWKDWWKHHOHFWULFDOORRSVQRWDUHEHQW GXULQJLQVWDOODWLRQLQRUGHUWRDYRLGGDPDJHG ZLUHV

(40)

Ref. intercon. Diagrams

25. Connect all power, signal-, and instrument cables to respective junction boxes according to the wiring diagrams. Make sure that the cables are of a sufficient free length from the outlet end of the service loop hoses to fixing points on the cable trays in order to absorb vibrations and creeping.

For further info. ref. sep. volume

MH 1722-037 26. Hydraulic service loop: Hoist and connect the service loop to the manifold in derrick.

Manipulate each hydr. Hose (4 ea.) to position for mounting to the service loop manifold. Mount the flanges to the manifold by means of resp. screws.

Prior to mounting: Clean underneath the manifold. Remove the sealing when the actual hose is at correct level. Clean the flange surface and insert the O-ring. Position the hose/flange and torque the screws to correct level.

For M12 : 110 Nm For M10 : 65 Nm MH 1722-037 27. Repeat for the service loop at the DDM side. MH 1700-030

& MH 3514-001

28. Mount the compensating system between the DDM and the travelling block. The chains should be cut to the correct length during assembly. Correction of length established by first mounting the shackles, G-links and chains to the brackets on the travelling block. Then mount the lower shackles & hydraulic cylinders to the lugs on the DDM. Have the cylinders fully extended. Cut the length so that when the chains are connected to the cylinders, no load is resting at the chains and minimum slack is attained.

29. Mount flexible air duct between the inlet duct on hook plate and the blower inlet duct on the DC-motor.

MH 1705-050 30. Hook-up and connect hydr. hoses between compensating cylinders and motion control valve.

MH 1705-050 31. Hook-up and connect all hydr. hoses between hydr. control valve cabinet and pipe handler. MH 1705-050 32. Hook-up and connect air hoses between air flex

brake and hydr. control valve unit. MH 1711-021

& MH 1712-036

33. Hoist, manipulate and connect the mud pipe. Mount clamp and torque screws to 600 Nm. MH 1700-030 34. Install and mount mud hose. Mount safety

(41)

MH 1726-011 & MH 1712-03

35. Connect the intermediate sub. This connection must be done very carefully to avoid damage of threads or shoulder at main shaft. 7 5/8" REG. A special thread compound is recommended: LOR 167-ML-50 (Weatherford) or equal. Screw the intermediate sub pin into the main shaft box by hand, (do not forget the seal assembly kit MH 1712-03 pos. 37, 40, 41, 42). MH 1726-011 36. Repeat for IBOP and saver sub.

NA 37. Set a DP into the slips in the rotary table. Screw saver sub into drill pipe by means of a chain tong. Hook-up a rig tong and torque up actual sub by means of a cathead.

Torque requirements:

For intermediate sub: 81000 Nm For IBOP’s saver sub: 63700 Nm

MH 1739-001 38. Mount the IBOP cylinders and cam sleeve. MH 1717-33

& MH 1720-008

39. Mount the torque wrench and adjust to the correct level by means of the turnbuckles. MH 1711-021 40. Mount elevator links and pneumatic elevator.

NA 41. Mount brackets w/sensors for crown block warning system at the rear side of one of the guide rails at an adequate level. Run cables between sensors, junction boxes and PLC cabinet.

42. The installation of the top drive is now finalised. Check that all screws and units are either

secured by means of stainless steel locking wire (x 1,0 mm) or that Nylock nuts are used.

Do not install the wash pipe due to avoid

overheating during rotation/commissioning test. The wash pipe requires mudflow for cooling when running the main shaft on the DDM. For further actions, see Pre-Commissioning Checks.

(42)

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(43)

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HYDR. FLOW: Q = 160 l/min (42 GPM)

HYDR. PRESSURE: P = 180 BARG (2610 PSI )

COOLING AIR FLOW (FAN): Q = 1,67 NM3/SEC ( 3500 SCFM)

COOLING AIR PRESSURE (FAN): P = 2540 Pa (10 in. H2O )

AIR FLOW INTERMITTENT Q = 60 NM3/H (35 SCFM) FOR

PNEUM. ELEVATOR

AIR PRESSURE: P = 7 BARG (100 PSI)

EL. POWER DC-MOTOR:

Max. continously: 1185A, 843 KW

0 - 750 VDC

Intermittent: 1435A, 1020 KW

EL. POWER AC-FAN: 12,5 KW, 460VAC/60 HZ

EL. POWER SPACE HEATER: 0,150 KW, 220 VAC

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(44)

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MECHANICAL:

1. Check that all hydraulic lines are connected according to the flow diagrams. 2. Check that all the inlet valves in the control valve unit are closed.

3. All hydraulic lines must be flushed and the pressure tested prior to starting the hydraulic power unit.

4. Check that lube oil level in swivel and gearbox are filled up according to lube diagrams.

5. Remove scaffolding etc., if any.

6. Check visually that no hand tools etc. are left on the DDM or dolly during the installation/assembly.

7. Keep all personnel clear of the DDM.

8. Ensure all electrical pre-commissioning checks to be performed (see next page). 9. Start the hydraulic power unit.

10. Open the valves in the control valve unit in this order; air, drain, return and pressure.

11. Check that the inlet pressure in the control valve unit is 160-170 bar.

The Top-drive hydraulic system is now ready for commissioning according to 4.3.3 in this manual.

ELECTRICAL:

1. Check that all power-cabling and control system wiring is connected according to the Interconnection diagrams MH 4010-131 to 140 (ref. separate volume) by performing a “point to point” continuity test.

2. Check all terminations trough the entire system to be securely tight, pay

particular attention to the DC-power terminals in derrick and Top-drive junction boxes.

3. Check that the safe area mounted control panel IC-10-0400 230VAC circuit breaker (S1) is switched off (loop diagram).

(45)

4. Remove 24VDC fuses f1 and f2 (loop diagram sheet 1) from terminals in IC-10-0400.

5. Remove all fuses for Top-drive pipe handling function solenoid valves. 6. Check the PLC Run/Stop switch in IC-10-0400 to be in STOP position. 7. Apply 230VAC power to the control cubicle IC-10-0400 by turning on the

feeder fuse/breaker (by others).

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8. Check 230VAC on incoming side of S1 in IC-10-0400 (loop diagram sheet 1), turn on if OK.

9. Check 24VDC output from power supplies in IC-10-0400, install fuses f1, f2 if OK.

10. Perform a loop test of all control-system loops involved in the complete system to ensure signal polarities etc. to be correct. Use signal simulator to check current and voltage loops.

11. Turn the PLC key switch from Stop to On position. Check the status light to be in steady Run with the Error lamp off.

12. Check direction of rotation on all AC-motors involved by operating the dedicated MCC starter.

13. The SCR DC-power and Field-supply to be tested according to the suppliers pre-commissioning procedures.

The Top-drive electrical & control system is now ready for commissioning according to 4.3.3 in this manual.

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(47)

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(48)

3$1(/$/$507(67

/$03 7(67. (Pipe handler operation panel is a part of the driller’s console (by others), and a test panel is used for the F.A.T.)

Push lamp test button minimum 1 sec. All lamps shall light up.

Tested: _Date:

Customer

Witnessed: MH signature:

(49)

$/$507(67

a) Simulate alarm and trip main winding temp.1 by using a PT-100 simulator connected to field terminals in control panel. Simulate alarm 120°C and trip 150°C. Check and verify on dedicated lamp in test panel.

b) Simulate alarm and trip main winding temp.2 by using a PT-100 simulator connected to field terminals in control panel. Simulate alarm 120°C and trip 150°C. Check and verify on dedicated lamp in test panel

c) Gearbox temp. high. Simulate an alarm by using a PT-100 simulator connected to field terminals in control panel. Simulate alarm 90°C. Check and verify on dedicated lamp in test panel.

d) Swivel temp. high. Simulate an alarm by using a PT-100 simulator connected to field terminals in control panel. Simulate alarm 100°C. Check and verify on dedicated lamp in test panel.

.

e) Lube oil pressure low. Run DDM, remove one wire to open pressure switch loop. Check and verify on dedicated lamp in test panel.

f) Operation error, ref 2.9.a.3 or 4.4.1

g) All off alarms above will give common alarm and the “alarm horn” will be illuminated

Tested: Date:

Customer

(50)

3,3(+$1'/(57(67

This test comprises test of the DDM-650-HY pipehandler. All functions will be controlled from the test panel.

&203(16$7,1*6<67(0$&7,9( &KHFNHG

1. Push button for ’Compensator Link - ACTIVE’.

---2. The indicator light will illuminate.

---3. The compensating cylinders will stroke in from fully

extended to fully retracted position.

---4. The function light shall be active for 5 minutes (time required doing a pipe connection). Cylinder position will then remain in active position until the shaft is loaded

and will then lower by the load gravity.

---Tested: Date:

Customer

Witnessed: MH signature

(51)

&203(16$7,1*6<67(0/2:(5 &KHFNHG

1. Push button for ’Compensator Link - LOWER’. ---2. The hydr. cylinders will move from full retracted to full

extended position.

---3. This function will last as long as the lower button is activated.

Perform intermediate checks during the cylinder stroke.

---Tested: Date:

Customer

(52)

3,3(+$1'/(5527$7,21&&: &KHFNHG

1. Check for correct direction of rotation.

---2. Push button for "Pipe handler Rotation - CCW".

By top view, the pipe handler shall now turn counter clock

wise as long as the button is activated.

---3. Check the Slewing Speed and adjust it if necessary on the

control valve unit. Slewing speed should be approx. 7-8 RPM. ---4. Rotate the Pipe handler for 1-one minute and record

the R.P.M.: __________R.P.M.

---Tested: Date:

Customer

(53)

3,3(+$1'/(5527$7,21&: &KHFNHG

1. Check for correct direction of rotation.

---2. Push button for "Pipe handler Rotation - CW".

By top view, the pipe handler shall now turn clockwise

as long as the button is activated.

---3. Check the Slewing Speed and adjust it if necessary on

the control valve unit. Slewing speed should be approx. 7-8 RPM. ---4. Rotate the Pipe handler for 1-one minute and

record the R.P.M.: __________R.P.M.

---Tested: Date:

Customer

(54)

3,3(+$1'/(5527$7,21$872 &KHFNHG

1. Push button for "Pipe handler Rotation - AUTO". ---2. The indicator lamp in this button will stay illuminated as long as the

function is active.

---3. Check that the pipe handler now rotates to the preset position. (The preset position is normally where the elevator opening is

facing the racking arm).

---4. When the “pipehandler rotation – auto” is on, activate the selector switch for "CCW" or "CW" rotation, the

"AUTO" light will now switch off, and pipe handler will rotate

until "CCW" or "CW" selector switch is released.

---Tested: Date:

Customer

(55)

/,1.6:,1*7,/7

D 1RUPDOPRGH &KHFNHG

1) Select "NORMAL"-mode by "NORMAL/STOP"- switch on the control panel.

Select "IN" mode by the "IN/OFF/OUT" switch (or foot pedal). The elevator links will swing the elevator "back" (drilling mode). This function will last as long as selector switch is in

"IN" position.

When the actuators are fully stroked, release the "IN/OFF/OUT"-selector switch and

elevator should remain steady in position without sign

of lowering.

---2) Select "OUT" mode by the "IN/OFF/OUT" switch The elevator links shall now swing down and lower elevator smoothly without jerking. When elevator links are in vertical position, release the "OUT" switch. The movement shall stop. Activate the switch to "OUT"- mode again, the elevator shall now swing out to mousehole position. (Stiff link). When the switch is released the elevator shall lower back to vertical

position by gravity.

---3) "SPEED"- adjust.

The ’Link Swing Speed’ can be adjusted at any time by the "Link Swing -SPEED" potentiometer. The speed velocity

(m/s) is not applicable.

---Tested: Date:

Customer

(56)

E 6WRSPRGH &KHFNHG

1. Select "STOP"- mode on the control panel. Activate switch for "IN"- or "OUT"- mode.

Adjust speed on pot. meter. The link swing speed can be adjusted from zero to full pre-set speed.

When elevator links are tilted towards "mouse hole" position, the elevator links will remain in position when the switch is

released.

---2. For lowering the elevator links back to vertical position,

simply select "NORMAL"- mode on the control panel.

---Tested: Date:

Customer

(57)

,%23 &KHFNHG

1. Activate the "IBOP- CLOSE" push button. The IBOP sleeve shall move upwards and close the IBOP.

The light will indicate "CLOSE”.

---2. Activate the "IBOP-OPEN" push button. The IBOP sleeve shall move downwards and open the IBOP. At the end of the stroke, the cylinders shall move upwards 5 -10 mm, so that

the IBOP-sleeve is "free" from the actuators.

---Tested: Date:

Customer

(58)

(/(9$7257(67 &KHFNHG

1. Activate the "Elevator OPEN"push button. The Elevator

shall open immediately and remain open. The cylinder pressure shall turn off after approx. 5 sec. (Check that there is no

mechanical obstruction).

---2. Simulate a drill pipe entering the elevator, by activating the trigger

mechanism on elevator, the elevator should close. ---3. Casing elevator, turn on switch in control panel door. Air supply

to elevator will be on.

---Tested: Date:

Customer

(59)

72548(:5(1&+7(67

The Torque Wrench test will comprise a number of test functions as, torque setting, Manual - & Automatic Make-up, Manual - & Automatic Break-out and interlocks to the drive-motors rotation.

D 7RUTXH:UHQFK&ODPS212)) &KHFNHG

1. Set ’Torque Wrench-MODE’-switch to ’MAN’-position and push

the "Clamp-ON" button. Check that the clamp goes ‘ON’. ---2. Push the "Clamp-OFF" button. Check that the clamps

goes 'OFF'.

---3. Rotate the main shaft, SLOWLY. Verify that the clamp on function is

disable as long as rpm. Is detected on speed gauge. ---4. Operator alarm will be given when attempting to operate the clamp on

while the shaft is rotating.

---Tested: Date:

Customer

(60)

E 7RUTXH6HWWLQJ &KHFNHG

The Torque Setting is recommended to be done at falling pressure. 1. Set ’Torque Wrench-MODE’-switch to ’SET’-position and push

the "Set Increase -(>>)"- and "Wrench-MAKE-UP" button. The ’Setting’ - and the "Readout"-gauge pointer shall move simultaneously from zero-0 to 60.000 ft.lbs. If necessary fine

adjust by rapid intermittent switching.

---2. Push the "Decrease- (<<)" button. The gauge pointers will move simultaneously from 60.000 ft. lbs. to 0-zero.

If necessary time adjust by rapid intermittent switching. ---3. Check lights in Push Buttons above when activating. ---4. Check that the output pressure correspond with torque

read-out by use of a calibrated hydraulic pressure gauge.

---Tested: Date:

Customer

(61)

F 7RUTXH0DQXDO0DNHXS &KHFNHG

1. Connect a 5"-inch drill pipe sub to the saver sub.

---2. Set the torque to 10.000 ft.lbs.

---3. Set the ’Torque Wrench-MODE’-switch to ’MAN(UAL)’-position and push the "Wrench-MAKE-UP" button.

Check that the Torque Wrench readout and the output pressure

correspond. Record in table below.

---4. Increase torque setting to 20.000- and 30.000 ft.lbs and repeat

as in item 3 above and record in table below. ---5. Disconnect the sub and continue the test against the ’end-stroke’

of the cylinders for 40.000-, 50.000- and 60.000 ft.lbs.

Record in table below.

---TORQUE SETTING "FT.LBS" TORQUE READ OUT "FT.LBS" EXPECTED PRESSURE (DP) "BAR" MEASURED PRESSURE (DP) "BAR" 0 10.000 (with sub) ... 20.000 " " ... 30.000 " " ... 40.000 (without sub) ... 50 000 " " ... 60.000 ... 0 27 ... 53 ... 80 ... 107 ... 133 ... 160 ... Tested: Date: Customer Witnessed: MH signature: Remarks:

(62)

G 7RUTXH0DQXDO%UHDNRXW &KHFNHG

1. Make-up a sub to 30.000 ft.lbs as in section above. ---2. Breakout the sub by pushing the ’Wrench - BREAK-OUT’

push button. Simultaneously check that the button is illuminating when

button is pressed.

---Tested: Date:

Customer

(63)

H 7RUTXH$XWRPDWLF0DNHXS &KHFNHG

1. Connect the 5”-inch drill pipe sub to the saver sub again.

---2. Set the torque to 10.000 ft.lbs.

---3. Set the 'Torque Wrench-MODE'-switch to 'AUTO'-position and push the "Wrench-MAKE-UP" button.

Check the Torque and record in table below.

---4. Check the Torque Wrench is making up until the Setting

torque value is achieved and then clamps turns off. ---5. Increase torque setting to 20.000- and 30.000 ft.lbs and repeat

as in item 4 above and record in table below.

---TORQUE SETTING "FT.LBS" TORQUE READ OUT FT.LBS" 0 10.000 (with sub) ... 20.000 " " ... 30.000 " " ... Tested: Date: Customer Witnessed: MH signature: Remarks:

(64)

I 7RUTXH$XWRPDWLF%UHDNRXW &KHFNHG

1. Make-up a sub to 30.000 ft.lbs as in section 2.9.c above. ---2. Set the ’Torque Wrench-MODE’-switch to ’AUTO’-position

and push the "Wrench-BREAK-OUT" button.

Simultaneously check that the button is illuminating when button is pressed.

Check the Torque Wrench clamps off after Breakout.

---Tested: Date:

Customer

(65)

/($.$1'35(6685(7(676

/($.$1'35(6685(7(673,3(+$1'/(56<67(0%$5:3 The pipe handler to be pressure and leak tested by supplying in excess pressure for a limited time.

a) Plug the piping to the pipe handler rotation motor. Activate all functions one after the other and hold for 2 minutes. Check for leakage.

b) Repeat point 1, but operate all functions in opposite direction. Check for leakage.

FUNCTION THEOR. W.P. TEST PRESSURE

T.W. MAKE-UP 160 BAR 230 BAR

T.W. BREAK-OUT 160 BAR 230 BAR

T.W. CLAMP ON 160 BAR 230 BAR

T.W. CLAMP OFF 160 BAR 230 BAR

IBOP OPEN 40 BAR 60 BAR

IBOP CLOSE 40 BAR 60 BAR

LINK SWING IN 160 BAR 175 BAR

LINK SWING OUT 160 BAR 175 BAR

COMP. SYSTEM ACTIVE ~130 BAR 175 BAR

COMP. SYSTEM LOWER 130 BAR 200 BAR

ELEVATOR ROT. CW 160 BAR 230 BAR

ELEVATOR ROT. CCW 160 BAR 230 BAR

MOUSEHOLE TILT (IN) 160BAR 230 BAR

MOUSEHOLE TILT (OUT) 160BAR 230 BAR

DOLLY RETRACTION 160BAR 230 BAR

DOLLY EXTEND 160BAR 230 BAR

Tested: Date:

Customer

(66)

527$7,217(676

385*(&21752/6<67(07(67

Start DDM blower by pushing the dedicated push button on the test panel. When the blower starts running, the DC-motor purge flow sensor will sense the ∆p (have to be above15 mbar) and feedback will be given to the PLC (I 1.2)

When the purge flow is ok, the DC-motor purge sequence timer (1 min.) will start running. When purge timer has completed and feedback from DC-motor purge pressure switch (0.8 mbar) is given to the PLC (I 1.1), the TD purge completed signal will be given to the SCR and Cyberbase. Shut down SCR.

5811,1*7(67

This test shall be executed in order to check that read-out speed at gauge corresponds with a manual tachometer. During the test, mark all temperatures and speeds on the enclosed logging sheet.

Take oil samples before and after the rotation test. Run for 1 hour at maximum speed in both directions and at both gears. Total running time should be 4 hours.

ACCEPTANCE CRITERIA:

Oil cleanness NAS 11

Temp. swivel 100C

Temp. gear box 90C

Temp. motor 135C

Max speed, gear 1 154 rpm Max speed, gear 2 237 rpm

(67)

Tested: Date:

Customer

NAS Class Test point Before

test After test Gearbox Swivel Remarks:

(68)

7HPS/RJ

Time R.P.M. Gear

used

CW/CCW Temperature 0C

Gear Oil Swivel Cooling Air

In Out

(69)

*($5/2&.7(67

&KHFNHG The gear lock is manually operated.

Push handle up to lock.

---Tested: Date:

Customer

(70)

*($56+,)77(67

&KHFNHG (OHFWULFDO

Prior to test, gear 1 to be selected. Change gear to 2. gear by operating The gear selector switch on the test panel. The gear 1 lamp will go off and the gear 2 lamp will flash until 2 gear is fully engaged. If gear 2 do not engage, turn the selector switch back to gear 1 and turn the main shaft and repeat. When gear 2 is selected, change to gear 1. gear 2 lamp will go off and gear 1 lamp flashes until gear 1 is fully engaged.

Start the DC motor and verify that the main shaft is rotating. Gear shift Should now be unable and an operator alarm will be given when attempting

to change gear.

--- 0HFKDQLFDO

Select 2 gear. Shut off hydraulic supply to pipe handler.

Check flag to see that there is no movement towards gear 1.

---Tested: Date:

Customer

(71)

$,5)/(;%5$.(

&KHFNHG The Air Flex Brake has three modes, OFF/AUTO/ON.

a) Start the rotation of the DDM, and select AIR FLEX BRAKE ON position. The air flex brake to engage and stop the rotation. The MOTOR BRAKE lamp to start flashing on pressure switch

feedback. Turn the DDM speed throttle to zero. ---b) Start the rotation of the DDM, and select AIR FLEX BRAKE

AUTO position. Turn the DDM speed throttle to zero, and at zero throttle the air flex brake to activate. The MOTOR BRAKE

lamp to activate on pressure switch feedback.

---Tested: Date:

Customer

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