Top Drive System Installation and Commissioning Manual

Transcription

1 TDS-1000A Top Drive System Installation and Commissioning Manual SM01040

2 General Information Conventions Notes, Cautions, and Warnings Illustrations Safety Requirements Personnel Training Recommended Tools Replacing Components Routine Maintenance General System Safety Practices General Safety TDS1000A Top Drive System

3 General Information This manual is intended for use by field engineering, installation, operation, and repair personnel. Every effort has been made to ensure the accuracy of the information contained herein. Varco International, Inc., will not be held liable for errors in this material, or for consequences arising from misuse of this material. Conventions Notes, Cautions, and Warnings 1 Notes, cautions, and warnings provide readers with additional information, and to advise the reader to take specific action to protect personnel from potential injury or lethal conditions. They may also inform the reader of actions necessary to prevent equipment damage. Please pay close attention to these advisories. Note: i The note symbol indicates that additional information is provided about the current topics. Caution: The caution symbol indicates that potential damage to equipment or injury to personnel exists. Follow instructions explicitly. Extreme care should be taken when performing operations or procedures preceded by this caution symbol. Warning: The warning symbol indicates a definite risk of equipment damage or danger to personnel. Failure to observe and follow proper procedures could result in serious or fatal injury to personnel, significant property loss, or significant equipment damage. Illustrations Illustrations (figures) provide a graphical representation of equipment components or screen snapshots for use in identifying parts or establishing nomenclature, and may or may not be drawn to scale. For component information specific to your rig configuration, see the technical drawings included with your Varco documentation. TDS1000A Top Drive System -3

4 General Information Safety Requirements 1 Varco equipment is installed and operated in a controlled drilling rig environment involving hazardous situations. Proper maintenance is important for safe and reliable operation. Procedures outlined in Varco manuals are the recommended methods of performing operations and maintenance. CAUTION: To avoid injury to personnel or equipment damage, carefully observe requirements outlined in this section. Personnel Training All personnel performing installation, operations, repair, or maintenance procedures on the equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool operation, and maintenance to ensure their safety. CAUTION: Personnel should wear protective gear during installation, maintenance, and certain operations. Contact the Varco Drilling Equipment training department for more information about equipment operation and maintenance training. Recommended Tools Service operations may require the use of tools designed specifically for the purpose described. Varco recommends that only those tools specified be used when stated. Ensure that personnel and equipment safety are not jeopardized when following service procedures or using tools not specifically recommended by Varco. Replacing Components Verify that all components (such as cables, hoses, etc.) are tagged and labeled during assembly and disassembly of equipment to ensure correct installment. Replace failed or damaged components with Varco certified parts. Failure to do so could result in equipment damage or injury to personnel. Routine Maintenance Equipment must be maintained on a routine basis. See the service manual for maintenance recommendations. CAUTION: Failure to conduct routine maintenance could result in equipment damage or injury to personnel. -4

5 General Information General System Safety Practices The equipment discussed in this manual may require or contain one or more utilities, such as water; or electrical, hydraulic or pneumatic power. CAUTION: Read and follow the guidelines below before installing equipment or performing maintenance to avoid endangering exposed persons or damaging equipment. 1 Isolate energy sources before beginning work. Avoid performing maintenance or repairs while the equipment is in operation. Wear proper protective equipment during equipment installation, maintenance, or repair. Proper Use of Equipment Varco equipment is designed for specific functions and applications, and should be used only for its intended purpose. Electrical Systems and Components All electrical wiring, junction boxes, sensors, glands, and related equipment are designed for the specific application, environment and particular zone where the equipment is intended to be used. Before beginning work on this equipment, familiarize yourself with the electrical schematics, as well as the equipment power and voltage requirements. When performing installation, maintenance, or repairs on the equipment, isolate all power. Lock out switches and tag them to prevent injury. Prior to disconnecting wires, verify that all wires and terminals are properly labeled to ensure proper reconnection. Hydraulic Systems and Components Hydraulic systems and components are designed for specific use in the drilling industry. The hydraulic pressure for this equipment can be as high as 3,000 psi. Before beginning work on any portion of the hydraulic system, familiarize yourself with the hydraulic and electrical schematics. Isolate, lock out, and tag the hydraulic and electrical power and controls. Take precautions when bleeding down residual system pressure, using bleed valves or equivalent techniques. WARNING: Hydraulic fluids can be extremely hot and under high pressure. Properly discharge all system accumulators. TDS1000A Top Drive System -5

6 General Information 1 Collect all residual hydraulic fluid in a container to prevent rig or environmental contamination. Take precautions to prevent hydraulic oil from leaking into other open electrical or mechanical components, such as junction boxes. Pneumatic Systems and Components Pneumatic systems and components are designed for specific use in the drilling industry. The pneumatic pressure for this equipment can be as high as 150 psi. Prior to beginning work on any portion of the pneumatic system, familiarize yourself with the pneumatic and electrical schematics. Isolate, lock out, and tag the pneumatic and electrical power and controls. Take precautions when bleeding down residual system pressure using bleed valves or equivalent techniques. Properly discharge all system accumulators. Water Cooling Systems and Components Water cooling systems and components are designed for specific use in the drilling industry. The water can reach temperatures high enough to cause scalding. Prior to beginning work on any portion of the cooling system familiarize yourself with the plumbing and electrical schematics. Isolate, lock out, and tag the cooling water and electrical power and controls. Take precautions when bleeding down residual system pressure using bleed valves or equivalent techniques. Collect all residual cooling water in a container to prevent rig or environmental contamination if necessary. Take precautions to prevent cooling water from leaking into other open electrical or mechanical components such as junction boxes. General Safety Equipment Motion Hazards Some of the Varco equipment travels either horizontally, vertically on rails, or both. WARNING: Avoid placing objects in or near the path of motion for this equipment. Such interference could cause personnel to be trapped or crushed by equipment. CAUTION: Keep the working envelope/zone of the equipment free from personnel. -6

7 General Information When Replacing Components During disassembly and reassembly of any equipment, verify all components such as cables, hoses, etc. are tagged and labeled to ensure reinstalling the components correctly. Replace failed or damaged components with Varco certified parts. Failure to do so could result in a hazard, equipment damage, or personal injury. During Routine Maintenance Equipment must be maintained on a regular basis. See the body of the service manual for maintenance recommendations. 1 CAUTION: Failure to conduct regular maintenance can result in a hazard, equipment damage, or injury to personnel. Visibility of Equipment Operation Clear, unobstructed visibility of all equipment functions is critical to safe operation. Do not block or impair the equipment operator's field of view. In cases where this is not possible, the customer must install video cameras to ensure adequate visibility. Proper Use of Equipment Varco equipment is designed for specific functions and applications and should be used only for the intended purpose. CAUTION: Do not hoist personnel using this equipment. TDS1000A Top Drive System -7

8 Long Term TDS Storage Pre-Installation Checklist Rig Preparation Documentation You Will Need Regulatory Standards You Will Use Tools You Must Provide Hardware Kits Derrick Termination Kit Components Installing the Kit TDS and Retract Guide Dolly Positioning the TDS Preparing for Installation Back Flange Rollers and Guide Rail Stops Installing the Web Rollers Traveling Block and Counterbalance Kit Installing or Removing the TDS Shims Controls Service Loops TDS Service Loop Assemblies Precautions Preparing the Fluids Loop Connecting the Fluids Loop Preparing the Electrical Loop Connecting the Electrical Loop Connecting the Power Connecting the Hydraulics Terminating Electrical Connections PH-100 Pipehandler Precautions Installing the IBOPs and Saver Sub Applying Torque Actuator Shell and the Crank Assemblies Installing the Rotating Link Adapter Installing the Hose Assemblies Positioning the Pipehandler Mud Hose Connecting the Mud Hose Attaching the S-Pipe to the Frame Removing the Exhaust Cover Motor Alignment System Installing the Bondura Bolt Lubricating the Bondura Bolt for the First Time TDS1000A Top Drive System

9 1 Verification Checklist General Pipehandler Service Loops and Mud Hose Electrical Post-Power Installation Installing Kits Installing the Elevator Links Adjusting the Motor Alignment Bar Commissioning Commissioning Checkout Procedures Tightening the Bondura Bolt Again Counterbalance System Using the System to Make Up and Break Out Pipe PH-100 Pipehandler Breaking Out the Saver Sub Breaking Out the Lower IBOP Valve Making Up the Lower IBOP Valve Breaking Out the Upper IBOP Valve Link Tilt IBOP Safety Valves Torque Values for Load Carrying Components

10 Long Term TDS Storage Avoid wide variations in temperature and high humidity. The preferred environment is clean and dry at 60 F ambient. If high humidity is unavoidable, 70 F is recommended. All exposed unpainted metal surfaces are coated with a rust preventive at the factory prior to shipment. However, check these surfaces periodically to be sure that no corrosion is taking place. The recommended rust preventive (slushing compound) for bare metal surfaces is Kendall Grade 5 (GE-D6C6A1) or equivalent. During storage, lubricant drains from the top half of the roller bearings in the motor, allowing corrosion on the exposed areas. To prevent corrosion, run the oil pump (i.e., rotate the motor and gear train) periodically to distribute lubricant over the top of the bearings. Perform this at three-month intervals if the TDS is stored indoors, and at monthly intervals if stored outdoors. Megger the drilling motor when placed into storage and at three-month intervals thereafter (monthly, if stored outside). Keep a record of the readings, as a drop between readings indicates an increase in moisture in the windings created by inadequate storage protection. If megger readings drop, bake the motor as soon as possible to restore proper resistance and avoid further damage. TDS1000A Top Drive System -3

11 Pre-Installation Checklist Rig Preparation General Winches will be used for installing the TDS when drawworks and the traveling block are not installed, functional or available. Rollers have been installed onto the traveling block. Derrick area is clear of obstructions, such as tugger lines and scaffolding. Block load pin has been inserted and retaining hardware permanently installed. CAUTION: The load block pins are instrumented load pins. Do not force the pins by striking them with hammers. Failure to follow this caution may result in damage to the load pin instrumentation. Service loop brackets and clamps have been created so the service loops can be attached to the derrick. Guide Rails Rigging Guide rails and bracing are installed and inspected to conform to Varco specification and installation tolerances as specified in this service manual and QA Guide rail stops are installed and can support the weight of the TDS-1000A and dolly assembly. Rigging of the long lines and other related rigging are inspected to ensure they will not interfere with the TDS and other rig equipment. All rigging hardware is inspected and properly sized to accommodate the weights of the tools to be installed in accordance with the following table: Tool Weights Tool Weight (lbs) Weight (kg) Motor Frame and Dolly 5,000 3,587 PH

12 Pre-Installation Checklist Rig Preparation Electrical All electrical and electronic cabling is installed in the derrick at the correct locations and heights per the TDS-1000A General Arrangement drawing. Make sure that the cables have sufficient length to allow for termination in the derrick J-boxes. All electronics are installed up to the derrick junction box, per the General Arrangement drawing. Hydraulic Hydraulic and air stand pipes are installed in the derrick, per the TDS-1000A General Arrangement drawing. The stand pipes are flushed clean and pressure tested. Prior to attaching any Varco equipment to the derrick s hydraulic plumbing, the customer shall provide a materials test certification per DIN 50049, section 3, certifying that the plumbing has been pickled, cleaned and flushed. The customer must also ensure that the hydraulic fluid and system are at a cleanliness level of IS /1 or better, according to the following source: Varco s SM00081, Hydraulic Fluid Cleanliness, and PC00011, Specification for Fluid Cleanliness and for Cleaning and Flushing Hydraulic Lines. Documentation You Will Need Electrical schematics for the Driller s console and Electrical loop TDS-1000A Product Documentation Package Commissioning checklists (see section titled "Commissioning" on page -30) Installation and commissioning FIPs: 3FIP0069, 3FIP0070 TDS-1000A Top Drive System Service Manual Supplemental Material Vendor Documentation Package Design Specification DS00008 (Design Torque Standard) BJ Service and Installation Manual IBOP Service Manual RBS Service Manual Drilling Motor Service Manual Lock Wire DS Specification Package of drawings Specifications for your particular rig TDS1000A Top Drive System -5

13 Pre-Installation Checklist Regulatory Standards You Will Use API Recommended Practice 85, Section (inspection frequency) ASTM A-75, Standard Method for Magnetic Particle Inspection of Steel Forgings ASTM E-709, Standard Recommended Practice for Magnetic Particle Inspection ASTM A-388, Standard Practice for Ultrasonic Examination of Heavy Steel Forgings Electrical Standards Electrical Documentation Standard Varco s SM00081, Hydraulic Fluid Cleanliness, and PC00011, Specification for Fluid Cleanliness and for Cleaning and Flushing Hydraulic Lines. SM00981 QA 0006 DIN 50049, section 3 Tools You Must Provide Crimping pliers Wire strippers Hydraulic crimper for the power lugs with the correct dies for the cable Hardware Kits Derrick Termination Kit Commissioning Spares Kit (see your Varco representative) Split Flange Kit Moisture Separation Kit Counterbalance Kit -6

14 Derrick Termination Kit Components TDS Derrick Power J-box Remote I/O J-box Pneumatic Filter/Regulatory Assembly Stand pipe fittings TDS service loop brackets Retract Control Plate Assembly Retract Dolly Service Loop Bracket Installing the Kit 1. Mount the plate assembly at racking board height within 15 feet of the service loop support bracket and four or five feet above the walk-around.. If a walk-around does not exist, construct a work platform to allow access to the J-boxes. 3. Manufacture the appropriate brackets and clamps to attach the plate to the derrick structure. See the Derrick Termination drawings for more information. i NOTE: Remember to provide convenient access for wiring and maintenance. TDS1000A Top Drive System -7

15 TDS and Retract Guide Dolly Positioning the TDS Upper Lifting Lugs on Motor Frame TDS Guide Rails Swing Bolts TDS Retract Guide Dolly Dolly Frame Top Lift Points on Guide Dolly 4 places Dolly Frame Bail Procedure Drill Floor CL Well TDS-1000A 41,000 lb 1. Prepare 1. Prepare the TDS the TDS and and retract retract system system to to be moved be moved to the to rig the floor. rig floor.. Ensure. Ensure that that the swing the swing bolts bolts between between the the frame frame and and retract retract dolly dolly are locked are locked and and secure secure to prevent to prevent the dolly the dolly from from extending extending during during rig-up. rig-up. 3. Using 3. Using a crane a crane that that is sized is sized to lift to at lift least at least 53,000 53,000 lbs. lbs. total, total, attach attach one one lift sling lift sling to to each each corner corner of the of TDS the TDS guide guide dolly. dolly. 4. Connect 4. Connect a winch a winch to each to each of the of two the two upper upper lifting lifting lugs lugs on the on TDS the TDS frame. frame. These These winches winches and and the rigging the rigging need need to to be rated be rated for at for least at least 53,000 53,000 lbs. total. lbs. total. 5. Lift 5. the Lift TDS the TDS to the to rig the floor rig floor and position and position so the it so bail the and bail top and of top the of dolly the frame dolly frame are directly are under directly the under TDS the guide TDS rails guide with rails the main with the shaft main the shaft direction in the direction of well of center. well center. -8

16 TDS and Retract Guide Dolly Preparing for Installation TDS Guide Rails Lower Lifting Lug places Upper Web Roller Bracket Assembly places Drill Floor CL Well Upper Back Flange Roller Assembly places Guide Rail Stops Procedure 1. Connect two tuggers to the lower two lifting Procedure lugs of the TDS frame. Each 1. Connect tugger and two its tuggers rigging to must the lower be able two to support lifting lugs 0,000 of the lbs. TDS frame.. Remove Each the tugger upper and web its roller rigging bracket must be assembly able to from support both 0,000 sides of lbs. the guide assembly.. Remove the upper web roller bracket assembly from both sides of the guide assembly. CAUTION: Do not remove the lower roller assemblies. CAUTION: Do not remove the lower 3. Remove roller the assemblies. upper back right and left flange 3. Remove roller assemblies the upper back from right the guide and left dolly. flange roller assemblies from the guide dolly. CAUTION: CAUTION: Do not remove Do not remove the front the or lower front or roller assemblies. lower roller assemblies. 4. Remove 4. Remove the TDS the TDS guide guide rail stops. rail stops. TDS1000A Top Drive System -9

17 TDS and Retract Guide Dolly Back Flange Rollers and Guide Rail Stops TDS Guide Rails Procedure Using Using winches winches and and tuggers, tuggers, hoist hoist the the assembly assembly to to about about feet feet above above the the floor. floor... Lower Lower the the tuggers tuggers while while maintaining maintaining the the height height of of the the winches winches until until the the TDS is TDS vertical. is vertical. CAUTION: Do not let the main shaft CAUTION: touch Do the not rig floor. let the main shaft touch the 3. rig Position floor. the TDS so the remaining set 3. Position of upper the flange TDS so rollers the remaining touch the TDS set of guide upper rails. flange rollers touch the TDS guide You rails. may need additional tuggers to You stabilize may need the TDS additional and keep tuggers it vertical. to 4. stabilize Install the back TDS and set of keep flange it vertical. rollers. 4. Install This the captures back set the of guide flange rail rollers. between the upper flange rollers. This captures the guide rail between 5. the Hoist upper the flange TDS, rollers. while carefully aligning and placing the lower 5. Hoist rollers the onto TDS, the while guide carefully rails. aligning and placing the lower rollers onto the 6. guide Install rails. the guide rail stops. 6. Install the guide rail stops. Back Set of Flange Rollers places Upper Flange Rollers places TDS Guide Rails places Drill Floor Lower Rollers places CL Well Guide Rail Stops places -10

18 TDS and Retract Guide Dolly Installing the Web Rollers Procedure Lower Lower the the TDS TDS until until the the frame frame is is just just above above the the guide guide rail rail stops. stops... Install Install the the upper upper web web rollers. rollers Lower Lower the the TDS TDS until until its its weight weight rests rests on the on rail the stops. rail stops Remove the the rigging rigging from from the the TDS TDS frame. frame. Upper Web Rollers places i NOTE: When lowering the block, monitor the weight indicator so the dolly is not binding anywhere along the path of travel. Drill Floor Guide Rail Stops places CL Well TDS1000A Top Drive System -11

19 TDS and Retract Guide Dolly Traveling Block and Counterbalance Kit When the drawworks and TDS extend/retract systems are operational: 1. String up the traveling block.. Extend the TDS over well center. 3. Lower the block into position over the TDS. 4. Connect the Counterbalance Kit to the block. i NOTE: When lowering the block, monitor the weight indicator so the dolly is not binding anywhere along the path of travel. Installing or Removing the TDS Shims 1. Measure the distance between the upper web rollers and inside of the TDS guide rails at several points in the derrick.. Take the average of the measurements and shim the upper web rollers so the nominal roller clearance is 0.18-inch. 3. Install (or remove) the shims to achieve alignment, then tighten and lockwire the roller bolts. 4. After the shims are installed (or removed), hoist the block again and monitor the weight indicator so the dolly isn t binding along the path of travel. 5. Place a tubular in the PS Extend the TDS over well center. 7. Lower the TDS until its shaft almost touches the tubular. 8. Install roller shims to align the TDS with well center. 9. Tighten and lockwire the roller bolts. i NOTE: When hoisting the block, monitor the weight indicator so the dolly is not binding anywhere along the path of travel. -1

20 Controls i NOTE: The throttle and torque limit controls are the standard controls used for the independent rotary drive table. 1. Mount the driller s console so it is within easy reach or view of the driller during operations.. Connect the wires as shown in the electrical schematics in the Engineering drawings. i NOTE: Appropriate cable glands are provided for the electric cables. Warning: If you choose to use control systems not manufactured by Varco, be aware that Varco systems are specifically designed with operational interlocks and safety devices to prevent possible injury to personnel or damage to the system. Other systems must meet Varco requirements. Varco highly recommends the use of its control systems. TDS1000A Top Drive System -13