TOP DRIVE OPERATIONS & MAINTENANCE MANUAL JULY 2007 HYBRID TECHNOLOGY UNIVERSAL LIFTING CEMENT HEAD. Det Norske Vertis Type Certificate D-2928

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1 TOP DRIVE UNIVERSAL LIFTING CEMENT HEAD SUPER SUB SEA OPERATIONS & MAINTENANCE MANUAL JULY 2007 Det Norske Vertis Type Certificate D-2928 HYBRID TECHNOLOGY 1443 South Gage Street, San Bernardino, California (909) FAX (909)

2 TABLE OF CONTENTS DNV Certification...1 Description...2 Operation...3 Service and Assembly Seal List...6 Rated Capacities and Handling...7 Flow Areas and Diameters...8 Dimensions and Weights Dimensional Drawings - Single & Double Dart PARTS LIST Single Dart Body Bulletin Double Dart Body Bulletin Upper Swivel Bulletin Upper Swivel Bulletin 588e...16 Bottom Sub Sea Bulletin Lever / Lever Tattle Tale Bulletin Lever Flag Bulletin Single Dart Cage Bulletin Double Dart Cage Bulletin Pin Puller Bulletin Ball Dropper Bulletin Large Ball Dropper Bulletin SUPER SUB SEA MANUAL TOC

3 DNV Certification Page 1 Rev 6/07

4 DESCRIPTION This Hybrid Technology Universal Top Drive Lifting Cement Head was designed from its inception for use in a top drive system. While it is relatively light and compact, it has the highest lift/pressure rating in the industry. Its optional subs add considerable versatility. The Top Drive Universal Lifting Cement Head allows the continuous and independent rotation, stroking (lifting) and high flow cementing simultaneously. Plugs can be loaded before the job and dropped by a manual or remote pin puller, without using a manifold. Slots in the Plug Cage allow the direct pressure on the bottom Plug from the flow passing the Cage to guarantee launch after the pin on the pin puller is retracted. The flow from circulation then cleans the Head from the cement. head is designed so that ample annular area exists around the largest size Cage to allow fluid flow at a reasonable velocity. The Plug cages use an adjustable length standoff/spring expeller to ensure the dart is pushed into the fluid flow for launch. A spring loaded, lever operated tattle tale releases a flag to indicate dart passage. It can be recocked without removal from the head. Both hook load and combined hook/pressure load capacities are increased by the one piece integral design. This no-weld construction contributes to the head s simplicity, compactness and lightness. The Sure Lock system has the ability to customize jobs with minimal inventory by changing the cage and the bottom sub only. The cement head uses a flow around design that keeps the plug out of the fluid path. Variable size Cages are available depending on which launching Plug is being used. The PAGE 2

5 OPERATION All standard operating procedures for flow rates and pump pressures apply when using the Hybrid Universal Lifting Cement Head. The Plug may be released without interruption of circulation flow. Please Note: the plug cannot freeze to the cage because it is naturally warmed by the flow of the circulation fluid temperature. Release of the Plug The Cage By cementing plug is released from the Cage by pin puller assembly. To release, unlock the safety and turn and the bonnet to the left (counterclockwise) approximately nine (9) turns. Right hand threads are used. The indicator pin will show in the bonnet at the end of the stroke. Inside the Plug cage, a captive expeller spring pushes the plug into the fluid flow. Tattle Tale The passage of the dart from its cage into the drill string is indicated by the Lever/Flag Tattle Tale. A lever extending into the head bore releases a spring-loaded arm to display a stored flag. The arm stroke is 3 in/76mm. The Tattle Tale assembly is recocked without removal from the head. To re-cock, push end of indicator arm in and hold. With a probe thru top hole, push indicator head into latch. Roll flag up, push between guard and arm. PAGE 3

6 SERVICE AND ASSEMBLY General Wash, dry and oil all parts. Inspect for damage. Particularly inspect O-Rings and backups for nicks or cuts. Pre-grease grooves before installing O-Rings and backups (if gland is assembled dry, something else besides grease will fill the groove). Body and Plug Cage Plug Cage is held in place in the body by the lips on the front edges of the pin dropper. The cage can only be assembled in one position. Ensure that the plug puller and plug are in their proper position. Note their names are stamped their proper port on the body. Screw into body until the front lips catch the tube of the plug cage and the shoulders make up. Set lock nuts with moderate tap of a hammer. Upper Swivel Sub Disassembly after every job is not required, if no leaks were observed from the bleed holes during the previous job. Wash circular section thoroughly. Grease each fitting until grease appears at opposite bleed hole. Rotate several times and lightly regrease. Use finger to plug bleed hole while lightly regreasing to force grease through bearing and through seal. Be sure to grease O-Ring land above Sure-Lock. If leaks were observed during operation, swivel must be disassembled for seal replacement and to clean bearings of possible contamination. Be sure to install wiper ring on body before installing the flow ring. The split (2 piece) keeper ring is used on the bottom side of the flow ring. Reaction plate #8 may be assembled to top or bottom or swivel in any convenient position. On assembly, be sure seal lips face each other. Grooves and shoulder have been angled to allow easy assembly. However, on disassembly it is easy for the lower seal lip to catch the upper lock ring groove. Remove the upper bearing and cover the groove with tape or a metal shim to make sliding the seal easy. Install 1502 adapter with lock nut loose. Set the lock with hammer and chisel, medium tight. PAGE 4

7 Pin Puller Disassembly not required unless bonnet is stiff to turn or seals leak. 1. Retract Screw Pin #21 2. Grease 3. Extend 4. Grease lightly Sure Lock Body Adapter Lube O-ring and land, be sure camlocks are turned flush, and assemble. When box is fully down over pin Sure Lock, rotate 60 to the right. Secure the Sure Lock by turning the 3 camlocks one half turn to the right (clockwise) with a 5/16 allen wrench, as pictured below. Lever Tattle Tale Disassembly not required unless lever is stiff to operate or seals leak. Unlocked Locked PAGE 5

8 SEAL LIST Swivel Upper Sub and Lower Sub # O-Ring and Backup...70 shore A Nitrile and Nitrile 226 # Wiper Ring...D9000 # Retainer Ring...Smalley WS900 # Bearing...Kaydon DF 090-CPO # Backup Ring...Teflon MS # Seal...Poly Pack Upper Sub Pin Puller O-Ring...70 shore Nitrile Backup Ring...Nitrile 440 # Bearing...KDD 205 # Backup Ring...Nitrile 325 # O-Ring...90 Shore A Nitrile # Backup Ring...Nitrile 226 # O-Ring...70 shore A Nitrile # Wiper...CR Lever/Flag Tattle Tale (Bulletin 627) # Backup Ring...Nitrile 226 # O-Ring...70 Shore A Nitrile # Backup Ring...Nitrile 218 # O-Ring...70 Shore A Nitrile Note: Seal material chemically compatible to N and N and PO PAGE 6

9 RATED CAPACITIES AND HANDLING (6 5/8 SIZE) Hook Load Lifting Capacity *1,2 Simultaneous Hook Load Lift & Pressure Working Pressure 10,000 PSI TEST Hydrostatic: 15,000 PSI Rated Capacities of Hook Load & Pressure - S.F. = 1.28 Working Pressure Pounds Load mt Lift 10, ,102, , ,147, , ,193, , ,239, , ,284, , ,330, , ,376, , ,421, , ,467, , ,513, ,558, Torque thru Sure Lock *3 Right hand rotation 70,000 Ft/lb = 11,300 Nm Left hand rotation 70,000 Ft/lb = 11,300 Nm CAUTION: Do not break tool joint thru head. Swivel Rotation Max speed 30 rpm Reaction plate must be secured to Rig to prevent twisting of cement lines. Minimum Operating Temperature 32 F / 0 C Handling Hoist Rings Hoist Rings on Body rated at 5,000 lbs. each. Hoist Rings on Lower Sub rated at 2,500 lbs each. Note #1: Head has a safety factor of 1.27 to 1 at test. Note #2: Actual lift capacity of tool is limited by the actual joint thread used. PAGE 7

10 FLOW AREAS AND DIAMETERS (6 5/8 BODY SIZE) Upper Sub Circulation Fittings Body Bore Size 4 1/4 inches = in 2 Flow Slots 4 each total = in 2 2 each (1.87 ID) = 4.81 in 2 Total Optional: 2 each (2.75 ID) = in 2 Total Body (Around Cage inside 7.56 inch body bore) Plug Size Cage Annular Flow Areas 4 1/ x in 2 5 1/ x in 2 6 5/ x in 2 Lower Sub Thread Size Bore Flow Area 4 1/ in 2 5 1/ in 2 6 5/ in 2 PAGE 8

11 Weights and Dimensions Swivel Upper Sub Assembly Complete with control swivel Part Number Weight lbs Length inches Single Plug Body Assembly Part Number Weight lbs Length inches Ball Dropper Assy Bottom Adapter Part Number Weight: 405 lbs. Length: PAGE 9

12 Weights and Dimensions Swivel Upper Sub Assembly Complete with control swivel Part Number Weight lbs Length inches Double Plug Body Assembly Part Number Weight lbs Length inches Bottom Adapter Ball Dropper Assy Part Number Weight: 405 lbs. Length: Page 10

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15 1443 So. Gage St., San Bernardino, CA (909) Fax (909) LIFTING CEMENT HEAD ARROWHEAD SURE LOCK STYLE (9L34h34) COMPLETE SINGLE DART ASSEMBLY PART NUMBER ITEM QTY PART # PART NAME Body Cam Lock 2 1/4 Dia Retainer Pin Lifting Eye & Bolts, 5000lbs Pin Puller, 4 1/2 in Stk Lock Nut Holding Bull Plug O-Ring Back Up Ring Ball Dropper Lock Nut 3 1/ Bulletin 589 Page 13 Rev 6/07

16 LIFTING CEMENT HEAD ARROWHEAD SURE LOCK STYLE (9L34h34) COMPLETE DOUBLE DART ASSEMBLY PART NUMBER ITEM QTY PART # PART NAME Body Cam Lock 2 1/4 Dia Retainer Pin Lifting Eye & Bolts, 5000lbs Pin Puller, 4 1/2 in Stk Lock Nut Holding Bull Plug O-Ring Back Up Ring Ball Dropper Lock Nut 3 1/ Bulletin 590 Page 14 Rev 6/07

17 1443 So. Gage St., San Bernardino, CA (909) Fax (909) LIFTING CEMENT HEAD ARROWHEAD SURE LOCK STYLE (9L34h 075) SWIVEL UPPER SUB ASSEMBLY PART NUMBER ITEM QTY PART # PART NAME Body (PN Listed Below) Keeper Ring 2a Drive Retainer Ring Flow Ring Adapter 2 3/4-8 x O-Ring 5a Back Up Ring Seal Ring Lock Nut Reaction Plate Lifting Eye & Bolts PCS 3/8-16 x 1 1/ Wiper Ring Retainer Ring Bearing Back Up Ring Seal Grease Fitting PCS 3/8-16 x 1 3/ Clevis Stop Button SHCS 3/8-24x Back Up Ring O-Ring Parts Kit 35 Note 35 is a bleed hole and should not be blocked a Torque 3/8-16 Bolts to 33 ft lbs. Torque 1/2-13 Bolts to 80 ft lbs. Use any bearing grease that suits your particular temperature conditions. Thread Swivel Body PN 6 5/8 FH API NC /2 FH XT NC /2 IF XT Bulletin 588 Page 15 Rev 6/07

18 1443 So. Gage St., San Bernardino, CA (909) Fax (909) LIFTING CEMENT HEAD SWIVEL UPPER SUB ASSEMBLY PART NUMBER: ITEM QTY PART # PART NAME Body Keeper Ring 2a Drive Retainer Ring Flow Ring Adapter 2 3/4-8 x O-Ring 5a Back Up Ring Seal Ring Lock Nut Reaction Plate Lifting Eye & Bolts PCS 3/8-16 x 1 1/ Wiper Ring Retainer Ring Bearing Back Up Ring Seal Grease Fitting PCS 3/8-16 x 1 3/4 35 Note 35 is a bleed hole and should not be blocked a Bulletin 706e Page 16 Rev 6/07

19 SUPER SUB SEA CEMENT HEAD LOWER ADAPTOR ASSEMBLY (9L 34h 134) PART NO THREAD STYLE /8 FH API NC /2 FH XT NC /2 IF XT ITEM QTY PART # PART NAME Bottom Adaptor O-Ring Back Up Ring Lifting Eye and Bolts, 2500 lbs Bolt On Housing Lock Nut Soc Hd Cap Scr 7/16-20x1 3/ Lock Nut 2 1/2-8 Acme Bolt on Lever Tattle Tale Button SHCS 3/8-24x1/2 4 6 BULLETIN 591 PAGE 17 REV 6/07

20 LIFT FLOW AROUND CEMENT HEAD BOLT-ON LEVER LEVER TATTLE TALE 2 1/2-8 ACME x 2.00 SEAL ASSY ITEM QTY PART # PART NAME Body Lever Ball Assy Back Up Ring O-Ring Bearing Gland Back Up Ring O-Ring Retainer Gland Retainer Ring Smalley WH Bolt On Housing Soc Hd Cap Scr 7/16-20x1 3/ Lock Nut 2 1/2-8 ACME Seal Kit Note: Torque 7/16-20 SHCS to 58 ft lb Caution: Assemble TT Body to Bottom Sub before torqueing SHCS Caution: Turn TT Body with Arrow Pointing Up Before setting lock nut # BULLETIN 581 PAGE 18 REV 6/07

21 LIFT FLOW AROUND CEMENT HEAD BOLT ON LEVER FLAG TATTLE TALE THREAD x SEAL: 2 1/2-8 ACME x 2.00 SEAL PART NUMBER: ITEM QTY PART # PART NAME Body Spring Indicator 2 Stroke Cover/Guard 2 Stroke * Ring * Flag Lever/Ball Assy * Retainer Ring Smalley WH-150 * Retainer Gland * Bearing Gland * Set Screw 1/2-28 x 1/4 * Back Up Ring * O-Ring 90 * Back Up Ring * O-Ring Seal & Parts Kit 4 C 6 5 D Note: Torque 7/16-20 SHCS to 58 ft lb 3 2 CAUTION: Assemble Lever/Flag Tattle Tale to Cement Head with Arrows Pointing UP. Arrange Guard so that the Flag can hang freely down RE-COCKING: 1) Push indicator pin a A (with hammer handle) and hold 2) Push indicator head 3 into latch with probe through hole C 3) Look through hold D to see indicator head in latch 4) roll flag up and push between pin and guard BULLETIN 584 PAGE 19 REV 6/07

22 SUPER SUB SEA CEMENT HEAD SINGLE DART CAGE SIZES: 6 5/8 5 1/2 4 1/2 ITEM PART NAME SIZE PART NO. 0 Assy 6 5/ / / Cap 6 5/ / / Cage 6 5/ / / Guide Tube Spring (3 ea) Top Collar Cap Screw (2 ea) 5/16x2.25 GR Lock Nut (2 ea) 5/ Top Spring Bottom Collar Notes: 1) The cage can be assembled from top or the bottom of the body of the cement head in vertical or horizontal positons ) Assemble Cage into Head Body. Install Pin Puller and Blanking Plug. Center port of the head with port of the cage. Their lips will hold cage in place. 3) Cement Plugs can be loaded from the top or the bottom of the head. Bulletin 592 Page 20 Rev 6/07

23 1443 So. Gage St., San Bernardino, CA (909) Fax (909) SUPER SUB SEA CEMENT HEAD DOUBLE DART CAGE SIZES: 6 5/8 5 1/2 4 1/2 ITEM PART NAME SIZE PART NO. 0 Assy 6 5/ / / Cap 6 5/ / / Cage 6 5/ / / Guide Tube Spring (3 ea) Top Collar Cap Screw (2 ea) 5/16x2.25 GR Lock Nut (2 ea) 5/ Top Spring Bottom Collar Notes: 1) The cage can be assembled from top or the bottom of the body of the cement head in vertical or horizontal positons. 2) Assemble Cage into Head Body. Install Pin Puller and Blanking Plug. Center port of the head with port of the cage. Their lips will hold cage in place. 3) Cement Plugs can be loaded from the top or the bottom of the head. Bulletin 593 Page 21 Rev 6/07

24 LIFT FLOW AROUND SUB SEA DART PIN PULLER THREAD x SEAL: 2 3/4-8 ACME x 2.37 PART NUMBER: ITEM QTY PART # PART NAME Pin Spring Lock Lever Lock Pin Jam Nut Bonnet Assembly Key Bearing Drive Shaft Cap * Set Screw (1/4-28 x 1/4 ) Grease Fitting Body Sub ACME * Back Up Ring * O-Ring 90 * Back Up Ring * O-Ring Wiper Indicator Rod Screw Pin Seal & Parts Kit A B LENGTHS AND WEIGHTS Part No. A B C Lbs GREASE PROCEDURE 1. Retract Screw Pin #21 2. Grease heavily 3. Extend Screw Pin; extra grease will bleed at hold #35 4. Grease lightly. Next use will force grease to drive shaft STROKE A Note: Hole #35 is a bleed hole, and should not be plugged Bulletin 577 Page 22 Rev 6/07

25 LIFT FLOW AROUND SUB SEA BALL DROPPER THREAD x SEAL: 3 1/4 ACME x 3.03 PART NUMBER: ITEM QTY PART # PART NAME Pin Spring Lock Lever Lock Pin Jam Nut Bonnet Assembly Key Bearing Drive Shaft Cap * Set Screw (1/4-28 x 1/4 ) Grease Fitting Body Sub ACME * Back Up Ring * O-Ring 90 * Back Up Ring * O-Ring Wiper Indicator Rod Screw Pin 22 1 Seal & Parts Kit BALL CAGE PN /75 Haliburton Note: Ball Cage Not Included in Assy PN GREASE PROCEDURE 1. Retract Screw Pin #21 2. Grease heavily 3. Extend Screw Pin; extra grease will bleed at hold #35 4. Grease lightly. Next use will force grease to drive shaft. Note: Hole #35 is a bleed hole, and should not be plugged Bulletin 560 Page 23 Rev 6/07

26 LIFT FLOW AROUND SUB SEA LARGE BALL DROPPER THREAD x SEAL: 3 7/8 ACME x PART NUMBER: ITEM QTY PART # PART NAME Pin Spring Lock Lever Lock Pin Jam Nut Bonnet Assembly Key Bearing Drive Shaft Cap * Set Screw (1/4-28 x 1/4 ) Grease Fitting Body Sub ACME * Back Up Ring * O-Ring 90 * Back Up Ring * O-Ring Wiper Indicator Rod Screw Pin Seal & Parts Kit BALL CAGE PN GREASE PROCEDURE 1. Retract Screw Pin #21 2. Grease heavily 3. Extend Screw Pin; extra grease will bleed at hold #35 4. Grease lightly. Next use will force grease to drive shaft. Note: Hole #35 is a bleed hole, and should not be plugged Bulletin 586 Page 24 Rev 6/07