COMMISSIONING DOCUMENTATION

Top Drive Model - GDM 500 Ton AC

Customer - Browning Drilling Company
GDS WO# M13931
TD SN 004

Form 253 Rev. 1 Feb. 2014

M13931 - 1 - On-site Commissioning Rev 0

 9841 Windmill Park Ln.
Houston, Texas 77064
P 713/623-1449
F 281/416-4495
info@globaldrillingsupport.com

The following document is to provide information regarding the commissioning and

functional testing of a 500 Ton GDS Top Drive. This includes, but is not limited to,
the function testing of the Top Drive System within the parameters set forth by
GDS International. This document will also cover the interface of the GDS TD
controls available/provided by other vendors that shall be incorporated within.
Data, documentation, and testing shall be documented. All processes and
procedures used in the gathering, executing, and testing of parameters are listed
within this document. Top Drive functional testing shall be performed in
accordance with GDS International data information and test parameters.

This commissioning document is specific to the interface of an Omron system

designed for Browning Drilling Company integrated with the TD control system.

Drawing references: Parts, Service, Data, and Operating Manual GDS TD SN 004

Location:

Date Released: 11 February 2014

Form 253 Rev. 1 Feb. 2014

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 Commissioning Procedure

1) Specifications

2) System Start up

3)Hydraulic Pressure Test

4)Top Drive Function Test

5) Top Drive Alarm And Warnings Test Procedures

6) System Run Test

7) Top Drive Hole Center (To Be completed on the Rig)

Form 253 Rev. 1 Feb. 2014

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 1) TOP DRIVE SPECIFICATIONS

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 Specifications
TD Model GDM-500/650 Ton AC

Static Hoist Rating 500 Short Tons 650 Short Tons

Drilling Electric Motor GEB20
Maximum Continous Current 1100 Amps
Maximum Intermittant Current 1470 Amps (15 Seconds)
Maximum Voltage 575 Volts
Frequency Range 0 to 117 Hz
Cooling System 15 HP Local Blower 3900 CFM
Continous HP Rating 800 HP 1150 HP
Gear Ratio 8.7059
Continous Torque Rating 45 000 Ft/Lbs 55 000 Ft/Lbs
Maximum Torque Rating 75 000 Ft/Lbs 65 000 Ft/Lbs
Brake Capacity 50 000 Ft/Lbs
Maximum Connection Break Out Torque 80 000 Ft/Lbs 75 000 Ft/Lbs
Pipe Clamp Capacity 110 000 Ft/Lbs
Pipe Handler Orientation 360˚/Unlimited - Comes with
Quill Connection 6 5/8 Reg 7 5/8 Reg
Mud Passage Diameter 3 inches
Mud Passage Maximum Circulating PSI 5000 PSI (7500 PSI Opt)
Remote Actuated IBOP 10000 PSI
Manual Actuated IBOP 10000 PSI
Stand Jump Travel 7.25 inches
Hook Weight 34 000 LBs
Height 23' with 144" Elevators
Width * Depth 4.4' * 5.6'
Lubrication System 2HP 5GPM Flow

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 2) SYSTEM START UP

Form 253 Rev. 1 Feb. 2014

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 GDP/TOP DRIVE START-UP
PRE-POWER SYSTEM WIRING CHECK GDP AND TOP DRIVE OK INITIAL
Ensure that all wiring in the GDP cabinet, Top Drive junction boxes, and upper Mast JB is
complete and properly terminated. Verify all cabling to ground.
Comments:

TD WIRING: OK INITIAL
Verify that all wiring is terminated properly. Verify with Diode Check that the Encoder is wired
correctly from the GDP to the TD. As well Verify wiring from the VFD to the GDP.

Ensure all cables glands are tight

Ensure that all wires are secure at terminal blocks and connections are tight / torqued as well as
all other points of termination.
Check all grounding/bonding cabling

Check all motors to ground with a Megger. Record the results below
Traction motor reading: _____ OHM Expected results: Min 2 M-OHM
Lube pump reading: _____ OHM Expected results: Min 2 M-OHM
Blower motor reading: _____ OHM Expected results: Min 2 M-OHM
HPU#1 motor reading: _____ OHM Expected results: Min 2 M-OHM
HPU#2 motor reading: _____ OHM Expected results: Min 2 M-OHM
HPU Cooling Fan reading: _____ OHM Expected results: 59 OHM
Ohm out the AUX motor windings, record the results below
Lube pump Motor reading: _____ OHM Expected results: 18 OHM
Blower motor reading: _____OHM Expected results: 2.2 OHM
HPU#1 motor reading: _____ OHM Expected results: 1.6 OHM
HPU#2 motor reading: _____ OHM Expected results: 1.6 OHM
HPU Cooling Fan reading: _____ OHM Expected results: 59 OHM
Comments:

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GDP POWER CHECKS OK INITIAL
Ensure the TD lock out button is pushed in, all fuses are open, check all fused wires to ground
with an OHM meter to verify no short ccts exist.
Check incoming supply on the top of CB1 Volts: ___ VAC Expected results: 600 VAC +/- 5%
(Need to re-check at Rig-up)
Make sure the Drillers Console TD E-Stop is pulled. Verify Continuity of the Estop UV trip CCT
between wires 732 and 734 of TD TB11 terminals 1 and 2
Close F1 Fuse, which should energize the UV trip and you should now have 24 VDC across CB1
UV trip coil wire 734 and 0030
Close CB1, check the incoming voltage between TB20/F1 to TB21/T1 (neutral) for 120VAC, close
120 volt TB11. This will send 120 VAC to the power supply of the PLC, the PLC should power up
and Run. Press the TD E-stop to ensure CB1 trips as well as the TD main brake.

Close fuses 4F and 5F on TB20 , this will supply 120VAC to PS1 and PS2 the primary and
secondary 24VDC power supplies. Verify the DC ok light has come on, record the voltage output
below
PS1 Volts: _____ VDC Expected results: 24 VDC +/- 5%
PS2 Volts: _____ VDC Expected results: 24 VDC +/- 5%
Close Fuse 6F on TB22, and Verfy that you have 24 volts at F1 TB40 of Drillers Console
terminals, if so close F1, the TD HMI screen at the drillers cabin should power up. Check that you
have communication between the HMI and the Siemens TD Main PLC (from separate 120v
source).
Close all remaining 120VAC and 24VDC fuses in the GDP, Check that All of the remaining fuses
in the Drillers Console (F2, F3, F4) have 24 Volts present on the line side. If so close all TD TB40
fuses.
Verify wire #'s, fuse #'s, and TB #'s

Comments:

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GDP POWER CHECKS OK INITIAL
Release the lock out button on the Drillers Console, verify that RL3 pulls in. Check for
communication Between the TD Main PLC and The TD Remote Rack.
Verify that Input I-0/0.2 on the main TD PLC rack comes on when the Blower runs.
Blower motor amps: ____ Amps Motor FLA: ___ Amps S.F 1.15 Overload set point: ____
Amps
Blower motor volts: ___ VAC Expected results: 600 VAC +/- 5%VAC
Verify that Input I-0/0.1 on the main TD PLC rack comes on when the Lube Pump runs.
Lube motor amps: ___ Amps Motor FLA 2.7 Amps S.F 1.25 Overload set point: ___ Amps

Lube motor volts: ___ VAC Expected results: 600 VAC +/- 5%VAC
Verify that Input I-0/0.3 on the main TD PLC rack comes on when HPU#1 runs.
HPU#1 motor amps: __ Amps Motor FLA: 24.5 Amps S.F 1.25 Overload set point: ___
Amps
HPU#1 motor volts: ___ VAC Expected results: 600 VAC +/- 5%VAC
Verify that Input I-0/0.4 on the main TD PLC rack comes on when HPU#2 runs.
HPU#2 motor amps: ___ Amps Motor FLA 24.5 Amps S.F 1.25 Overload set point: ___
Amps

HPU#2 motor volts: ___ VAC Expected results: 600 VAC +/- 5%VAC
Verify that Input I-0/0.4 on the main TD PLC rack comes on when HPU#2 runs.
HPU Cooling Fan motor amps: ___ Amps Motor FLA 24.5 Amps S.F 1.25 Overload set
point:___ Amps

HPU Cooling Fan motor volts: ___ VAC Expected results: 600 VAC +/- 5%VAC
Verify that I-1/1.3 E-stop / lockout is active on the PLC, push in the TD Lockout button in the
drillers cabin, verify we lose the input on the PLC, verify the Lockout relay (R3) drops out, verify
the drive is unable to start, Observe the Lockout Status on Top Drive Drill or Trip Screen

Verify that if either the lockout or E-stop buttons in the drillers cabin are pressed that none of the
TD aux motors (Blower, Lube Pump, HPU#1, and HPU#2) can be started manually or
automatically. Verify that the TD transfer Panel contactor will open if either the TD lockout or E-
stop are pressed
Verify that if the TD HPU E-stop (located on the TD HPU) is pressed both HPU#1 and HPU#2 will
shut off and will not start until the HPU E-stop is reset. As well verify that you will have an HPU E-
Stop Alarm on the HMI.
Comments:

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Drillers Cabin IO Checks - Unplug the IDS Ethernet cable from the GDP ethernet switch and
the profibus cable from the TD CPU going to the TD. This will disable anything on the TD
OK INITIAL
from functioning. Monitor GDP I/O on the HMI screen.

Switch the TD to Trip Enable - I-1/1.4 should come on.

Switch the TD to Drill Enable - I-1/1.5 should come on. (Switch back to OFF when finished)
Switch the TD IBOP to Open - I-1/1.6 should come on.
Switch the TD IBOP to Auto - I-1/1.7 should come on.
Switch the TD IBOP to Close - I-2/0.0 should come on.
Switch the TD Brake to On - I-2/0.1 should come on. (Switch back to OFF when finished)
Activate the TD Motor Control Joystick left - I-2/0.2 should come on.
Activate the TD Motor Control Joystick Right - I-2/0.3 should come on.
Activate the TD Motor Control Joystick Up - I-2/0.4 should come on.
Activate the TD Motor Control Joystick Down - I-2/0.5 should come on.
Activate the TD Motor Control Joystick PB1 - I-2/0.6 should come on. (Black PB)
Activate the TD Motor Control Joystick PB2 - I-2/0.7 should come on. (Red PB)
Activate the TD Motor Control Joystick PB3 - I-2/1.0 should come on. (Yellow PB)
Activate the TD Motor Control Joystick PB4 - I-2/1.1 should come on. (Green PB)
Activate the TD Pipe Handler Joystick left - I-2/1.2 should come on.
Activate the TD Pipe Handler Joystick Right - I-2/1.3 should come on.
Activate the TD Pipe Handler Joystick Up - I-2/1.4 should come on.
Activate the TD Pipe Handler Joystick Down - I-2/1.5 should come on.
Activate the TD Pipe Handler Joystick PB3 - I-2/1.6 should come on. (Yellow PB)
Activate the TD Pipe Handler Joystick PB4 - I-2/1.7 should come on. (Green PB)
Comments:

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 3) HYDRAULIC PRESSURE TEST

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Form 253 Rev. 1 Feb. 2014 M13931 - 12 - On-site Commissioning Rev 0
 TOP DRIVE HYDRAULIC PRESSURE SETTINGS

1 Main HPU #1
Specified
Set at (PSI) (initial)
(PSI)

2350
Rotation Marked Yes No

2 Main HPU #2
Specified
Set at (PSI) (initial)
(PSI)

2350
Rotation Marked Yes No

3 Top Drive Brake: Pressure reducing cartridge

Install test gauge at GA1 and GB1 Test Specified Set at (initial)

Stations. GA1 should read 1300 psi.

1300
Function Directional Valve to B position or
turn Brake selector switch to “ON”. GB1
should read 1300 psi. Adjust 20A
cartridge to 1300 psi. if required

4 Handler Lock: Pressure reducing cartridge

Specified Set at (initial)
Install test gauge at GA2 and GB2 Test
Station. GA2 should read system psi. 1000
Function Directional Valve to B position or
activate PH Unlock. GB2 should read
system psi. Adjust 20B until it just reaches
1000PSI.

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 TOP DRIVE HYDRAULIC PRESSURE SETTINGS

5A Handler Rotate: Pressure reducing cartridge

Specified Set at (initial)
Install test gauge at GA3 and GB3 Test
Station. 30CA and 30 CB should both be 1800
set for mid range. Function the Directional
Valve to A position or move joystick to
“FORWARD” (handler locked) GA3 should
read 1800 psi Function DCV to B position
or move joystick to “REVERSE” (handler
locked) GB3 should read 1800 psi Adjust
20 C (cartridge) if required.

5B PH Forward and Reverse speed/flow Forward

Speed Should be between 20 and 22 Specified Set at (initial)
seconds for one complete revolution. 20 to 22
Adjust both 30 CA for Forward speed and Seconds
30 CB for Reverse Speed
Reverse
Specified Set at (initial)

20 to 22
Seconds

6A Link Tilt and Link Tilt Float (Extend): Pressure reducing cartridge A
Ensure there is a1MM orifice installed in Specified Set at (initial)

“T” port of the L.T.Float directional valve.

1200
The counterbalance valves should both be
Preset to 2500 PSI. 30DA and 30 DB Pressure relief cartridge A
should both be set for Mid Range. Fully Specified Set at (initial)
“Extend” the LT cylinders. GA4 should
1350
read 1200 psi.
For initial set up of LT Extend, extend the
cylinders all the way and keep the
directional valve actuated, gauge at GA4,
Turn 22D clockwise all the way in, adjust
25EA untill you read 1325PSI. Go back
and adjust 22D CCW until you read
1200PSI

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 TOP DRIVE HYDRAULIC PRESSURE SETTINGS

6B Link Tilt and Link Tilt Float (Retract):

For initial set up of LT Retract, The HPU Pressure relief cartridge B
must be set between 2800PSI to Specified Set at (initial)
3000PSI. Retract the cylinders all the way
and keep the directional valve actuated 2750
adjust 25EB CW until you reach 2750.
With the HPU set back to 2350 the
pressure on GB4 will be 2350

6C LT Extend and Retract speed/flow Extend

Should be between 10 and 15 seconds Specified Set at (initial)
for extend and retract. Adjust both 30 DA 10 to 15
for Extend speed and 30 DB for Retract Seconds
Speed
Retract
Specified Set at (initial)

10 to 15
Seconds

7 Stand Jump: 20G

Insure the Topdrive is hanging safely from Specified Set at (initial)
the crane; lift Top Drive up off of the stop
1950
pins, or shipping pins in the test stand
track. Install test gauge at GA7 Test 25GA
Station. Adjust 30G all the way out CCW. Specified Set at (initial)
Adjust 20G all the way in CW. Activate
stand jump switch on console, and adjust 1850
25GB CW until you read system pressure 25GB
2350PSI. At this point the cylinders should Specified Set at (initial)
be retracted, and the top drive in full up
position. Turn off stand jump at console 2350
and adjust 25GA to allow the top drive to
slowly descend and record PSI. The stand
jump cylinders should extend and lower
the top drive. Adjust 20G CCW half way
out; activate stand jump switch on the
console, and adjust 20G CW until top
drive lifts slowly. Record PSI - NOTE:
Final setup will have to be done on the rig
with the TD hanging from the block.

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 TOP DRIVE HYDRAULIC PRESSURE SETTINGS

8 IBOP: Pressure reducing cartridge

Counterbalance valve should be preset for Specified Set at (initial)
400PSI. Install test gauge at GA8 and
GB8 Test Stations. Function the A side of 1500
the directional valve (Open), adjust 20H Pressure reducing cartridge B
until GA8 reads 1500 PSI. Function the B Specified Set at (initial)
side of the directional valve (Close), adjust
800
22H untill GB8 reads 800 PSI.

9 Back up Wrench Gripper: Pressure reducing cartridge

Install test gauge at GA11 and GB11 Test Specified Set at (initial)
Stations. Function A side of the directional
1800
valve Open Adjust 20K until GA11 reads
1800 psi. Function B side, GB11 should
read 1800 psi.

10 TD Return Relief valve Pressure relief cartridge

Relief needs to be removed to be set at (initial)
Specified Set at
750
750

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 4) TOP DRIVE FUNCTION TEST

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 TOP DRIVE FUNCTION TEST
Function /
Control DESCRIPTION OK INITIAL
Position
TD Selection Switch selected to Trip. TD Status Indication on the HMI - Drill, Backup
Joystick and Trip Screens will indicate "Top Drive tripping Enabled", enables the TD
for all hydraulic functions.
TD
Test procedure: Select Trip position with the Top Drive Selection Switch, observe the
Selection Trip
TD Status on the HMI indicates "Top Drive tripping Enabled". Verify that both HPU#1
Switch
or #2 can be selected from the HMI and will start/run. all hydraulic features are
available (Hydraulic pressure read out available at TD HMI Analog screen) .

TD Selection Switch selected to Drill. TD Status Indication on the HMI - Drill, Backup
Joystick and Trip Screens will indicate "Top Drive drilling Enabled", enables the TD for
Drilling and Torque functions. Blower and lube pump motors will start. TD Status
display will indicate "Top Drive enable Faulted" if all drill enable conditions are not
TD met.
Selection Drill Test procedure: Select Drill position with the Top Drive Selection Switch, observe the
Switch TD Status on the HMI indicates "Top Drive drilling Enabled". Observe blower is
running, observe Lube pump has turned on (check TD Analog screen for pressure
readings) verify that both HPU#1 or #2 can be selected from the HMI and will start/run.
Switch to off, all motors shut down and all functions are disabled.

TD Selection Switch selected to Off TD Status Indication on the HMI - Drill, Backup
Joystick and Trip Screens will indicate "Top Drive Off", all functions are disabled
TD
Selection Off
Test procedure: Select Off position with the Top Drive Selection Switch, observe the
Switch
TD Status on the HMI indicates "Top Drive Off". Observe that all functions are
disabled if activated.
TD Selection Switch selected to Off TD Status Indication on the HMI - Drill, Backup
Joystick and Trip Screens will indicate "Top Drive Off", all functions are disabled

Test procedure 1: Select Trip position with the Top Drive Selection Switch, Select
HPU#1, HPU #1 should start and continue to run, Select Drill position with the Top
TD HPU
HPU#1 or Drive Selection Switch, HPU#1 Should continue to run, Select Off with the Top Drive
selectionH
HPU#2 Selection Switch, HPU#1 should remain running. Test procedure 2: With HPU#1
MI PB
running, select HPU#2, HPU#1 should stop running and HPU#2 should start running.
Test procedure 3: With the Top Drive Selection Switch in the Off position, verify that
either HPU#1 & HPU#2 will operate when selected. Attempt to operate hydraulic
functions and verify that they are disabled.

When the HPU E-stop is pressed, if either HPU#1 or #2 is running in hand or in auto
the HPU will trip and the HMI will indicate that the HPU E-Stop has been pressed
TD HPU E- PB on TD
Stop HPU Test procedure 1: With HPU#1 running push the E-Stop, HPU#1 will stop running
and we should have an alarm indicating HPU E-Stop is pressed. Rest HPU E-stop and
test with HPU#2, the same results should occur.

Comments

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 Function /
Control DESCRIPTION OK INITIAL
Position
Moving the TD Pipe Handler Joystick in the Up Direction will activate the Link Tilt
TD Pipe Cylinders to Extend
JS UP (Link
Handler
Tilt Extend) Test procedure: Select Trip or Drill position with the Top Drive Selection Switch and
Joystick start an HPU if one is not running. Move the TD Link Tilt Joystick in the upward
Direction and Observe that the Link Tilt cylinder extends.
Moving the TD Pipe Handler Joystick in the Down Direction will activate the Link Tilt
TD Pipe JS Down Cylinders to Retract
Handler (Link Tilt Test procedure: Select Trip or Drill position with the Top Drive Selection Switch and
Joystick Retract start an HPU if one is not running. Move the TD Link Tilt Joystick in the Downward
Direction and Observe that the Link Tilt cylinder Retracts
Toggling the TD Pipe Handler Joystick - Link Tilt Float Joystick will activate the Link
Tilt Cylinders to Float.
TD Pipe PB4 (Green Test procedure: Select Trip or Drill position with the Top Drive Selection Switch and
Handler - Link Tilt start an HPU if one is not running. Extend your LT Cylinders and Bails/elevators out,
Joystick Float) toggle Link Tilt Joystick once to float the cylinders and toggle again to maintain.
Toggle back to neutral and activate either LT extend or Retract, this will automatically
toggle the LT cylinders.

Toggling the TD Pipe Handler Joystick - PH Unlock PB will activate the Pipe Handler
Lock to Unlock.
TD Pipe PB3 (Yellow
Handler - PH Test procedure: Select Trip or Drill position with the Top Drive Selection Switch and
Joystick Unlock) start an HPU if one is not running. Toggle the PH Unlock Joystick, the PH will Unlock
and if there is no PH rotation commanded the PH will automatically lock after 3
seconds.
Moving the TD Pipe Handler Joystick in the Left Direction will move the PH in the
Forward (CW) Direction.
TD Pipe Left (PH Test procedure: Select Trip or Drill position with the Top Drive Selection Switch and
Handler Rotate start an HPU if one is not running. Toggle the PH Unlock Joystick, the PH will Unlock,
Joystick Forward) within 3 seconds move the PH JS Left, this will rotate the TD PH Reverse. When the
joystick is released for 30 seconds, the Pipe Handler will automatically lock again.

Moving the TD Pipe Handler Joystick in the Right Direction will move the PH in the
Reverse (CCW) Direction.
TD Pipe Right (PH Test procedure: Select Trip or Drill position with the Top Drive Selection Switch and
Handler Rotate start an HPU if one is not running. Toggle the PH Unlock Joystick, the PH will Unlock,
Joystick Reverse) within 3 seconds move the PH JS Right, this will rotate the TD PH Forward. When the
joystick is released for 3 seconds, the Pipe Handler will automatically lock again.

Comments: Do the links move up when they are extended?

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 Now test the HMI Back-up Pipe Handler Joystick functionality from the HMI Back-up Joystick screen, the functionality
should be the same as the Console Joystick.
Function /
Control DESCRIPTION OK INITIAL
Position
Activating PH Back up Joystick will enable the HMI Back Up joystick and disable the
TD Pipe
joystick from functioning.
Handler Activate PH
HMI Back Back Up Test procedure: Try and activate the PH Backup joystick from the HMI, it should not
up Joystick function. Toggle the "Activate PH Back UP JS" HMI button, try and function the
Joystick physical joystick, it should not function. Function the HMI BU JS, as per below, it
should be completly functional
Pressing the Back up TD Pipe Handler Joystick in the Up Direction will activate the
TD Pipe
Link Tilt Cylinders to Extend
Handler
UP (Link Tilt Test procedure: Select Trip or Drill position with the Top Drive Selection Switch and
HMI Back
Extend) start an HPU if one is not running. Pressing the TD Pipe Handler Back up Joystick in
up
Joystick the upward Direction and Observe that the Link Tilt cylinder extends.

Pressing the TD Pipe Handler Back up Joystick in the Down Direction will activate the
TD Pipe
Link Tilt Cylinders to Retract
Handler
Down (Link Test procedure: Select Trip or Drill position with the Top Drive Selection Switch and
HMI Back
Tilt Retract start an HPU if one is not running. Press the TD Pipe Handler Back up Joystick in the
up
Joystick Downward Direction and Observe that the Link Tilt cylinder Retracts

Toggling the TD Pipe Handler Back up Joystick - Link Tilt Float PB will activate the
Link Tilt Cylinders to Float.
TD Pipe
Handler PB4 (Green Test procedure: Select Trip or Drill position with the Top Drive Selection Switch and
HMI Back - Link Tilt start an HPU if one is not running. Extend your LT Cylinders and Bails/elevators out,
up Float) toggle Back up JS PB4 once to float the cylinders and maintain. Toggle back to
Joystick activate either LT extend or retract.

Toggling the TD Pipe Handler Back up Joystick - PH Unlock PB will activate the Pipe
TD Pipe
Handler Lock to Unlock.
Handler PB3 (Yellow
HMI Back - PH Test procedure: Select Trip or Drill position with the Top Drive Selection Switch and
up Unlock) start an HPU if one is not running. Toggle the PH Unlock PB, the PH will Unlock and if
Joystick there is no PH rotation commanded the PH will automatically lock after 3 seconds.

Pressing the TD Pipe Handler Back up Joystick in the Left Direction will move the PH
TD Pipe in the Forward (CW) Direction.
Handler Left (PH Test procedure: Select Trip or Drill position with the Top Drive Selection Switch and
HMI Back Rotate start an HPU if one is not running. Toggle the PH Unlock Back up PB, the PH will
up Forward) Unlock, within 3 seconds Press the PH JS Left, this will rotate the TD PH Forward.
Joystick After the Joystick has been released for 3 seconds the Pipe Handler will automatically
lock again.
Pressing the TD Pipe Handler Back up Joystick in the Right Direction will move the
TD Pipe PH in the Reverse (CCW) Direction.
Handler Right (PH Test procedure: Select Trip or Drill position with the Top Drive Selection Switch and
HMI Back Rotate start an HPU if one is not running. Toggle the PH Unlock PB, the PH will Unlock,
up Reverse) within 3 seconds Press the PH JS Right, this will rotate the TD PH Reverse. After the
Joystick Joystick has been released for 3 seconds the Pipe Handler will automatically lock
again.
Comments

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 Function /
Control DESCRIPTION OK INITIAL
Position
Make up Torque Limit Adjustable from 0 to 55,000 Ft/lbs. Can be adjusted on either
the Drilling Screen or the Backup Joystick Screen.
HMI Make Test procedure: Select Trip or Drill position with the Top Drive Selection Switch.
Up torque HMI Press the numerical Touch screen button and enter a value in the above range and
Limit ensure that it displays, Enter a value above the maximum Range and ensure that the
display will not exceed the maximum selectable value above.

Drill Torque Limit Adjustable from 0 to 47,500 Ft/lbs. Can be adjusted on either the
Drilling Screen or the Backup Joystick Screen.
HMI Drill
torque HMI Test procedure: Select Trip or Drill position with the Top Drive Selection Switch.
Limit Press the numerical Touch screen button and enter a value in the above range and
ensure that it displays, Enter a value above the maximum Range and ensure that the
display will not exceed the maximum selectable value above.
Spin Torque Limit Adjustable from 2000 to 6000 Ft/lbs. Can be adjusted on either the
Drilling Screen or the Backup Joystick Screen.
Test procedure: Select Trip or Drill position with the Top Drive Selection Switch.
HMI Spin Press the numerical Touch screen button and enter a value in the above range and
Torque HMI ensure that it displays, Enter a value above the maximum Range and ensure that the
Limit display will not exceed the maximum selectable value above. Enter a value below the
minimum Range and ensure that the display will not display less than the minimum
selectable value above.

Drill Speed Preset Adjustable from 0 to 240 RPM. Can be adjusted on either the
Drilling Screen or the Backup Joystick Screen.
HMI Drill
Speed HMI Test procedure: Select Trip or Drill position with the Top Drive Selection Switch.
Preset Press the numerical Touch screen button and enter a value in the above range and
ensure that it displays, Enter a value above the maximum Range and ensure that the
display will not exceed the maximum selectable value above.
Spin Speed Adjustable from 5 to 40 RPM. Can be adjusted on either the Drilling
Screen or the Backup Joystick Screen.
Test procedure: Select Trip or Drill position with the Top Drive Selection Switch.
Press the numerical Touch screen button and enter a value in the above range and
HMI Spin
HMI ensure that it displays, Enter a value above the maximum Range and ensure that the
Speed
display will not exceed the maximum selectable value above. Enter a value below the
minimum Range and ensure that the display will not display less than the minimum
selectable value above.

Comments

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 Function /
Control DESCRIPTION OK INITIAL
Position
Toggling the TD Motor Control Joystick - BUW Close PB will activate the BUW to
Close Once the BUW is closed toggle again to open. BUW Close is interlocked with
the DW to prevent Damage to the TD and BUW assembly, as well as injury.
Test procedure: Select Trip or Drill position with the Top Drive Selection Switch and
TD Motor PB2 (Red -
start an HPU if one is not running. Toggle the BUW Close PB, the BUW will close.
Control BUW
Toggle again and the BUW will open. Close the BUW and try and hoist the draw
Joystick Close)
works, ensure that the Draw works does not move and there is an alarm on the RIG
Third Party HMI. Open the BUW and slowly hoist the draw works, the draw works
should keep moving and the BUW should not close, there should be an BUW Gripper
interlock alarm on the GDS HMI
Toggling the TD Motor Control Joystick - "Torque/Drill PB" will toggle the TD Motor
Control Joystick Between Drill and Torque Modes. This will change the Functionality of
the Joystick - The "TD Mode" Indication on the HMI - Drill, Backup Joystick, and Trip
TD Motor PB4 (Green Screens will indicate "Top Drive In Torque Mode" or "Top Drive in Drill mode"
Control -Torque/
Joystick Drill) Test procedure: Select Drill position with the Top Drive Selection Switch. Toggle the
Torque/Drill PB, and Verify that the "TD Mode" status changes back and forth as
toggled between "Top Drive In Torque Mode" or "Top Drive in Drill mode".

Toggling the TD Motor Control Joystick - "Drill Reverse PB" will toggle the TD Motor
Direction Between Forward and Reverse, this button is active only if the TD mode is
selected to Drill Mode. The "TD Mode" Indication on the HMI - Drill, Backup Joystick,
and Trip Screens will indicate "Top Drive In Drill Mode" or "Top Drive in Drill Reverse "
TD Motor PB1 (Black -
Control Drill Test procedure: Select Drill position with the Top Drive Selection Switch and start an
Joystick Reverse) HPU if one is not running. Ensure that your TD Mode is selected to "Drill Mode",
Toggle the Drill Reverse PB, and Verify that the "TD Mode" status changes back and
forth as toggled between "Top Drive In Drill Mode" or "Top Drive in Drill Reverse". You
are now ready test the operating functionality of the Joystick.

Comments

Form 253 Rev. 1 Feb. 2014

M13931 - 22 - On-site Commissioning Rev 0

 Function /
Control DESCRIPTION OK INITIAL
Position
TD Motor Control Joystick up (Drill Mode) Moving the joystick up will increase speed,
as long as you keep the joystick in the upward position, until maximum speed is
reached. At any time if the joystick is released the speed will be maintained at the
TD Motor value it was at before it was released. With the TD mode in Drill Reverse, the
Up (Drill operation will be the same but rotation will be in the Reverse direction and limited to a
Control
Mode maximum of 100 RPM
Joystick
Increase
(Drill Test procedure: Select Drill position with the Top Drive Selection Switch and start an
Speed)
Mode) HPU if one is not running, verify and your BUW is open and quill is free to rotate. In
Drill Mode Push the Motor control Joystick up until the speed ramps up to about 100
RPM. Release the joystick and verify the speed does not change. (Keep the TD
rotating for the next step)
TD Motor Control Joystick down (Drill Mode) Moving the joystick Down will Decrease
speed, as long as you keep the joystick in the downward position, until zero speed is
reached. At any time if the joystick is released the speed will be maintained at the
TD Motor value it was at before it was released. With the TD mode in Drill Reverse, the
Down (Drill operation will be the same but rotation will be in the Reverse direction.
Control
Mode
Joystick
Decrease
(Drill Test procedure: With the TD still rotating, Move the TD Motor Control Joystick down
Speed)
Mode) and hold it down until it reaches about 50 RPM and release the joystick. Verify that the
speed remains constant after releasing the JS. Continue moving the TD MC JS down
until zero speed is reached, release the JS and ensure that the TD does not rotate.

TD Motor Control Joystick Right (Drill Mode) Moving the joystick Right will enter the
preset speed value into the speed referance, and the TD will ramp up speed until the
preset value is acheived. If the Preset value is lower than the actual speed when the
JS is moved to the right, the speed will ramp down to the preset value. When the
joystick is released the speed will be maintained at the preset value. With the TD
TD Motor
Right (Drill mode in Drill Reverse, the operation will be the same but rotation will be in the
Control
Mode Reverse direction and limited to a maximum of 100 RPM
Joystick
Preset
(Drill
Speed) Test procedure: Select Drill position with the Top Drive Selection Switch and start an
Mode)
HPU if one is not running, verify that you are in Drill mode and your BUW is open and
quill is free to rotate. Enter a preset value of 100 RPM toggle the joystick to the right
and the speed will ramp to 100 RPM. Change the Preset value to 75 RPM and toggle
the JS to the right again the speed will ramp down to 75 RPM. (Keep the TD rotating
for the next step)
TD Motor TD Motor Control Joystick Left (Drill Mode) Toggling the joystick Left will ramp the TD
Control Left (Drill speed down to Zero speed.
Joystick Mode Zero Test procedure: With the TD still rotating, Toggle the TD Motor Control Joystick to
(Drill Speed) the left. Verify that the speed ramps down to Zero RPM and remains there.
Mode)
TD Motor Test procedure: In drill mode toggle the drill Reverse PB so the TD mode is selected
Control to drill reverse. Function the TD Mode Joystick up, down, and left to ensure that it
Drill functions the same in reverse as it does in forward with the exception of the RPM
Joystick
Reverse limited to 100 RPM. (There is NO preset in reverse)
(Drill
Mode)
Comments

Form 253 Rev. 1 Feb. 2014

M13931 - 23 - On-site Commissioning Rev 0

 Function /
Control DESCRIPTION OK INITIAL
Position
Holding the TD Motor Control Joystick Left (Spin in) with drill enabled and selected to
Torque mode will rotate the TD at the Preset Spin speed in the forward direction.
TD Motor When the Joystick is released the TD will stop spinning.
Control
Left Test procedure: Select Drill position with the Top Drive Selection Switch and start an
Joystick
(Spin In) HPU if one is not running, verify that you are in Torque mode and your BUW is open
(Torque
Mode) and quill is free to rotate, select 20 RPM for a spin speed. Hold the JS to the Left, the
TD will rotate forward at 20 RPM, when the JS is released the TD will stop rotating

Holding the TD Motor Control Joystick Right (Spin Out) with drill enabled and selected
to Torque mode will rotate the TD at the Preset Spin speed in the Reverse direction.
TD Motor When the Joystick is released the TD will stop Rotating.
Control
Right (Spin
Joystick Test procedure: Select Drill position with the Top Drive Selection Switch and start an
Out)
(Torque HPU if one is not running, verify that you are in Torque mode and your BUW is open
Mode) and quill is free to rotate, select 20 RPM for a spin speed. Hold the JS to the Left, the
TD will rotate reverse at 20 RPM, when the JS is released the TD will stop rotating

Holding the TD Motor Control Joystick Up (Make Up) with drill enabled and selected to
Torque mode will rotate the TD Forward at 15 RPM as long as you are holding the JS
TD Motor up. The torque will be limited to the set Make up limit, but the torque and ramping will
Control be tested later in the torque section of this document.
Up
Joystick
(Make Up) Test procedure: Select Drill position with the Top Drive Selection Switch and start an
(Torque HPU if one is not running, verify that you are in Torque mode and your BUW is open
Mode) and quill is free to rotate. Set the Make up torque to 10 000 ft/lbs. move the joystick up
and hold it there thew TD will rotate forward at 15 RPM until the joystick is released.

Holding the TD Motor Control Joystick Down (Breakout) with drill enabled and
selected to Torque mode will rotate the TD Reverse at 15 RPM as long as you are
TD Motor holding the JS up. The torque will be limited to the Maximum intermittant torque listed
Control in the specs, but the torque and ramping will be tested later in the torque section of
Down this document.
Joystick
(Breakout) Test procedure: Select Drill position with the Top Drive Selection Switch and start an
(Torque
Mode) HPU if one is not running, verify that you are in Torque mode and your BUW is open
and quill is free to rotate. Move the joystick down and hold it there thew TD will rotate
reverse at 15 RPM until the joystick is released.

Form 253 Rev. 1 Feb. 2014

M13931 - 24 - On-site Commissioning Rev 0

 Now test the HMI Back up Motor Control Joystick functionality from the HMI Back up Joystick screen, the functionality
should be the same as the Joystick.
Function /
Control DESCRIPTION OK INITIAL
Position
Activating MC Back up Joystick will enable the HMI Back Up joystick and disable the
TD Motor
HMI - joystick from functioning.
Control
Activate MC Test procedure: Try and activate the MC Backup joystick from the HMI, it should not
HMI Back
Back Up function. Toggle the "Activate MC Back UP JS" HMI button, try and function the
up
Joystick physical joystick, it should not function. Function the HMI BU JS, as per below, it
Joystick
should be completly functional
Toggling the TD Motor Control Joystick - BUW Close PB will activate the BUW to
TD Motor Close Once the BUW is closed toggle again to open. BUW Close is interlocked with
HMI - the DW to prevent Damage to the TD and BUW assembly, as well as injury.
Control
PB2 (Red -
Joystick
BUW
Back up Test procedure: Select Trip or Drill position with the Top Drive Selection Switch and
Close)
Joystick start an HPU if one is not running. Toggle the BUW Close PB, the BUW will close.
Toggle again and the BUW will open.
Toggling the TD Motor Control Joystick - "Torque/Drill PB" will toggle the TD Motor
Control Joystick Between Drill and Torque Modes. This will change the Functionality of
TD Motor the Joystick - The "TD Mode" Indication on the HMI - Drill, Backup Joystick, and Trip
HMI - Screens will indicate "Top Drive In Torque Mode" or "Top Drive in Drill mode"
Control
PB4 (Green
Joystick
-Torque
Back up Test procedure: Select Drill position with the Top Drive Selection Switch. Toggle the
/Drill)
Joystick Torque/Drill PB, and Verify that the "TD Mode" status changes back and forth as
toggled between "Top Drive In Torque Mode" or "Top Drive in Drill mode".

Toggling the TD Motor Control Joystick - "Drill Reverse PB" will toggle the TD Motor
Direction Between Forward and Reverse, this button is active only if the TD mode is
selected to Drill Mode. The "TD Mode" Indication on the HMI - Drill, Backup Joystick,
TD Motor and Trip Screens will indicate "Top Drive In Drill Mode" or "Top Drive in Drill Reverse "
Control HMI - PB1
Joystick (Black -Drill Test procedure: Select Drill position with the Top Drive Selection Switch and start an
Back up Reverse) HPU if one is not running. Ensure that your TD Mode is selected to "Drill Mode",
Joystick Toggle the Drill Reverse PB, and Verify that the "TD Mode" status changes back and
forth as toggled between "Top Drive In Drill Mode" or "Top Drive in Drill Reverse". You
are now ready test the operating functionality of the Joystick.

Comments

Form 253 Rev. 1 Feb. 2014

M13931 - 25 - On-site Commissioning Rev 0

 Function /
Control DESCRIPTION OK INITIAL
Position
TD Motor Control Joystick up (Drill Mode) Pressing the joystick up will increase speed,
as long as you keep the joystick button Pressed, until maximum speed is reached. At
any time if the joystick is released the speed will be maintained at the value it was at
TD Motor before it was released. With the TD mode in Drill Reverse, the operation will be the
Control HMI - same but rotation will be in the Reverse direction and limited to a maximum of 100
Joystick Up (Drill RPM
(Drill Mode
Mode) Increase Test procedure: Select Drill position with the Top Drive Selection Switch and start an
Back up Speed) HPU if one is not running, verify and your BUW is open and quill is free to rotate. In
Joystick Drill Mode Push the Motor control Joystick button up until the speed ramps up to about
100 RPM. Release the joystick and verify the speed does not change. (Keep the TD
rotating for the next step)

TD Motor Control Joystick down (Drill Mode) Pressing the joystick Down will Decrease
speed, as long as you keep the joystickbutton Pressed, until zero speed is reached. At
TD Motor any time if the joystick is released the speed will be maintained at the value it was at
Control HMI - before it was released. With the TD mode in Drill Reverse, the operation will be the
Joystick Down (Drill same but rotation will be in the Reverse direction.
(Drill Mode
Mode) Decrease Test procedure: With the TD still rotating, Push the TD Motor Control Joystick button
Back up Speed) down and hold it down until it reaches about 50 RPM and release the joystick. Verify
Joystick that the speed remains constant after releasing the JS. Continue moving the TD MC
JS down until zero speed is reached, release the JS and ensure that the TD does not
rotate.
TD Motor Control Joystick Right (Drill Mode) Moving the joystick Right will enter the
preset speed value into the speed referance, and the TD will ramp up speed until the
preset value is acheived. If the Preset value is lower than the actual speed when the
JS is moved to the right, the speed will ramp down to the preset value. When the
TD Motor joystick is released the speed will be maintained at the preset value. With the TD
Control HMI - mode in Drill Reverse, the operation will be the same but rotation will be in the
Joystick Right (Drill Reverse direction and limited to a maximum of 100 RPM
(Drill Mode
Mode) Preset Test procedure: Select Drill position with the Top Drive Selection Switch and start an
Back up Speed) HPU if one is not running, verify that you are in Drill mode and your BUW is open and
Joystick quill is free to rotate. Enter a preset value of 100 RPM toggle the joystick button to the
right and the speed will ramp to 100 RPM. Change the Preset value to 75 RPM and
toggle the JS button to the right again the speed will ramp down to 75 RPM. (Keep
the TD rotating for the next step)

TD Motor TD Motor Control Joystick Left (Drill Mode) Toggling the joystick Left button will ramp
Control the TD speed down to Zero speed.
HMI -
Joystick Test procedure: With the TD still rotating, Toggle the TD Motor Control Joystick
Left (Drill
(Drill button to the left. Verify that the speed ramps down to Zero RPM and remains there.
Mode Zero
Mode)
Speed)
Back up
Joystick
Comments

Form 253 Rev. 1 Feb. 2014

M13931 - 26 - On-site Commissioning Rev 0

 Function /
Control DESCRIPTION OK INITIAL
Position
TD Motor Test procedure: In drill mode toggle the drill Reverse PB so the TD mode is selected
Control to drill reverse. Function the TD Mode Joystick buttons up, down, and left to ensure
Joystick that it functions the same in reverse as it does in forward with the exception of the
HMI - Drill RPM limited to 100 RPM and no preset speed.
(Drill
Reverse
Mode)
Back up
Joystick
Pressing the TD Motor Control Joystick Left button (Spin in) with drill enabled and
TD Motor selected to Torque mode will rotate the TD at the Preset Spin speed in the forward
Control direction. When the Joystick button is released the TD will stop spinning.
Joystick
HMI - Left
(Torque Test procedure: Select Drill position with the Top Drive Selection Switch and start an
(Spin In)
Mode) HPU if one is not running, verify that you are in Torque mode and your BUW is open
Back up and quill is free to rotate, select 20 RPM for a spin speed. Press the JS left button, the
Joystick TD will rotate forward at 20 RPM, when the JS button is released the TD will stop
rotating
Holding the TD Motor Control Joystick Right button(Spin Out) with drill enabled and
TD Motor selected to Torque mode will rotate the TD at the Preset Spin speed in the Reverse
Control direction. When the Joystick button is released the TD will stop Rotating.
Joystick
HMI - Right
(Torque Test procedure: Select Drill position with the Top Drive Selection Switch and start an
(Spin Out)
Mode) HPU if one is not running, verify that you are in Torque mode and your BUW is open
Back up and quill is free to rotate, select 20 RPM for a spin speed. Hold the JS Right button,
Joystick the TD will rotate reverse at 20 RPM, when the JS button is released the TD will stop
rotating
Toggling the TD Motor Control Joystick - "Spin Maintatin" PB with drill enabled and
selected to Torque mode will give you a 2 second window to toggle the joystick left or
right (Spin In or Spin Out), Spin in or spin out will be latched on to rotate the TD in
spin mode indefinitely un till the joystick is move in any direction again, or the Spin
TD Motor maintain PB is toggled again.
Control
HMI - PB3 Test procedure: Select Drill position with the Top Drive Selection Switch and start an
Joystick
(Yellow - HPU if one is not running, verify that you are in Torque mode and your BUW is open
(Torque and quill is free to rotate, select 20 RPM for a spin speed. Toggle the spin maintain PB
Spin
Mode)
Maintain) once and witin 2 seconds, toggle the TD MC JS left, the TD should rotate forward, at
Back up 20 RPM and maintain that speed until the spin maintain PB is toggled to the right or
Joystick spin maintain is toggled again. Repeat the test for Spin out (JS Right) and this time
toggle the joystick to the left to disable from spin maintain, then test that toggling the
spin maintain PB again disables spin maintain.

Holding the TD Motor Control Joystick Up button (Make Up) with drill enabled and
selected to Torque mode will rotate the TD Forward at 15 RPM as long as you are
TD Motor holding the JS up. The torque will be limited to the set Make up limit, but the torque
Control and ramping will be tested later in the torque section of this document.
Joystick
HMI - Up
(Torque
(Make Up) Test procedure: Select Drill position with the Top Drive Selection Switch and start an
Mode)
HPU if one is not running, verify that you are in Torque mode and your BUW is open
Back up
and quill is free to rotate. Set the Make up torque to 10 000 ft/lbs. press the joystick up
Joystick
button and hold it there, the TD will rotate forward at 15 RPM until the joystick button
is released.

Form 253 Rev. 1 Feb. 2014

M13931 - 27 - On-site Commissioning Rev 0

 Function /
Control DESCRIPTION OK INITIAL
Position
Holding the TD Motor Control Joystick Down (Breakout) with drill enabled and
selected to Torque mode will rotate the TD Reverse at 15 RPM as long as you are
TD Motor holding the JS up. The torque will be limited to the Maximum intermittant torque listed
Control in the specs, but the torque and ramping will be tested later in the torque section of
Joystick HMI - this document.
(Torque Down Test procedure: Select Drill position with the Top Drive Selection Switch and start an
Mode) (Breakout) HPU if one is not running, verify that you are in Torque mode and your BUW is open
Back up and quill is free to rotate. Press the joystick button down and hold it there the TD will
Joystick rotate reverse at 15 RPM until the joystick button is released.

When selected to wired, the Encoder feedback signal runs from the TD to the GDP
panel where it will feed an optical isolator. The output of the optical isolator will be
hardwired down to the VFD.
Test procedure 1: At the GDP, make sure the TD Encoder feedback is selected to
wired with the "Encoder feedback" key switch, the HMI Help and Maintenance screen
should display the following message "Encoder Switched to Wired feedback between
the Top Drive and the Drillers Cabin - Check TD transmitter and drill cabin Reciever"
Encoder Test procedure 2: Select Drill position with the Top Drive Selection Switch and start
Encoder
Feedback an HPU if one is not running, verify that you are in Drill mode. Rotate the TD at 50
Feedback
selected to RPM, Take scope readings of A, and B signals and then A/ and B/, increase RPM to
Test
Wired 150 RPM and record A, and B signals and then A/ and B/, increase RPM to 250 RPM
and record A, and B signals and then A/ and B/ all at the GDP. Test procedure 3:
Take readings at the VFD - Rotate the TD at 50 RPM, Take scope readings of A, and
B signals and then A/ and B/, increase RPM to 150 RPM and record A, and B signals
and then A/ and B/, increase RPM to 250 RPM and record A, and B signals and then
A/ and B/ all at the VFD.

Capture Encoder Feedback from the above readings and attach to this document
Comments

Form 253 Rev. 1 Feb. 2014

M13931 - 28 - On-site Commissioning Rev 0

 Function /
Control DESCRIPTION OK INITIAL
Position
Brakes switched on, HMI will display that the brakes are on, brakes will apply, Brakes
off the TD will rotate freely. Brakes will release if applied during the torque and spin
modes
Test procedure 1: Select Drill position with the Top Drive Selection Switch and verify
that you are in drill mode, start an HPU if one is not running. Set the brakes on the
top drive using the "Brake On" Switch, enter a preset speed of 10 RPM and start with
a drill limit of 10 000 Ft/lbs. toggle the TD MC joystick to the right. Slowly increase
your drilling torque limit with 10 000 ft/lb increments until you reach 47 000 ft/lbs,
observe the torque on the display, and verify that the brakes hold. As well verify that
your torque limit entered matches the actual torque display on the HMI analog and
Brake digital gauges. Toggle the TD MC joystick to the left and the torque should ramp down
On
Switch to zero.

Test Procedure 2: With the TD still in Drill enable toggle TD switch so that the TD is
in torque mode. Move the joystick to the left (spin in) the brakes should automatically
release and the TD should spin freely at the the preset spin speed.

Test Procedure 3: With the TD still in Drill enable and in torque mode. Set the
brakes, click on the make up torque box on the main screen and enter a value of
10,000 ft/lbs, push and hold the torque up button observe the brakes release and the
quill will turn at 15 RPM until the button is released.

While Drilling if the TD Torque ramp down HMI PB is pressed the speed will decrease
to 12 RPM and the Torque will slowly ramp down. If torque restore is pressed the
speed will remain at 12 RPM and the set torque linit will be restored back to the TD.

Test procedure 1: Select Drill position with the Top Drive Selection Switch and verify
that you are in drill mode, start an HPU if one is not running. Enter a preset speed of
Torque 20 RPM and a drill limit of 10 000 Ft/lbs. Press the Torque Ramp down button, the
Ramp speed will decrease 15 RPM, toggle the TD MC joystick to the right (Preset) and the
Down/ HMI PB's speed will ramp back to 20 RPM.
Torque
Restore Test Procedure 2: With the TD still in Drill enable and drill mode, set the brakes,
toggle your MC JS with a preset speed of 20 RPM and a drill limit of 10 000 Ft/lbs.
The TD should stall at 10 000 ft/lbs, toggle the Torque rampdown PB the torque
should ramp down to zero, toggle the Torque restore PB and the torque should
immediately restore to the set torque limit of 10 000 ft/lbs. Release the brake and the
TD should rotate at 15 RPM.

Comments

Form 253 Rev. 1 Feb. 2014

M13931 - 29 - On-site Commissioning Rev 0

 Function /
Control DESCRIPTION OK INITIAL
Position
Ensure that the Drill torque requested, displayed, and measured are all within
tolerance. All personnel must be clear of the rig floor prior to this test being completed
Maximum torque will be limited by the maximum torque of the smallest connection +
TJ clamp torque force.

Drill Mode
Torque
Limits and Torque Test Test procedure: Step 1: Select Drill position with the Top Drive Selection Switch and
actual verify that you are in drill mode, start an HPU if one is not running. Step 2: The TD
torque must be screwed into a small pup joint or equivalent. Step 3 Install tongs (in
conjunction with a calibrated load cell) onto the pup joint at a 90 degree angle to
the TD. Step 4: Select 5000 ft/lbs for a drill limit. Step 5: Select 10 RPM for a preset
speed, and toggle the joystick to the right (preset) the tongs will tighten up. Step 6:
Increase the torque per the increments on the following page and fill out the results..

Record data below. Load cell reading should be within 1 000 ft/lbs up to 10 000 ft/lbs requested and
within 5% of requested above 10 000 ft/lbs.

Drill Torque Test Data OK INITIAL

5,000 FT/LBS requested 5000 FT/LBS expected FT/LBS Display: FT/LBS Load cell:

10,000 FT/LBS requested 10,000 FT/LBS expected FT/LBS Display: FT/LBS Load cell:

20,000 FT/LBS requested 20,000 FT/LBS expected FT/LBS Display: FT/LBS Load cell:

30,000 FT/LBS requested 30,000 FT/LBS expected FT/LBS Display: FT/LBS Load cell:

40,000 FT/LBS requested 40,000 FT/LBS expected FT/LBS Display: FT/LBS Load cell:

50,000 FT/LBS requested 50,000 FT/LBS expected FT/LBS Display: FT/LBS Load cell:

Comments: L.C. S/N and Calibration Certs

Form 253 Rev. 1 Feb. 2014

M13931 - 30 - On-site Commissioning Rev 0

 Function /
Control DESCRIPTION OK INITIAL
Position
Now that the Torque has been verified to be accurate, we can test the Make up and Breakout functionality and
ensure that the ramp times are adequate.

Check Spin in and Make Up sequence

Test Procedure: Will need a test sub or joint of pipe in the slips. Select Drill position
TD Motor with the Top Drive Selection Switch and verify that you are in torque mode, start an
Spin In (JS
Control HPU if one is not running. lower the TD into the box of the sub or pipe, select spin in
Left) &
Joystick (JS left). Once the pipe shoulders up, close the gripper and select Make up (JS up)
Make Up
(Torque the Torque will ramp up to the selected Makeup limit, hold for one second, the torque
(JS Up)
Mode) will then ramp back down. The joystick can then be released.

Check Spin out and Breakout sequence

Test Procedure: Will need a test sub or joint of pipe in the slips. Select Drill position
TD Motor with the Top Drive Selection Switch and verify that you are in torque mode, start an
Control Breakout HPU if one is not running. Close the gripper on the TJ, when the joint breaks,bring the
Joystick (JS down) & joystick back to the center position and toggle the BUW open, select Spin out (joystick
(Torque (JS right) right).
Mode)

Comments:

Form 253 Rev. 1 Feb. 2014

M13931 - 31 - On-site Commissioning Rev 0

 Repeat the Torque test in Torque Mode and record the results
Function /
Control DESCRIPTION OK INITIAL
Position
Ensure that the Make up torque requested, displayed, and measured are all within
tolerance. All personnel must be clear of the rig floor prior to this test being completed
Maximum torque will be limited by the maximum torque of the smallest connection +
TJ clamp torque force.

Torque
Mode
Test procedure: Step 1: Select Drill position with the Top Drive Selection Switch and
Torque
Torque Test verify that you are in torque mode, start an HPU if one is not running. Step 2: The TD
Limits and
must be screwed into a small pup joint or equivalent. Step 3 Install tongs (in
actual
conjunction with a calibrated load cell) onto the pup joint at a 90 degree angle to
torque
the TD. Step 4: Select 5000 ft/lbs for a Make up limit. Step 5: Select 10 RPM for a
preset spin speed, and toggle the joystick to the left (spin in) the tongs will tighten up
go to make up (MC JS Up), the torque will ramp to the Make up torque limit value and
then ramp back down. Step 6: Increase the torque per the increments on the following
page and fill out the results..

Record data on the below Load cell reading should be within 1000 ft/lbs up to 10 000 ft/lbs requested and
within 5% of requested above 10 000 ft/lbs.
5,000 FT/LBS requested 5000 FT/LBS expected FT/LBS Display: FT/LBS Load cell:

10,000 FT/LBS requested 10,000 FT/LBS expected FT/LBS Display: FT/LBS Load cell:

20,000 FT/LBS requested 20,000 FT/LBS expected FT/LBS Display: FT/LBS Load cell:

30,000 FT/LBS requested 30,000 FT/LBS expected FT/LBS Display: FT/LBS Load cell:

40,000 FT/LBS requested 40,000 FT/LBS expected FT/LBS Display: FT/LBS Load cell:

50,000 FT/LBS requested 50,000 FT/LBS expected FT/LBS Display: FT/LBS Load cell:

Comments

Once this test is completed satisfactorily, the load cell and tongs can be removed as they will no longer be needed for
commissioning

Form 253 Rev. 1 Feb. 2014

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 Function /
Control DESCRIPTION OK INITIAL
Position
Testing the Maximum Make up Torque available on the TD, Maximum will be 77
824 Ft/lbs in Make Up.

Max ***Make Sure all of the 6 and 5/8" connections are properly torqued and tool joint
Torque clamps are properly torqued to prevent Slippage***
Make Up Test procedure: Select Drill position with the Top Drive Selection Switch and start an
(Torque
(JS Up) HPU if one is not running. Ensure that your TD Mode is selected to "Torque Mode".
Mode
Make Up) Enter 77 824 Ft/lbs, for a make up limit, close you gripper on the sub to be torqued
and proceed with torque up sequeance, once the Torque reaches 77 824 Ft/lbs, let the
torque ramp back to zero and release the joystick.

Testing the Maximum Breakout Torque available on the TD, Maximum will be 99,000
Max ft/lbs in Breakout
Torque
Breakout
(Torque ***Make Sure all of the 6 and 5/8" connections are properly torqued and tool joint
(JS down)
Mode clamps are properly torqued to prevent Slippage*** During this test we will not actually
Breakout) be breaking out of a connection, we will be testing the maximum torque capability of
the TD and all components.
Comments

Form 253 Rev. 1 Feb. 2014

M13931 - 33 - On-site Commissioning Rev 0

 Function /
Control DESCRIPTION OK INITIAL
Position

In the event of the "PH unlocked sensor fault" this button can be actuated to allow the
operator to make or break a connection, it allows a 30 second window to make or
break a connection, with PH unlocked status.
****Note - The handler must be visually checked to ensure the PH is actually locked
as this bypass is only meant to bypass a sensor problem NOT a lock problem****

Test Procedure: Step 1 At the PLC JB, remove the wire from PLC_R1_M7/T3 Step 2
Select Drill position with the Top Drive Selection Switch and start an HPU if one is not
running. Ensure that your TD Mode is selected to "Torque Mode". you should see "PH
Unlocked - Sensor" message on the Drill and BU JS screens. Step 3 On the TD HMI
Drill or Backup Joystick screen. select 10 000 Ft/lbs "Make up torque" Step4 Close
Bypass Push
the gripper on a TJ, as you would if you were making a connection. You will see the
PH Lock (toggle)
following alarm "GDM-PH Unlocked with the BUW closed - Torque will not be
possible without PH override - PH Lock must be checked first" Step 5 Push the MC
JS in the upward (Make Up) direction the TD will not torque up. push the "Bypass PH
Lock" button, you will see the following alarm "GDM-PH LOCK BYPASSED
*****Check visually to ensure that the handler is locked****" Push the MC JS in the
upward (Make Up) direction again, you now have a 2 minute window to complete your
connection. You should as well see the following alarm "GDM-Torque with PH
Bypassed - Handler must be visually checked to ensure it is locked". All alarms will be
logged to memory for future referance.

Comments

Form 253 Rev. 1 Feb. 2014

M13931 - 34 - On-site Commissioning Rev 0

 Function /
Control DESCRIPTION OK INITIAL
Position

Opens the remote actuated IBOP, HMI Displays the status of the valve.
IBOP
Open
Switch Test Procedure: Select Drill or Trip position with the Top Drive Selection Switch and
start an HPU if one is not running. Select Open with the IBOP switch, observe the
valve is fully opening .

Closes the remote actuated IBOP, HMI Displays the status of the valve.
IBOP
Close Test Procedure: Select Drill or Trip position with the Top Drive Selection Switch and
Switch
start an HPU if one is not running. Select Open with the IBOP switch, observe the
valve is fully opening .
Comments: Mud Pump Simulated

Form 253 Rev. 1 Feb. 2014

M13931 - 35 - On-site Commissioning Rev 0

 Function /
Control DESCRIPTION OK INITIAL
Position

This is intended to allow the driller to automatically move the Pipe handler to any one
of four preset PH positions depending on which positions are activated. Automatic
Auto- HMI PB - mode can be turned on/off from the Drill, Trip, and Backup joystick screens. The
matic Pipe automatic pipe handler can be operated from either the Drill, Backup joystick, or trip
Pipe Handler in screens as well as from the PH Joystick. Set points can only be changed from the trip
Handler Auto Mode screen, but all positions can be activated or de-activated from the Drill or Trip screens.
At 0* the elevators should bo pointing directly at the racking board, at 180* the pipe
handler will be in drill mode (elevator handles pointed towards the draw works)

Test Procedure 1: Select Drill or Trip position with the Top Drive Selection Switch
and start an HPU if one is not running. Rotate the pipe handler in Manual mode and
stop with the elevators pointed towards the Monkey board or mouse hole, the handler
Auto- HMI PB -
position should be at 0*, if it is not press the "zero PH position" button on the Trip
matic Pipe
screen, this will set the Handler position to zero. Test Procedure 2: Trip Screen -
Pipe Handler in
Enter 45* for Handler Trip Pos #1, Enter 315* for Handler Trip Pos #2, Enter 180* for
Handler Auto Mode
Handler Drill Position. Procedure 3: Toggle the Pipe handler manual mode PB to
Auto mode. Activate Trip Pos #1, Trip Pos #2, Drill Pos, and Zero Pos from either the
trip or Drill Screens, put the link tilt cylinders in float.

Procedure 4: Start from position 0*. From either the Drill or Trip screen, toggle the
Unlock Handler HMI PB, and within 3 seconds toggle the right (reverse) arrow, the TD
PH will rotate to the left and stop at 45*. Toggle the handler unlock & forward arrow
Auto- HMI PB - again, the TD will rotate to the right and stop at 180*. Toggle the handler unlock &
matic Pipe forward arrow again, the TD will rotate to the right and stop at 315*. Toggle the
Pipe Handler in handler unlock forward arrow again, the TD will rotate to the right and stop at 0*.
Handler Auto Mode Procedure 5: Toggle the Unlock Handler HMI PB, and within 3 seconds toggle the left
(Reverse) arrow, the TD PH will rotate to the left and stop at 315*. Toggle the handler
unlock & "Activate Zero Pos" the TD PH will move to the right and stop at 0 * (When
the "Activate Zero Pos" is toggled the TD moves in the closest direction to zero).

Comments

Form 253 Rev. 1 Feb. 2014

M13931 - 36 - On-site Commissioning Rev 0

 Function /
Control DESCRIPTION OK INITIAL
Position
Repeat the above test procedure using the joystick controls. Whe the Automatic Pipe
Joystick handler is in automatic mode, the joystick PH unlock PB and left and right joystick
Automatic Operation- movements work the same as the HMI push buttons above.
Pipe Pipe
Handler Handler in
Auto Mode
Test Procedure : Repeat the above procedure with the joystick controls. Everything
Joystick should operate the same with the exception of the "move to zero" PB as this is not
Automatic Operation- available when using the joystick.
Pipe Pipe
Handler Handler in
Auto Mode

Repeat the above test procedure using the Back Up joystick screen controls. Whe the
Back Up
Automatic Pipe handler is in automatic mode, the Back Up joystick PH unlock PB and
Joystick
Automatic left and right joystick movements work the same as the HMI push buttons above.
Operation-
Pipe
Pipe
Handler
Handler in
Auto Mode
Test Procedure : Repeat the above procedure with the Back Up joystick controls.
Back Up Everything should operate the same with the exception of the "move to zero" PB as
Joystick this is not available when using the Back Up joystick controls.
Automatic
Operation-
Pipe
Pipe
Handler
Handler in
Auto Mode

Comments

Form 253 Rev. 1 Feb. 2014

M13931 - 37 - On-site Commissioning Rev 0

 5) TOP DRIVE ALARM AND WARNINGS
TEST PROCEDURE

Form 253 Rev. 1 Feb. 2014

M13931 - 38 - On-site Commissioning Rev 0

 TOP DRIVE ALARM AND WARNINGS TEST PROCEDURE
Power Faults Descriptions OK Initial

Top Drive 24V Cause and effect: Alarm for lost main power supply, back up supply
Primary supply still operating TD, still functional

Test procedure: Remove fuse "1F" on TB 22 Note alarm on GDS HMI

screen.

Top Drive 24V Cause and effect: Alarm for lost back up power supply, only primary
Back up supply supply still operating, TD still functional

Test procedure: Remove fuse "2F" on TB 22 Note alarm on GDS HMI

screen.

GDP 24V Cause and effect: Alarm for lost main power supply, only back up
Primary supply supply still operating, TD still functional

Test procedure: Remove fuse "4F" on TB 20 Note alarm on GDS HMI

screen.

GDP 24V Back Cause and effect: Alarm for lost back up power supply, only primary
up supply supply still operating, TD still functional

Test procedure: Remove fuse "5F" on TB 20 Note alarm on GDS HMI

screen.

GDP 24V Both Cause and effect: Alarm for loss of both power supplies, TD will no
supplies longer function

Test procedure: Remove 24 volt status to the Main PLC from each
24VDC power Supply.
Comments:

Form 253 Rev. 1 Feb. 2014

M13931 - 39 - On-site Commissioning Rev 0

 Signal Errors Descriptions OK Initial

Cause and effect: signal error for failed RTD sensor. Temperature Out
TD Lube Oil
of Range Error on the Analog Screen, Alarm on the TD HMI, TD still
Temp
functional

Test procedure At the TD PLC JB, remove wire from

PLC_R1_M11/T2. Note alarm on GDS HMI screen, as well as
indication on the Analog Screen

Cause and effect: signal error for failed RTD sensor. Temperature Out
TD Ambient
of Range Error on the Analog Screen, Alarm on the TD HMI, TD still
Temp
functional

Test procedure At the TD PLC JB, short PLC_R2_M2/6 to

PLC_R2_M2/T7. Note alarm on Top Drive Diagnostics screen. Note
alarm on GDS HMI. Remove wire from PLC_R2_M2/T6. Note alarm
on GDS HMI screen, as well as indication on the Analog Screen

Cause and effect: signal error for failed RTD sensor. Temperature Out
TD Brake Temp of Range Error on the Analog Screen, Alarm on the TD HMI, TD still
functional

Test procedure At the TD PLC JB, short PLC_R2_M2/T12 to

PLC_R2_M2/T13. Note alarm on Top Drive Diagnostics screen. Note
alarm on GDS HMI. Remove wire from PLC_R2_M2/T12. Note alarm
on GDS HMI screen, as well as indication on the Analog Screen

Cause and effect: signal error for failed RTD sensor. Temperature Out
TD Motor
of Range Error on the Analog Screen, Alarm on the TD HMI, TD still
Winding 1 Temp
functional

Test procedure At the TD PLC JB, short PLC_R2_M2/T0 to

PLC_R2_M2/T1. Note alarm on Top Drive Diagnostics screen. Note
alarm on GDS HMI. Remove wire from PLC_R2_M2/T0. Note alarm
on GDS HMI screen, as well as indication on the Analog Screen

Cause and effect: signal error for failed RTD sensor. Temperature Out
TD Motor
of Range Error on the Analog Screen, Alarm on the TD HMI, TD still
Winding 2 Temp
functional

Test procedure At the TD PLC JB, short PLC_R2_M2/T2 to

PLC_R2_M2/T3. Note alarm on Top Drive Diagnostics screen. Note
alarm on GDS HMI. Remove wire from PLC_R2_M2/T2. Note alarm
on GDS HMI screen, as well as indication on the Analog Screen

Form 253 Rev. 1 Feb. 2014

M13931 - 40 - On-site Commissioning Rev 0

 Signal Errors Descriptions OK Initial

Cause and effect: signal error for failed RTD sensor. Temperature Out
TD Motor
of Range Error on the Analog Screen, Alarm on the TD HMI, TD still
Winding 3 Temp
functional

Test procedure At the TD PLC JB, short PLC_R2_M2/T4 to

PLC_R2_M2/T5. Note alarm on Top Drive Diagnostics screen. Note
alarm on GDS HMI. Remove wire from PLC_R2_M2/T4. Note alarm
on GDS HMI screen, as well as indication on the Analog Screen

Cause and effect: signal error for all Motor RTD sensors failed.
All TD Motor
Temperature Out of Range Errors on the Analog Screen, Alarm on the
Windings Temp
TD HMI, TD still functional

Test procedure: At the TD PLC JB, short/remove PLC_R2_M2/T0,

PLC_R2_M2/T2, PLC_R2_M2/T4 as noted above.Note alarm on GDS
HMI screen, as well as indications on the Analog Screen

Cause and effect Signal error for possible failed pressure switch.
TD Air Flow
Triggered if the air pressure switch on the TD is closed while the TD is
switch
on the AUX position and the blower is NOT running, TD still functional

Test procedure: At the TD PLC JB, remove the N.O wire from
PLC_T4/T2, jump 24VDC into the input, enable the TD in the AUX
position, Note alarm on GDS HMI

Cause and effect: Signal error for pressure sensor. Triggered if the TD
TD Oil pressure
is in the "AUX" position, lube pump is off, and oil pressure is being
sensor
read by the transducer, TD still functional

Test Procedure: With the TD in the AUX position, at the TD PLC JB

remove the wire from PLC_R2_M1/T10 inject a 8 mA signal into the
input. Note alarm at the GDS HMI. Pressure can be read on the Top
Drive Analog Screen

Cause and effect Signal error for disconnected/broken wire or failed

TD Lube Flow
Transducer. Triggered if the 4 to 20 mA transducer current drops
UnderRange
below 3.48 mA.

Test procedure: Remove the wire 401 from PLC_R2_M1/T0 Note

alarm at the GDS HMI and indication on the Top Drive Analog Screen

Form 253 Rev. 1 Feb. 2014

M13931 - 41 - On-site Commissioning Rev 0

 Signal Errors Descriptions OK Initial

TD Hydraulic Cause and effect Signal error for disconnected/broken wire or failed
System Pressure Transducer. Triggered if the 4 to 20 mA transducer current drops
UnderRange below 3.48 mA.

Test procedure: Remove the wire 403 from PLC_R2_M1/T2 Note

alarm at the GDS HMI and indication on the Top Drive Analog Screen

TD Hydraulic Cause and effect Signal error for disconnected/broken wire or failed
Return Pressure Transducer. Triggered if the 4 to 20 mA transducer current drops
UnderRange below 3.48 mA.

Test procedure: Remove the wire 405 from PLC_R2_M1/T4 Note

alarm at the GDS HMI and indication on the Top Drive Analog Screen

TD Hydraulic Cause and effect Signal error for disconnected/broken wire or failed
Temperature Transducer. Triggered if the 4 to 20 mA transducer current drops
UnderRange below 3.48 mA.

Test procedure: Remove the wire 407 from PLC_R2_M1/6 Note alarm
at the GDS HMI and indication on the Top Drive Analog Screen

TD Lube Cause and effect Signal error for disconnected/broken wire or failed
Pressure Before Transducer. Triggered if the 4 to 20 mA transducer current drops
Filter UR below 3.48 mA.

Test procedure: Remove the wire 409 from PLC_R2_M1/T8 Note

alarm at the GDS HMI and indication on the Top Drive Analog Screen

TD Lube Cause and effect Signal error for disconnected/broken wire or failed
Pressure After Transducer. Triggered if the 4 to 20 mA transducer current drops
Filter UR below 3.48 mA.

Test procedure: Remove the wire 411 from PLC_R2_M1/T10 Note

alarm at the GDS HMI and indication on the Top Drive Analog Screen

Cause and effect Signal error for disconnected/broken wire or failed

TD Lube Flow
Transducer. Triggered if the 4 to 20 mA transducer current drops
UnderRange
below 3.48 mA.

Test procedure: Remove the wire 401 from PLC_R2_M1/T0 Note

alarm at the GDS HMI and indication on the Top Drive Analog Screen

Form 253 Rev. 1 Feb. 2014

M13931 - 42 - On-site Commissioning Rev 0

 Signal Errors Descriptions OK Initial

TD Temperature Cause and effect: Signal error for the RTD card in the PLC rack, TD
sensing still functional

At the TD PLC JB pull the RTD card from PLC_R2_M2, Note alarm on
GDS HMI. TD must be in Drill or Trip selection.

TD pressure Cause and effect: Signal error for the Analog card in the PLC rack, TD
sensing still functional

At the TD PLC JB pull the Analog card from PLC_R2_M1, Note alarm
on GDS HMI. TD must be in Drill or Trip selection.

Pipe Handler Cause and effect: signal error for failed PH Encoder. TD still
Encoder Fault functional, Auto Pipe Handler Mode is disabled

At the TD PLC JB, Remove the Encoder module or unplug the PH

encoder at the encoder and rotate the Pipe Handler.Note alarm
Indication that the Pipe Handler Encoder is not Functional,

PH lock (sensor) Cause and effect: Triggered if the PH rotation lock is unlocked and PH
error lock close status remains, TD still functional

Test procedure: At theTD PLC JB remove the wire from

PLC_R1_M4/T2. Install 24VDC jumper on the input, push the "Rotate
Unlock". Observe the alarm on the GDS HMI

Comments:

Form 253 Rev. 1 Feb. 2014

M13931 - 43 - On-site Commissioning Rev 0

 Communi-
Descriptions OK Initial
cation faults

Cause and effect: alarm for loss of communication to both racks at the
Comm Fault TD
TD, alarm, TD will no longer function

Remove 24vdc to the TD PLC JB by opening fuse's "1F" and "2F"on

TB 22 in the GDP. Note the alarm.

Cause and effect: alarm for loss of communication to ET 200 at the

Comm Fault TD
TD, alarm, TD will no longer function

Test procedure: Rotate the TD at 50 RPM At the TD PLC JB remove

Profibus connector on the APB module 1. The TD should shut down.
Note alarm on the GDS HMI. Repeat again with a torque limit of 10
000 ft/lbs and the brakes on, the torque should ramp down before the
TD shuts down

Cause and effect: alarm for loss of communication to ET 200 at the

Comm Fault TD
TD, alarm, TD still functional, loss of analog and temperature readings

Test procedure: Rotate the TD at 50 RPM At the TD PLC JB remove

comm connector on the ET 200. The TD should keep rotating. Note
alarm on the GDS HMI.

Comments:

Form 253 Rev. 1 Feb. 2014

M13931 - 44 - On-site Commissioning Rev 0

 Top Drive
Descriptions OK Initial
Warnings

Lube Filter - Cause and effect: warning for high differential pressure, warning
Differential comes on at 40 PSI and resets at 35 PSI. Pressure read out on the
Pressure High GDS HMI ANALOG screen, top drive still functional

Test procedure: At the TD PLC JB, remove wire 409 from

PLC_R1_M9/T13, inject an adjustable mA signal into the module
Note alarm on Top Drive Diagnostics screen, observe the pressure
reading on the GDS HMI ANALOG screen, top drive still functional

Cause and effect: Alarm for Lube Oil temp, warning comes on at 80
Lube Oil High
degrees C and remains on until 76 degrees C. Temperature read out
Temperature
on the GDS HMI Analog screen, TD still functional.

Test procedure: At the TD PLC JB, check ohm value between

PLC_R1_M11/T6 to PLC_R1_M11/T2. Observe temperature on the
GDS HMI ANALOG screen.

TD Low Lube Cause and effect Alarm for Low Lube Oil Pressure warning comes on
Pressure at 10PSI and resets at 12 PSI

Test procedure: Remove the wire 401 from PLC_R1_M8/T13, inject

an mA signal and note the pressure reading on the GDS HMI analog
screen when the the low pressure alarm appears

TD Low Lube Cause and effect Alarm for Low Lube Oil flow warning comes on at
Flow **GPM and resets at ** GPM

Test procedure: Remove the wire 401 from PLC_R1_M8/T13, inject

an mA signal and note the flow reading on the GDS HMI analog
screen when the the low flow alarm appears

TD Hydraulics - Cause and effect: Increase of Hydraulic return pressure. Set point of
Return Pressure 600 PSI, reset of 500 PSI. Pressure can be viewed on the GDS HMI,
to High analog screen, TD still functional

At the TD PLC JB, remove the wire #405 from PLC_R1_M8/T15,

inject an adjustable mA signal into the card. Note alarm on the GDS
HMI. observe pressure on the GDS analog screen

Form 253 Rev. 1 Feb. 2014

M13931 - 45 - On-site Commissioning Rev 0

 Top Drive
Descriptions OK Initial
Warnings

TD Hydraulics - Cause and effect: monitors HYD system pressure. Set point to go off
Pressure Low at 700 PSI, remain off until 1500 PSI, TD still functional

Test procedure: Shut the both HPU's pressure and return lines at the
base of the derrick, push the AUX button on the TP. Note alarm on the
GDS HMI. observe pressure on the GDS analog screen

Hydraulic - Cause and effect: warning for high hydraulic Temperature warning
Manifold Temp. comes on at 80 degrees C and resets at 76 Degrees C. Temperature
High read out on the GDS analog screen, TD still functional

At the TD PLC JB remove the wire on PLC_R1_M8/T16, inject an

adjustable mA signal into the module to simulate a high temp fault.
Note alarm on Top Drive Diagnostics screen, observe temperature on
the GDS analog screen

Cause and effect: Motor temp display, in degrees Celsius. Warning

Motor comes at 135 degrees C, motor will shut down at 150 degrees C and
Temperature will not re-start until it has dropped below 135*C. Temperature on the
High Shut Down GDS analog screen. TD motor functions unavailable, all Trip functions
still available.

Cause and effect: loss of air flow to the traction motor, will result in
eventual motor shut down if drilling 15 000 ft lbs or higher for 15
minutes, between 15000 ft/lbs and 45 000 ft/lbs the SD time will be 5
TD Motor - Air
minutes, over 45 000 ft/lbs the SD time will be 1 minute. . The Motor
Flow Low
high temperature SD is reduced from 135*C warning/ 150*C SD to
110*C warning and 135*C SD. TD motor functions unavailable, all Trip
functions still available.

Test procedure: Enable the TD, cover the air intake of the blower.
Note alarm on the GDS HMI.

Form 253 Rev. 1 Feb. 2014

M13931 - 46 - On-site Commissioning Rev 0

 Top Drive
Descriptions OK Initial
Warnings

Brake With Cause and effect: RPM request while the brakes are locked, TD will
Throttle not turn

Apply Brake in drill mode and Ramp RPM up Note Indication on the
GDS HMI.

IBOP Valve
Cause and effect: Triggered when the pumps are running and the
closed with Mud
valve is in the closed position, TD still functional.
Pumps Running

Test procedure: Close the valve and turn the mud pumps on, Note
alarm on the GDS HMI

IBOP activated Cause and effect: Triggered when the valve is activated with both
with HPU OFF HPU's OFF, valve not functional

Test procedure: shut the HPU off, actuate the open or close switch for
the valve, Note alarm on the GDS HMI. When the HPU is turned on
again the valve should open or close dependant on the position of the
switch.

Cause and effect: Warning for high brake temp, warning comes on at
Brake Caliper
80 degrees C and remains on until 70 degrees C. Temperature read
Temp. High
out on the GDS HMI Analog screen, brakes still functional.

Test procedure: At the TD PLC JB remove the wire on

PLC_R1_M11/T7 and insert an adjustable rheostat from
PLC_R1_M11/T7 to PLC_R1_M11/T3, adjust the rheostat to
simulate a high temp fault. Note alarm on Top Drive Diagnostics
screen, observe temperature on the GDS HMI ANALOG screen.

Form 253 Rev. 1 Feb. 2014

M13931 - 47 - On-site Commissioning Rev 0

 Top Drive
Descriptions OK Initial
Warnings

Cause and effect: Triggered if the brake is activated in Drill mode with
Drilling with
a speed request, or if the brakes are activated from on to off with an
brake activated
HPU not running,

Test procedure Step 1: Select Drill position with the Top Drive
Selection Switch and verify that you are in Drill mode, start an HPU if
one is not running. Step 2: Set the brakes, turn off the HPU from the
HMI. Step 3: enter a value of 10,000 ft/lbs and 10 RPM preset Use the
MC JS presets. Step 4: toggle the MC JS right the TD will torque up,
"Brake with Throttle" indicator on the drill screen will come on. Step 5.
turn off the brakes, the alarm will remain on until HPU is started and
actually releases the brakes.

Spin or Torque
Cause and effect: Triggered if the brake is activated and torque or
with brake
spin are selected
activated

Test procedure Step 1: Select Drill position with the Top Drive
Selection Switch and verify that you are in torque mode, start an HPU
if one is not running. Step 2: Set the brakes. Step 3: Use the MC JS
and hold the MC JS left for spin in the TD will brakes will release and
the TD will be free to spin, message on the drill screen "brakes with
Spin torque". push the joystick up and verify that the brakes are still
released tand the TD is free to spin as well error message should
remain.

Cause and effect: comes on if the TD is selected to run in the

Operating encoderless mode at the VFD or from the TD Testing and
Encoderless configuration screen, used as an indicator on the Drill and Backup
Joystick screeens.

Test procedure: At the HMI Testing and configuration screen (user

GDS, password GDS123) switch the unit to encoderless mode,
observe the indicator on the GDS HMI.

Comments:

Form 253 Rev. 1 Feb. 2014

M13931 - 48 - On-site Commissioning Rev 0

 Top Drive
Descriptions OK Initial
Warnings

Cause and effect: triggered if the TD is selected to Drill and the lube
Lube Pump Off pump running signal is not sensed ,TD will shut down after 10 minutes
of rotating.

Test procedure Step : Select Drill position with the Top Drive Selection
Switch and verify that you are in Drill mode. Rotate the TD at 5 RPM
turn the Lube pump off, the TD will shut down after 10 minutes.
Repeat with the brakes on and 10 000 ftlbs torque linit, ensure that the
Torque will unwind before the TD shuts down.

Cause and effect: triggered if the TD is selected to Drill and the

TD Blower not
Blower is turned off or the run status is missing, temperature 120 *C,
running
or if RTD module failure or Motor RTD failures.

Test procedure Step 1: Select Drill position with the Top Drive
Selection Switch and verify that you are in Drill mode.Turn off the
Blower at the breaker. insert an adjustable rheostat from positive RTD
transducer terminal to either of the negative transducer terminals.
Adjust the rheostat to simulate a high temp fault. Note alarm at the
GDS HMI and TD shutdown Alarm.

Cause and effect: triggered if the TD is selected to Drill or trip and

TD HPU #1 Not HPU#1 is selected but not running or the run status has been lost. TD
Running Drill functions still functional, however obviousely the hydraulic
functions are no longer functional.

Test procedure Step : Select trip position with the Top Drive Selection
Switch and select HPU#1. Turn HPU#1 off at the MCC. Note the alarm
on the GDS HMI.

Cause and effect: triggered if the TD is selected to Drill or trip and

TD HPU #2 Not HPU#2 is selected but not running or the run status has been lost. TD
Running Drill functions still functional, however obviousely the hydraulic
functions are no longer functional.

Test procedure Step : Select trip position with the Top Drive Selection
Switch and select HPU#2. Turn HPU#2 off at the MCC. Note the alarm
on the GDS HMI.

Form 253 Rev. 1 Feb. 2014

M13931 - 49 - On-site Commissioning Rev 0

 Top Drive
Descriptions OK Initial
Warnings

Cause and effect: Level switch to monitor the HPU Tank Level, TD
HPU Low Level
Drill functions still functional, alarm indication only.

Test procedure Step : With the TD in Trip selection, disconnect the

input from the level switch to the PLC input at the HPU J-box.

Cause and effect: Temperature RTD and transducer to monitor the

HPU Tank High
HPU Temperature, displays on the TD HMI Analog screen. TD Drill
Temperature
functions still functional, alarm indication only.

Test procedure Step : With the TD in Trip selection, disconnect the

RTD from the transducer positive terminal only (white wire) in the HPU
temperature j-box. insert an adjustable rheostat from positive RTD
transducer terminal to either of the negative transducer terminals.
Adjust the rheostat to simulate a high temp fault. Note alarm at the
GDS HMI and indication on the Top Drive Analog Screen.

IBOP in Auto
Cause and effect: Alarm to indicate that the IBOP is in Auto mode with
mode with the
the HPU off - therefore IBOP will not be able to function
HPU turned off

Test procedure Step : With the TD in Trip selection and an HPU

running, select IBOP Auto with the IBOP switch. Turn the HPU OFF,
note the alarm on the GDS HMI.

Comments:

Form 253 Rev. 1 Feb. 2014

M13931 - 50 - On-site Commissioning Rev 0

 6) TOP DRIVE RUN TEST

Form 253 Rev. 1 Feb. 2014

M13931 - 51 - On-site Commissioning Rev 0

 VERTICAL UNLOADED RUN TEST – TEMPERATURE AND PRESSURE DATA

TIME (Hours) 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5

SPEED (RPM) 0
TORQUE (FT-LB) 0

Ambient *F

A.C. Motor middle temp gun *F

A.C. Motor (RTD 1) *F

A.C. Motor (RTD 2) *F

A.C. Motor (RTD 3) *F

Lube Oil Temp *F

Upper Seals (Bonnet) *F

Upper Main Bearing *F

Lower Main Bearing *F

Pinion bearing Top *F

Pinion Bearing Bottom *F

TB Upper Bearing Temp. *F

TB Lower Bearing Temp. *F

Motor Coupling *F

Hydralic Return *F

Lube Oil Flow (GPM)

System Lube Before Filter (PSI)

System Lube After Filter (PSI)

Differential Lube (PSI)

DS Idler Bearing Top *F

DS Idler Bearing Bottom *F

ODS Idler Bearing Top *F

ODS Idler Bearing Bottom *F

Lube Cooler IN *F

Lube Cooler OUT *F

* NOTE: ALL TEMPERATURES TO BE RECORDED IN *F

Form 253 Rev. 1 Feb. 2014

M13931 - 52 - On-site Commissioning Rev 0

 VERTICAL UNLOADED RUN TEST – TEMPERATURE AND PRESSURE DATA

TIME (Hours) 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5

SPEED (RPM)
TORQUE (FT-LB)

Ambient *F

A.C. Motor middle temp gun *F

A.C. Motor (RTD 1) *F

A.C. Motor (RTD 2) *F

A.C. Motor (RTD 3) *F

Lube Oil Temp *F

Upper Seals (Bonnet) *F

Upper Main Bearing *F

Lower Main Bearing *F

Pinion bearing Top *F

Pinion Bearing Bottom *F

TB Upper Bearing Temp. *F

TB Lower Bearing Temp. *F

Motor Coupling *F

Hydralic Return *F

Lube Oil Flow (GPM)

System Lube Before Filter (PSI)

System Lube After Filter (PSI)

Differential Lube (PSI)

DS Idler Bearing Top *F

DS Idler Bearing Bottom *F

ODS Idler Bearing Top *F

ODS Idler Bearing Bottom *F

Lube Cooler IN *F

Lube Cooler OUT *F

* NOTE: ALL TEMPERATURES TO BE RECORDED IN *F

Form 253 Rev. 1 Feb. 2014

M13931 - 53 - On-site Commissioning Rev 0

 VERTICAL LOADED RUN TEST – TEMPERATURE AND PRESSURE DATA

TIME (Hours) 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5

SPEED (RPM) 0
TORQUE (FT-LB) 0

Ambient *F

A.C. Motor middle temp gun *F

A.C. Motor (RTD 1) *F

A.C. Motor (RTD 2) *F

A.C. Motor (RTD 3) *F

Lube Oil Temp *F

Upper Seals (Bonnet) *F

Upper Main Bearing *F

Lower Main Bearing *F

Pinion bearing Top *F

Pinion Bearing Bottom *F

TB Upper Bearing Temperature *F

TB Lower Bearing Temperature *F

Motor Coupling *F

Hydralic Return *F

Lube Oil Flow (GPM)

System Lube Before Filter (PSI)

System Lube After Filter (PSI)

Differential Lube (PSI)

DS Idler Bearing Top *F

DS Idler Bearing Bottom *F

ODS Idler Bearing Top *F

ODS Idler Bearing Bottom *F

Lube Cooler IN *F

Lube Cooler OUT *F

* NOTE: ALL TEMPERATURES TO BE RECORDED IN *F

Form 253 Rev. 1 Feb. 2014

M13931 - 54 - On-site Commissioning Rev 0

 VERTICAL LOADED RUN TEST – TEMPERATURE AND PRESSURE DATA

TIME (Hours) 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5

SPEED (RPM)
TORQUE (FT-LB)

Ambient *F

A.C. Motor middle temp gun *F

A.C. Motor (RTD 1) *F

A.C. Motor (RTD 2) *F

A.C. Motor (RTD 3) *F

Lube Oil Temp *F

Upper Seals (Bonnet) *F

Upper Main Bearing *F

Lower Main Bearing *F

Pinion bearing Top *F

Pinion Bearing Bottom *F

TB Upper Bearing Temperature *F

TB Lower Bearing Temperature *F

Motor Coupling *F

Hydralic Return *F

Lube Oil Flow (GPM)

System Lube Before Filter (PSI)

System Lube After Filter (PSI)

Differential Lube (PSI)

DS Idler Bearing Top *F

DS Idler Bearing Bottom *F

ODS Idler Bearing Top *F

ODS Idler Bearing Bottom *F

Lube Cooler IN *F

Lube Cooler OUT *F

* NOTE: ALL TEMPERATURES TO BE RECORDED IN *F

Form 253 Rev. 1 Feb. 2014

M13931 - 55 - On-site Commissioning Rev 0

 7) TOP DRIVE HOLE CENTER

Form 253 Rev. 1 Feb. 2014

M13931 - 56 - On-site Commissioning Rev 0

 Top Drive Alignment and Travel
TOP DRIVE INITIAL ALIGNMENT OK INITIAL
Check for quill centering over well when Top Drive is positioned
at floor as follows below:
1. Ensure the bales and elevators are installed on the TD

2. Put a stand of pipe in the slips with the box at connection

height
3. Lower the TD so that the lower IBOP valve is going into the
center of the box tolerance is +/- 1/2"
4. Adjust the TD jacking bolts in or out if necessary

Comments

Form 253 Rev. 1 Feb. 2014

M13931 - 57 - On-site Commissioning Rev 0

 TOP DRIVE TRAVEL OK INITIAL
Visual inspection: Ensure the top drive has been checked for
loose bolts, foreign objects, materials, etc that could pose a
hazard.

Slowly hoist the top drive over its entire travel range while
watching the weight indicator, visually verify clearances, use
caution when approaching the racking board and the crown

Comments

Form 253 Rev. 1 Feb. 2014

M13931 - 58 - On-site Commissioning Rev 0

 NOTES

Form 253 Rev. 1 Feb. 2014

M13931 - 59 - On-site Commissioning Rev 0