Catwalk

Project SLR T1000 Ecuador Rig #1

Product SmartCat, type SC 3,6-45

Doc Title User Manual Rev 01

Doc No 25-215-GP21-A-XE-101 Page 53 of 229

4 COMMISSIONING AND OPERATION

4.1 Mechanical Completion – Check List

4.1.1 Signature card

Mechanical Completion

Catwalk Machine

Serial Number: …………………………………

Approved ready for Energizing(IAT/ FAT)(Mandatory)

………………………………………………….. Name (Block Letters) of Cameron representative

………………………………………………….. Sign.

………………………………………………….. Date

Approved ready for SHIPMENT(Mandatory)


………………………………………………….. Sign.

………………………………………………….. Date

Approved ready for PRE-COMMISSIONING(Optional)


………………………………………………….. Sign.

………………………………………………….. Date





4.1.2 Introduction

4.1.2.1 Purpose

The purpose of this procedure is to show how to perform mechanical completion for a Cameron product in order to ensure the product is as complete as possible at defined stages in the delivery, and that the necessary safety actions and reviews has been performed before energizing. The MC activities also include component/item identification by registering serial numbers on components.

4.1.2.2 Objective

The initial energizing/pressurization of equipment is the most safety critical point during a project and must be managed with zero ambiguity. Utilizing Mechanical Completion Check Lists in conjunction with simple permit and HRA/SJA to work is the most effective way to manage the energizing/pressurization of equipment in an environment where multiple phases of a project are concurrent in the same geographic location. The MC processes to take place prior to energizing for IAT, and at site prior to Pre-Commissioning activities starts.

4.1.2.3 Scope

Mechanical Completion is an activity that starts at the project kick-off and ends when the product/system commissioning is completed. As a contract normally is limited to product delivery plus commissioning support, the MCCR’s shall be completed only at:

• Sub-Contractor(Part 1): At manufacturer’s facility. (Where the IAT/FAT has taken place) Additional to Mechanical Completion the MCCRs contain checks for Final Inspection. Due to drilling equipment often being partially completed during IAT/FAT final assembly, touch-up painting, preservation etc. have to wait until rig down and packing process start – therefore:

• Final Inspection(Part 2): To take place at manufacturer’s facility. (Where the IAT/FAT has taken place and prior to closing transport boxes).

If projects have contractual clauses specifying mechanical completion to be done according to client own standards - contractual obligation overrules the contents of this document. Part 3 will then prevail.





4.1.3 Mechanical Completion (MC) Principles

4.1.3.1 Overall Goal

• The overall goal of Mechanical Completion is to verify the completeness of the product and ensure safe testing.

• The Mechanical Completion Check Lists must be established and issued before MC activities start – both at sub-contractor, at test facility, – and if agreed in contract at yard/rig.

• Product deliveries shall be as complete as possible prior to shipment.

• Repeating of MC checks shall be avoided, wherever possible.

• Any carry over work (COW) shall be avoided where possible. Where COW is required the tasks shall be identified at the punch list. The punches shall ASAP be loaded into the ONCE punch system.

4.1.3.2 Responsibilities

MC execution at Sub-contractor shall be executed by the sub-contractor, and if called for - checked and verified by Cameron Product Controller. The MC shall be carried out prior to energizing the product, followed up during the test phase, and completed prior to FAT of the product. Final Inspection shall also be executed by sub-contractor. If called for Cameron Product Controller shall check & verify. The Final Inspection shall be carried out after FAT completion and final preservation has been carried out, but prior to closing boxes for transport. MC execution at Site shall be executed as agreed and specified in contract (normally yard). MCCR’s for use at site are proposals by Cameron. If client prefer they may be used as presented, alternatively the checks may be used as input to the client/yard overall MC.





4.1.3.3 Documentation for a MC Package

Mechanical Completion Check Records are forms that shall be completed in two (or three) stages – (depending on the equipment and contract): Sub-contractor: Prior to energizing the equipment at test facility. Final Inspection: Prior to closing boxes for shipment. Option At Site: If agreed in contract: After completion of installation – but prior to energize the product/system for pre-commissioning activities. All products, by Product Manager, must establish PD specific Mechanical Completion (Check Lists), (XF-030) for their equipment.

• Relevant MCCRS from this SP should be copied to the PD document.

• MCCRs from this SP that are not applicable shall be deleted from the PD versions.

• Check points not applicable for any of the stages should to be marked N/A.

• Project/Product specific MC requirements must be listed in the MCCR named “Equipment Specific”.

• The MCCR’s shall be attached and be part of the document: Mechanical Completion (Check Lists), ref doc.code XF-030.

The PD version shall be used as basis for the project deliveries. The MCCR lists to be completed by the PDT as applicable for all 3 phases. If project specific MCCR’s are required these should be made with the PD version as template.

4.1.3.4 Using the MCCR’s

The MCCR are “live” documents that shall follow the product through the stages:

• Assembly, IAT & FAT

• Preservation/packing

• Option: At site (after installation & prior to commissioning).

It is the Production Controller’s responsibility to make sure the MCCR’s are completed as applicable for stages prior to delivery. When the MCCR’s are completed prior to delivery the signed MCCR’s shall be attached and part of the MC Report – Prior to Delivery, doc no XG-030. The XG-030 shall be available and part of the Product Handover Meeting. It is recommended for Cameron I&C manager to provide themselves a copy/set of the completed: MC Report – Prior to Delivery, doc no XG-030, as these will confirm Mechanical Completion checks taken place prior to delivery.





4.1.3.5 References

Document ID Document Title / Description

-GP21-A-XM-001 General Arrangement Drawing

20036382 Catwalk Main Assembly

20035939 Substrucure

20037016 Lower Ramp

20036268 Upper Ramp

20036819/ 20037194 Walking and Elevating Legs No1 and No2

20036933/ 20036628 Front Legs DS and ODS

20036540 Telescopic Frame

20035398 Tubular Feeding Units

20036262 Pusher

20036531 Pinned Leg

-GP21-A-XN-001 Dimension Control Drawing

-GP21-A-XF-801 IAT Procedure, Hydraulic System

-GP21-A-XR-801-812 Hydraulic Flow Diagrams

-GP21-A-XW-801 Hydraulic Parts List

-GP21-A-XF-111 Instrument/Cable Test Records

-GP21-A-XP-101-105 Electrical Sub Block Diagrams

-GP21-A-XS-101-113 Electrical Wiring Diagrams

SP-102 Equipment Marking

SP-1005 Painting Specification

SP-1007 Bolting Specification

SP-1008 Preservation, Packing, and Storage

SP-1021 Fabrication Specification for Land Rig Equipment

SP-1012 Guideline for Serial Number and Traceability

SP-2000 Specification for Electrical Installations

SP-2001 Specification for Earthing, Glanding and Termination

SP-3002 Specification for Offshore Hydraulic / Air piping and Fittings





4.1.3.6 MC Check Records Lists Mechanical Completion Check Records (MCCR):

The following standard MCCRs are listed in this document:

• Catwalk Machine Main Assembly

• Catwalk Machine Main Assembly Fasteners

• Substructure Mechanical

• Substructure Hydraulic

• Substructure Electrical

• Lower Ramp Mechanical

• Lower Ramp Hydraulic

• Lower Ramp Electrical

• Upper Ramp Mechanical

• Upper Ramp Hydraulic

• Upper Ramp Electrical

• Walking and Elevating Legs Mechanical

• Walking and Elevating Legs Hydraulic

• Walking and Elevating Legs Electrical

• Front Legs DS and ODS Mechanical

• Front Legs DS and ODS Hydraulic

• Front Legs DS and ODS Electrical

• Telescopic Frame Mechanical

• Telescopic Frame Hydraulic

• Telescopic Frame Electrical

• Tubular Feeding Units Mechanical

• Tubular Feeding Units Hydraulic

• Tubular Feeding Units Electrical

• Pusher Mechanical

• Pinned Leg Mechanical

• Pinned Leg Hydraulic

• Pinned Leg Electrical





MC CHECK RECORD

Sheet no.

General

Tag no: 25-215-GP21-

Product: Catwalk Main Assembly 20036382

PO no:

Sub-Contractor:

Prod.Code: GP21

System:

Subsystem:

Reference doc’s: Cameron Sense standards SP-102, SP-1005, SP-1008

INSTALLATION CHECK SUB-CONTR FINAL INSP.

SITE Punchlist Item

no. SC CS SC CS

01 Machine cleaned 02 Parking bolts/fixtures removed 03 Scaffolding removed 04 All loose items and tools removed 05 Product name plate 06 Cameron logo 07 08 09 10 11 12 13 14

COMMENTS:

SUB-CONTR FINAL INSPECTION SITE

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MC CHECK RECORD

Sheet no.

Fasteners

Tag no: 25-215-GP21-

Product: Catwalk Main Assembly 20036382

PO no:

Manufacturer:

Prod.Code: GP21

System:

Subsystem:

Reference doc’s: Cameron Sense standard SP-1007


SITE Punchlist Item no. SC CS SC CS

01 Fasteners to be either HDG or A4 02 Secondary Retention done correctly 03 Locking wire made of stainless steel

04 Check screws to have 2 tread length out from nut or structure

05 Washers installed

06 Proper flat support for washers, nuts, and screw heads

07 Essential and primary fasteners tightened to correct torque.

08

For 3rd party equipment: SP-1007 may not be applicable – if so – check for proper installation. If other material then HDG or A4 – fasteners to be preserved as per SP-1008.

09 10 11 12

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MC CHECK RECORD

Sheet no.

Mechanical

Tag no:

Product: Substructure Assembly 20035939

PO no:

Sub-Contractor:

Prod.Code: GP21

System:

Subsystem:

Reference doc’s: General Arrangement & Assembly Drawings, SP-102, SP-1005, SP-1007, SP-1008


SITE Punchlist Item

no. SC CS SC CS

01 Machine cleaned 02 Parking bolts/fixtures removed 03 Scaffolding removed 04 All loose items and tools removed 05 Product name plate 07 Fasteners to be either HDG or A4 08 Secondary Retention done correctly 09 Locking wire made of stainless steel





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MC CHECK RECORD

Sheet no.

Hydraulic

Tag no:


PO no:

Manufacturer:

Prod.Code: GP21

System:

Subsystem:

Reference doc’s: Assembly Drawings, Hydraulic Schematics, SP-1005, SP-1008, SP-3002


SITE Punchlist Item

no. SC CS SC CS

1. Hydraulic Cylinders installed correctly

2. Hydraulic Cylinders protected from accidental impacts/collisions

3. Hydraulic Cylinders pressure tested

4. Hydraulic Cylinders - No mechanical damage

5. Hydraulic Cylinders - Painting 6. Hydraulic Cylinders - Preservation

7.

Hydraulic hoses & Piping - All piping and hydraulic hoses installed complies with respective hydraulic schematic (ref drawing: XR-nnn)

8. Hydraulic hoses & Piping - Piping material AISI 316

9. Hydraulic hoses & Piping - Fitting body material AISI 316

10. Hydraulic hoses & Piping - Nuts made of chrome plated steel

11. Hydraulic hoses & Piping - Pipe bending radius OK

12. Hydraulic hoses & Piping - Hose type OK and complies with pressure rating

13. Hydraulic hoses & Piping - Hose fitting of chrome plated steel

14. Hydraulic hoses & Piping - Hose bending OK

15. Hydraulic hoses & Piping - No hose snagging against steel structure

16. Hydraulic hoses & Piping - Max one elbow on same hose

17. Hydraulic hoses & Piping - Distance between pipe clamps

18. Hydraulic hoses & Piping - Secondary retention for pipe clamps

19. Hydraulic hoses & Piping - Flushing carried out

20. Hydraulic hoses & Piping - Pressure testing carried out

21. Hydraulic Valves & Valve Blocks - All valves & valve blocks installed in





accordance with respective hydraulic schematic (ref drawing: XR-nnn)

22. Hydraulic Valves & Valve Blocks - All hydr. Ports connected to hydr. lines or sealed by use of metallic plug

23. Tagging as per XR-nnn drawing

24. Hydraulic Valves & Valve Blocks - Mounting bolts tightened

25. Hydraulic Valves & Valve Blocks - Flushing carried out according to -GP21-A-XF-801

26. Hydraulic Valves & Valve Blocks - Pressure testing carried out according to -GP21-A-XF-801

27. Hydraulic Valves & Valve Blocks - Pressure setting carried out according to -GP21-A-XF-801

28. 29.

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MC CHECK RECORD

Sheet no.

Electrical

Tag no:


PO no:

Manufacturer:

Prod.Code: GP21

System:

Subsystem:

Reference doc’s: Assembly Drawings, Sub-Block Drawings, SP-1008, SP-2000

INSTALLATION CHECK SUB-CONTR FINAL INSP. SITE

Punchlist Item no.

SC CS SC CS

1. Cable trays and ladders made of AISI 316

2. Cable tray & ladders supported properly 3. Tray ends sealed by rubber band

4. No power and instrument cabling on same ladder/tray

5. Cables on trays installed side by side

6. Cables on tray/ladder strapped every 300 mm (max)

7. Trays/ladders filled max 75%

8. Max bending radius for single core cables ≥ 12 x D

9. Max bending radius for multi core cables ≥ 10 x D

10. Cable trays/ladders grounded 11. Cable tags installed for all cables 12. Earthing/bonding (general) 13. Maintenance access 14. Junction Box tag 15. Junction Boxes -20% spare terminals

16. Junction Boxes - Gland entry in bottom or from a side.

17. Junction Boxes - For side entry gland – drip nose on incoming cable

18. Junction Boxes -Correct rubber bushing in gland fits cable OD

19. Junction Boxes - Drain plug installed (for outdoor JB’s)

20. Junction Boxes - IP rating 21. Junction Boxes - Preservation

22. Onboard Instrumentation - Check instruments against dwg’s & data sheets

23. Onboard Instrumentation - Check calibration certificates

24. Onboard Instrumentation - Leakage tested

25. Onboard Instrumentation - Protected from accidental impacts/collisions





26. Onboard Instrumentation - Gland entry in bottom or from a side.

27. Onboard Instrumentation - For side entry gland – drip nose on incoming cable

28. Onboard Instrumentation - Tag’s correct and mounted

29. Onboard Instrumentation - Cables supported by cable tray max 100 mm from instrument cable entry

30. Field Instrumentation - Check instruments against dwg’s & data sheets

31. Field Instrumentation - Check calibration certificates

32. Field Instrumentation - Leakage tested

33. Field Instrumentation -Protected from accidental impacts/collisions

34. Field Instrumentation - Gland entry in bottom or from a side.

35. Field Instrumentation - For side entry gland – drip nose on incoming cable

36. Field Instrumentation - Tag’s correct and mounted

37. Field Instrumentation - Cables supported by cable tray max 100 mm from instrument cable entry

COMMENTS:


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MC CHECK RECORD

Sheet no.

Mechanical

Tag no:

Product: Lower Ramp Assembly 20037016

PO no:

Sub-Contractor:

Prod.Code: GP21

System:

Subsystem:



SITE Punchlist Item

no. SC CS SC CS






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MC CHECK RECORD

Sheet no.

Hydraulic

Tag no:


PO no:

Manufacturer:

Prod.Code: GP21

System:

Subsystem:



SITE Punchlist Item

no. SC CS SC CS






7.



























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MC CHECK RECORD

Sheet no.

Electrical

Tag no:


PO no:

Manufacturer:

Prod.Code: GP21

System:

Subsystem:



Punchlist Item no.

SC CS SC CS









10. Cable trays/ladders grounded 11. Cable tags installed for all cables 12. Earthing/bonding (general) 13. Maintenance access 14. Junction Box tag 15. Junction Boxes - 20% spare terminals



18. Junction Boxes - Correct rubber bushing in gland fits cable OD


















33. Field Instrumentation - Protected from accidental impacts/collisions





COMMENTS:


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MC CHECK RECORD

Sheet no.

Mechanical

Tag no:

Product: Upper Ramp Assembly 20036268

PO no:

Sub-Contractor:

Prod.Code: GP21

System:

Subsystem:



SITE Punchlist Item

no. SC CS SC CS






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MC CHECK RECORD

Sheet no.

Hydraulic

Tag no:


PO no:

Manufacturer:

Prod.Code: GP21

System:

Subsystem:



SITE Punchlist Item

no. SC CS SC CS






7.



























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MC CHECK RECORD

Sheet no.

Electrical

Tag no:


PO no:

Manufacturer:

Prod.Code: GP21

System:

Subsystem:



Punchlist Item no.

SC CS SC CS



































COMMENTS:


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MC CHECK RECORD

Sheet no.

Mechanical

Tag no:

Product: Walking and elevation legs

Assembly20036819/ 20037194

PO no:

Sub-Contractor:

Prod.Code: GP21

System:

Subsystem:



SITE Punchlist Item

no. SC CS SC CS






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MC CHECK RECORD

Sheet no.

Hydraulic

Tag no:


Assembly20036819/ 20037194

PO no:

Manufacturer:

Prod.Code: GP21

System:

Subsystem:



SITE Punchlist Item

no. SC CS SC CS






7.



























28. 29.

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MC CHECK RECORD

Sheet no.

Electrical

Tag no:


Assembly20036819/ 20037194

PO no:

Manufacturer:

Prod.Code: GP21

System:

Subsystem:



Punchlist Item no.

SC CS SC CS


















25. Onboard Instrumentation - Protected from





accidental impacts/collisions













COMMENTS:


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MC CHECK RECORD

Sheet no.

Mechanical

Tag no:

Product: Front Legs DS and ODS 20036933/

20036628

PO no:

Sub-Contractor:

Prod.Code: GP21

System:

Subsystem:



SITE Punchlist Item

no. SC CS SC CS






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MC CHECK RECORD

Sheet no.

Hydraulic

Tag no:


20036628

PO no:

Manufacturer:

Prod.Code: GP21

System:

Subsystem:



SITE Punchlist Item

no. SC CS SC CS






7.



























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MC CHECK RECORD

Sheet no.

Electrical

Tag no:


20036628

PO no:

Manufacturer:

Prod.Code: GP21

System:

Subsystem:



Punchlist Item no.

SC CS SC CS


















25. Onboard Instrumentation - Protected from





accidental impacts/collisions













COMMENTS:


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MC CHECK RECORD

Sheet no.

Mechanical

Tag no:

Product Telescopic Frame Assembly 20036540

PO no:

Sub-Contractor:

Prod.Code: GP21

System:

Subsystem:



SITE Punchlist Item

no. SC CS SC CS






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MC CHECK RECORD

Sheet no.

Hydraulic

Tag no:

Product: Telescopic frame Assembly 20036540

PO no:

Manufacturer:

Prod.Code: GP21

System:

Subsystem:



SITE Punchlist Item

no. SC CS SC CS






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MC CHECK RECORD

Sheet no.

Electrical

Tag no:

Product: Telescopic frame Assembly 20036540

PO no:

Manufacturer:

Prod.Code: GP21

System:

Subsystem:



Punchlist Item no.

SC CS SC CS



































COMMENTS:


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MC CHECK RECORD

Sheet no.

Mechanical

Tag no:

Product Tubular Feeding Units 20035398

PO no:

Sub-Contractor:

Prod.Code: GP21

System:

Subsystem:



SITE Punchlist Item

no. SC CS SC CS






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MC CHECK RECORD

Sheet no.

Hydraulic

Tag no:

Product: Tubular Feeding Units 20035398

PO no:

Manufacturer:

Prod.Code: GP21

System:

Subsystem:



SITE Punchlist Item

no. SC CS SC CS






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MC CHECK RECORD

Sheet no.

Electrical

Tag no:

Product: Tubular Feeding Units 20035398

PO no:

Manufacturer:

Prod.Code: GP21

System:

Subsystem:



Punchlist Item no.

SC CS SC CS



































COMMENTS:


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MC CHECK RECORD

Sheet no.

Mechanical

Tag no:

Product: Pusher Assembly 20036262

PO no:

Sub-Contractor:

Prod.Code: GP21

System:

Subsystem:



SITE Punchlist Item no. SC CS SC CS






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MC CHECK RECORD

Sheet no.

Mechanical

Tag no:

Product Pinned Leg Assembly 20036531

PO no:

Sub-Contractor:

Prod.Code: GP21

System:

Subsystem:



SITE Punchlist Item

no. SC CS SC CS






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MC CHECK RECORD

Sheet no.

Hydraulic

Tag no:

Product: Pinned Leg Assembly 20036531

PO no:

Manufacturer:

Prod.Code: GP21

System:

Subsystem:



SITE Punchlist Item

no. SC CS SC CS






7.
























25. Hydraulic Valves & Valve Blocks - Protected from accidental impacts/collisions




29.

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MC CHECK RECORD

Sheet no.

Electrical

Tag no:

Product: Pinned Leg Assembly 20036531

PO no:

Manufacturer:

Prod.Code: GP21

System:

Subsystem:



Punchlist Item no.

SC CS SC CS



































COMMENTS:


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r

Exe

cuto

r Sign: Date:

Name:

QC

Rep

r

QC

Rep

r

Com

pany

Sign: Date:





4.1.3.7 COMPONENT/ITEM IDENTIFICATION

Ref. SP-1012 and Item Location Drawings: Items subject to traceability control are highlighted at the Item Location Drawings – as applicable for each product. The item location drawings to be used during tracing the serial/ID of the item. When completed the serial/ID to be transferred to table below.

ITEM TRACEABILITY LIST

Product: Substructure Assembly

Item Location Dwg: NA

ITEM NO: DESCRIPTION (ITEM NAME) QTY SERIAL NO / ID COMMENT

7K-20037262 WIRE 6X36 IWRC 1960GALV Ø12MMX50M TIMBLE

1

7K-20037290 DRAG CHAIN JIB 1

7K-20036563 DRAG CHAIN 1

7K-9032057 ASSEMBLY, CATWALK T1000 REM. CTRL SYSTEM

1

7K-20037160

RUD LOAD RING VLBG PLUS 3,5T M20 H=55

2

7K-20035227 OPEN SPELTER 14-16 1

7K-20037281 RUD VLBG-2,5T - M20X1,5, NS-EN 1977-4 6

7K-20035533 SWIVEL HOOK - BKL-13-10 6,7T 1

7K-20037072 CHAIN FRAM 10X30,5 - 310 LINKS 4

7K-20034220-002 CATWALK RIO CABINET 5

7K-20034220-002 CATWALK RIO 2 CABINET 1

7K-20034220-002 Operation Hydraulic Oil Pressure 1

7K-20034220-002 RIG-UP Hydraulic Oil Pressure 1

9032866 Prop. dir. valve PVG32-1, Non-ATEX 2







9029876 Motor Valve Block 1

9030632 Shut-Off Block 1



9032954 Prop. dir. valve PVG120-1 Non-ATEX 1


9032950 Prop. dir. valve PVG120-1 Non-ATEX 1

9031096 Prop. dir. valve PVG120-32 1+2 Non-ATEX 1



9032172 Hydraulic Cylinder 63/30x150 LR 4

9032173 Hydraulic Cylinder 100/80x150, LR W lub.free bearings

4


9032469 Hydraulic Cylinder 63/30x130 - LR lub.free 4


9029772 Hydraulic Cylinder 140/70x1370 LR W.sensor & lub free bearing

2

9032662 Hydraulic Cylinder 100/80x3800 LR W sensor & lub.free bearings

1

9032626 Hydraulic Cylinder 40/25x150 LR lub.free 2


9032626 Hydraulic Cylinder 40/25x150 LR lub.free 2

9032482 Hydr. cyl Ø80/40X500 LR w/spherical composite bearing

1


9032663 Hydr. cyl Ø50/35x140 LR 2






9032869 Orbital motor 160ccm 3

9016637 Accumulator 2

20032755 Crane winch 1

20037642 Gear w/ break 1

20036686 Gear 4

20032755 Winch 1

Name:

Signature:

Date:





4.1.4 Mechanical Completion - Punch List

Project no:

Equipment: Catwalk

Pun

ch It

em N

o.

Notes:

A-punches: Significant punches, which has to be corrected before next phase.

B-punches: Minor punches that may be left to a later phase.

Responsible Executor sub-contractor. The punch may be cleared by sub-contractor of Cameron’s repr.

Sta

tus

Pun

ch

Cle

ared

dat

e

Cleared by

Res

pons

ible

Exe

cuto

r

Sub

-Con

trac

tor

Cam

eron





Verified Sub-Contractor Cameron

Name

Sign

Date





4.2 Commissioning Test Procedure

4.2.1 Signature Card

Commissioning Test Procedure

Catwalk Machine

Serial Number ……………………………………….

Test Location / Date

…………………../…………………..

Test Responsible ……………………………………….

Representatives from

Company name Name (Block letter)

Initials Test witnessed (test approved)

Client

Class

Owner

Supplier

Cameron





4.2.2 Introduction

4.2.2.1 Purpose

The purpose of this document is to define the Commissioning activities and acceptance criteria for the Commissioning test. The acceptance criteria are derived from governing rules and regulations, Project specifications and Cameron internal requirements.

4.2.2.2 General

General conditions and requirements related to the Commissioning are as follows:

• The appointed test engineer is the only person that is allowed to make any changes to the

Commissioning program.

• If any deviations from acceptance criteria occur during Commissioning, these deductions shall be

recorded in the specified punch list.

• A copy of the signed Commissioning report and cleared punch list shall be filed in the User

Manual.

• The sequence of the testing activities may be changed if more practical.

• After complete Commissioning, the Client/Owner, Class (if applicable) and the Cameron

representatives shall sign the Signature Card.

4.2.2.3 Commissioning Program

The following Commissioning program is covered by the Commissioning Test Procedure:

• Standalone operations– mechanical/hydraulic/electrical/control system.

• Sequence operations in integration with other equipment.

NOTE:

This test document has been designed so that all tests have to be performed successively. If parts of the test are skipped, vital safety functions which later are assumed to be working, may fail due to

incomplete testing.





4.2.2.4 Safety

A Commissioning test may involve activities like load testing and movement of heavy equipment and hydraulic pressure testing. To avoid any injuries, personnel other than the testing crew shall be attending from a safe distance. In order to minimize the risk, the test responsible will conduct a safety briefing. The purpose is to ensure that all participants have understood the activities which are stated in this procedure, and that all safety measures stated above are in place, all test activities shall be reviewed to identify any potential hazards.

DANGER:

The following precautions must be adhered to.

• The test area around the machinery and the control stand shall be marked with red/white cord or other similar marking.

• All personnel within the markings must wear hard hats and eye-protection whenever the HPU is running.

• A test responsible shall be appointed, responsible for coordinating all activities on and around the machine during testing. Before any startup, the test responsible must be consulted.

• Before any inspection of the machine, the hydraulic supply must be closed, and the emergency stop button activated.

4.2.2.5 Prior / Other Testing

All MC / EC A-punch should be cleared prior to starting the tests described in this procedure. Before moving any new function or starting the equipment for the first time, always consult the test responsible in case other disciplines must be involved in the testing.





4.2.2.6 Required Equipment

In addition to the required equipment stated in the Commissioning Pre-Requisite the following test equipment is recommended at test site to complete the test without disturbance:

To complete this Commissioning Procedure, the following equipment is needed:

• Hydraulic power 350 l/min, 210 bar (3000 psi)

• Electric Power 230V, 1.5 kW

• 1 calibrated distance measuring laser

• Soft slings for misc lifting

• Tubulars for test, e.g. small diameter DP, large diameter DP and DC

• Necessary equipment to secure the machine

• Access to DCR and Operator Chair

• Calibrated distance measuring laser

• Stopwatch

• Other test equipment - Laptop w/ Siemens Simatic software - Fluke / Processmeter

4.2.2.7 References

References are made to the following documents and drawings:

Doc.Title Doc.No

General Arrangement Drawings -GP21-A-XM-001

Lifting and Transportation Drawing -GP21-A-XM-006

Installation Instructions Section 3.3

Hydraulic Schematics -GP21-A-XR-801 to 806

Electrical Sub-Block Diagrams -GP21-A-XP-101 to 105

IAT Report -GP21-A-XG-001

FAT Report -GP21-A-XG-010

Pre-Commissioning procedure -GP21-A-XF-040

Commissioning Pre-Requisite -EA01-A-XC-041

Flushing records Appendix to FAT Report

Packing and Preservation Section 3.1

Alarm Test Description -GP21-A-YA-003

Bolting Specification SP-1007





4.2.3 First Start-up

Special considerations/tests required to perform a safe and correct start-up are described in this chapter. These items must be signed out before starting up the machine.

4.2.3.1 Preparations

4.2.3.1.1 Control System

Item Description Sign Date Punch No.

1. Loop Check

Verify that instrumentation to control cabinet has been looped out and is

ready for power up.

2. Power to Control Cabinet

Apply power to the Control cubicles;

• 230 V or 1.5kW

• Main power

• Verify healthy status on all instruments

3. Network

Open the Catwalk network status pop-up and verify that all DP-nodes are

available and without errors.





4.2.3.1.2 Mechanical and Hydraulical


1. Mechanical Installation Complete

Before energizing the machine, ensure that the machine is properly installed

and ready for operation.

• MC filled out

• Any transport clamps removed

• Any locking pins opened

2. Hydraulic Installation Complete

Before energizing the machine, ensure that the hydraulics system is properly

installed and ready for operation.

• MC filled out

• All axis function tested from hydraulic levers





4.2.3.2 Energizing

This section describes the activities necessary to energize the system.


1. Machine On

Activate machine from operator chair.

• Shut off valve is activated and applying hydraulic pressure to the

system.

• System pressure reading on front screen is correct.

Parameter Value [bar]

System Pressure

2. Machine On – Check for leakages

Activate the machine and keep it on for at least 5 minutes.

• Make sure there are no visual leakages.

3. Machine Off

Switch off machine.

Verify:

• Shutoff valve closes.

• System pressure drops.





4.2.3.3 Safety Checks


1. Aux Emergency Stop

Activate machines on and manual mode, then activate the aux emergency

stop on the Control System and check that;

• Shut off valve is deactivated.

• Power to proportional control valves is disconnected.

• System is switched off.

• Correct alarm is reported.

2. Emergency stop test from Substructure

Operate any function on the Ramp assembly. Press the emergency stop on the Substructure.

- Verify that the functions stop.

- Repeat test on all 4 emergency stops





4.2.3.4 Individual Functions

This section covers testing of the individual functions of the Ramp assembly (upper and lower ramps), including verification of performance. The tests will be performed either via the control system from the X-COM in a box or RRC.

Item Description OK/ Sign

Date Punch No.

1. Ramp angular position

Straighten the Ramp assembly (lower and upper ramp) by operating the Ramp Lower/Elevate cylinders.

• Check that Ramps moves freely and without collisions and abnormal noise and that cables and hoses do not stretch or bend beyond manufacturer recommendation.

• Operation is smooth both with joystick control and against end stop.

• Verify electrical position feedback on operator screen console by observing numerical value on screen and record the Ramp angle in the table below.

Parameter X-com Actual

Straightened Ramp Angle

Lowered Ramp horizontal

Upper ramp horizontal






Date Punch No.






Date Punch No.

2. Pipe Pusher

Run the Pusher forward and backward along entire Ramp assembly (lower and upper ramp).

Ramp to be straightened during Pusher run.

• Check that the directional marking correspond to the movement.

• Check that the Pipe Pusher runs along entire length of both Ramps assembly without any collisions or abnormal noises.

• Verify electrical position feedback on operator screen console by observing numerical value on screen and record the distance in the table below.

Parameter Target X-COM read-out Actual

Travel distance 27893 ±50mm






Date Punch No.

3. Pipe Limiter DS

Operate the Pipe Limiters on DS.

• Verify electrical position feedback on operator screen console.

• Verify that Limiters on Lower are activated.

• Check that Limiters moves freely and without collisions and abnormal noise and that cables and hoses do not stretch or bend beyond manufacturer recommendation.

Parameter Target Actual

Angle engaged 90(±3) deg

Angle disengaged 0 (+0-3) deg






Date Punch No.

4. Pipe Limiter ODS

Operate the Pipe Limiters on ODS.


• Verify that Limiters on Lower Ramp are activated.

• Check that Limiters moves freely and without collisions and abnormal noise and that cables and hoses do not stretch or bend beyond manufacturer recommendation.

Parameter Target Actual

Angle engaged 90(±3) deg

Angle disengaged 0 (+0-3) deg






Date Punch No.

5. Pipe Kicker DS

Engage Pipe Kicker on DS.

• Verify electrical position feedback on operator screen console by observing value on screen and record the parameter in the below table.

• Check that Pipe Kicker moves freely and without collisions and abnormal noise and that hoses do not stretch or bend.

Parameter Target Min

Pipe Kicker engaged TRUE TRUE

Pipe Kicker disengaged FALSE FALSE






Date Punch No.

Disengage Pipe Kicker on DS.


• Check that Pipe Kicker moves freely and without collisions and abnormal noise and that hoses do not stretch or bend.


Pipe Kicker engaged FALSE FALSE

Pipe Kicker disengaged TRUE TRUE






Date Punch No.

6. Pipe Kicker ODS

Engage Pipe Kicker on ODS.


• Check that Pipe Kicker moves freely and without collisions and abnormal noise and that hoses do not stretch or bend beyond manufacturer recommendation.


Pipe Kicker engaged TRUE TRUE

Pipe Kicker disengaged FALSE FALSE






Date Punch No.

Disengage Pipe Kicker on ODS


• Check that Pipe Kicker moves freely and without collisions and abnormal noise and that hoses do not stretch or bend beyond manufacturer recommendation.


Pipe Kicker engaged FALSE FALSE

Pipe Kicker disengaged TRUE TRUE






Date Punch No.

7. Casing Receiver (Pipe Ejectors DS)

Engage Casing Receivers


• Check that Casing Receivers moves freely and without collisions and abnormal noise and that hoses do not stretch or bend beyond manufacturer recommendation.


Casing Receiver engaged TRUE TRUE

Casing Receiver disengaged FALSE FALSE






Date Punch No.

Disengage Casing Receivers


• Check that Casing Receivers moves freely and without collisions and abnormal noise and that hoses do not stretch or bend beyond manufacturer recommendation.


Casing Receiver engaged FALSE FALSE

Casing Receiver disengaged TRUE TRUE






Date Punch No.

8. Pipe Ejector ODS

Engage Pipe Ejector ODS


• Check that Pipe Ejectors moves freely and without collisions and abnormal noise and that hoses do not stretch or bind.

Parameter Target Min Actual

Pipe Ejector

engaged

TRUE TRUE

Pipe Ejector

disengaged

FALSE FALSE






Date Punch No.

Disengage Pipe Ejector ODS


• Check that Pipe Ejectors moves freely and without collisions and abnormal noise and that hoses do not stretch or bind.


Pipe Ejector

engaged

FALSE FALSE

Pipe Ejector

disengaged

TRUE TRUE






Date Punch No.

9. Crane Arm Winch

Run the Winch and check hook height. To be done at two different heights, approx. 1 and 8 meters above the ground.

• Verify electrical position feedback on operator screen console by observing value on screen and record the parameter in the table below.

• Check that wire moves freely without touching any steel parts of the Telescopic Jib and guide.

• Check that end switch up and down functions.

Parameter Value in X-COM Actual

Hook Height (1 m)

Hook Height (8 m)






Date Punch No.

10. Crane Arm Telescopic Jib

Ensure that the Hook is more than 3,8 m below tip of the Jib.

Run the Telescope Jib.

• Verify that the Jib runs freely inside Guide Unit without

collisions and abnormal sounds.

• Check that the Drag Chain moves freely in and out of the

Guide Unit without collisions and abnormal noise.

• Verify electrical position feedback on operator screen console

by observing numerical value on screen and record the

distance in the table below.

Parameter Target Value in X-COM Actual

Jib Extension 3800±10 mm






Date Punch No.

11. Tubular feeding unit DS side

Ensure that TFU are in transportation if the legs are not extended.

• Drive the carriages up and done, verify that the carriages

chains run freely inside TFU and without collisions and

abnormal.



Upper position

Lower position






Date Punch No.

12. TFU Indexer DS side

Engage TFU Indexer.

• Verify that the Pipe Indexer runs freely inside TFU without collisions and abnormal noise and that cables and hoses do not stretch or bend beyond manufacturer recommendation.


(timer operated).


Disengaged






Date Punch No.

13. Tubular feeding unit ODS side

Ensure that TFU are in transportation if the legs are not extended.

• Drive the carriages up and done, verify that the carriages

chains run freely inside TFU and without collisions and

abnormal.



Upper position

Lower position






Date Punch No.

14. TFU Indexer ODS side

Engage TFU Indexer.

• Verify that the Pipe Indexer runs freely inside TFU without collisions and abnormal noise and that cables and hoses do not stretch or bend beyond manufacturer recommendation.


(timer operated).


Disengaged






Date Punch No.

15. Walking Elevating legs DS

Secure the Lower Ramp to the Substructure by using the hydraulic operated Locking Pins on each side of the Substructure.

1. Verify that the Walking Foot moves freely inside the Hinged Leg without collisions and abnormal noise and that cables and hoses do not stretch or bend beyond manufacturer recommendation. It shall be possible to turn the “foot” 90 degrees when the Lifting cylinder is retracted and Locking device is in disengaged position.

2. When all 4 Lifting cylinders are in retracted position run the Walking system back and forth to check that they move freely and without collisions and abnormal noise and that cables and hoses do not stretch or bend beyond manufacturer recommendation.





4.2.3.5 Ramp Folding / Unfolding

This section covers the required overload test to be carried out.


Date Punch No.

1. Ramp Folding / Unfolding by use of SRS, Self Raising System

This tests shall be performed by using the X-COM control system or RRC.

Preparations:

• Ramp shall be in Pipe Loading position(resting position).

• Put the manual Ramp Lock Pins into locked position.

• Run SRS until Struts are in correct position for connection to Upper Ramp.

• Connect both Struts to Upper Ramp by activating Strut Locking Pins. Verify Engaged signal on Operator screen console.


Strut Locking Pins

engaged

TRUE TRUE










Date Punch No.

2. Folding the Ramp

This test shall be performed by using the remote panel control system.

• Ensure that SRS system is in position to retract Translation Cylinder.

• Retract Translation Cylinders until Front Leg Pivot Bolts on Telescopic part of Substructure are loose.

• Attach soft sling to leg and connect this to the Pulling Winch. Pull in until slings are fairly tight.

• Connect Ram Tool to Pivot Bolt and hammer out the two Pivot Bolts.

• Start Folding procedure using The Radio Remote Control Panel.

• Continue folding procedure until Upper Ramp is completely folded and rests on the rubber stoppers.





4.2.3.6 DP Operation


Date Punch No.

1. Drill Pipe Loading

• Place one DP (from range 3 ½ to 5 ½) on DP feeder tables carriages.

• lift the tables carriages up to move DP towards Pipe Indexer.

• Activate Pipe Indexer to load DP on the Upper Ramp.

• Activate Pipe Limiters.

• Drive Pipe pusher towards DP and activate the Pipe Arm.

• Straighten the Ramp.

• Drive DP towards DF using Pipe Pusher.

2. Drill Pipe Unloading

• Drive DP down towards Lower Ramp

• Drive pipe pusher to parking position

• Ensure pipe carriages are on upper position.

• Activate Pipe Kicker to move DP towards Ramp Pipe Ejector.

• Activate Ramp Pipe Ejector to move DP towards Feeding Table.

• Indexer on feeder table should be in lower position.

4.2.3.7 Casing Operation


Date Punch No.

1. Casing Loading

• Place one CSG feeder tables carriages.

• Lift the tables carriages up to move CSG towards Pipe Indexer.

• Activate Pipe Indexer to load CSG on the Upper Ramp.

• Activate Pipe Limiters.

• Drive Pipe pusher towards CSG and activate the Pipe Arm.

• Straighten the Ramp.

• Drive CSG towards DF using Pipe Pusher.






Date Punch No.

2. Casing Unloading

• Drive CSG down towards Lower Ramp

• Drive pipe pusher to parking position

• Ensure pipe carriages are on upper position.

• Activate Pipe Kicker to move CSG towards Ramp Pipe Ejector.

• Activate Ramp Pipe Ejector to move CSG towards Feeding Table.

• Indexer on feeder table should be in lower position.





4.2.3.8 Active Guide Roller

This section covers testing of Active Guide Roller used for Guide Roller on the Crane arm Trip in/out sequences.


Date Punch No.

1. Active Guide Roller during Trip in and Trip out

This tests shall be performed by using the X-COM control system/RRC and tubular of sufficient length.

Preparations:

• Ramp shall be in Upper Ramp Straight or Drill floor Position.

• TDA is lowered towards DF ready for pick up.

• Tubular is placed in the pusher and ready to be latched to TDA.

• Set the 2-off Guide Profile in guide position and lock with pins.

Tripping in

1- Latch Tubular to TDA

2- Drive TDA upwards.

3- Pusher should follow TDA in a sync move.

4- Crane Arm is partially extended, to allow the Guide roller arm to swing.

5- When Tubular in semi vertical position and pusher at end position, engage Guide Roller.

6- Tubular should be in contact with Guide Roller.

7- Continue driving TDA upwards, extend Crane arm when tubular has left the pusher.

8- Continue extending Crane Arm until the tubular is in vertical





position.

9- Disengage Guide Roller.

10- Retract Crane Arm.

Tripping out

1- Tubular is latched to TDA and in vertical position to DF

2- Extend the Crane Arm to until Guide Roller passes the tubular.

3- Engage Guide Roller.

4- Simultaneously, retracted the Crane Arm and drive TDA downward.

5- Crane Arm is partially extended, to allow the Guide roller arm to swing.

6- Continue the previous step until the Tubular rest in the pusher bucket.

7- Disengage Guide Roller.

8- Retract Crane Arm.

• Check that Crane Arm and Tail-In Guide move freely and without collisions and abnormal noise and that cables and hoses do not stretch or bend beyond manufacturer recommendation.

• Operation is smooth both with joystick control and against end stop.

• Verify electrical feedback on operator screen console by observing numerical value on screen.





4.2.4 Attachments

The following documents are attached to this section:

• Punch list, T-01-01-02

EXTERNAL PUNCH LIST

Project No:

Equipment:

Pu

nch

Ite

m N

o.

Notes:

A-punches: Significant punches, which has to be corrected before next phase.

B-punches: Minor punches that may be left to a later phase.

Responsible Executor is either Cameron or manufacturer of equipment.

Ca

teg

ory

(A

or

B)

Re

sp

onsib

le

Exe

cu

tor

Verified Client Cameron

Name

Sign

Date

NOTE!

All punches shall be transferred to the CAMERON Punch System and can be inspected by client in the next phase of the project.





4.3 Operating Instructions

4.3.1 Introduction

The operating instructions are supplied to guide the user through safe and efficient operation of the equipment. This document covers the use of the Catwalk Machine (CWM).

4.3.2 Health, Safety and Environment (HSE)

The equipment delivered under this contract has been designed in accordance with current HSE regulations and standards. In order to prevent injuries to personnel and preserve the integrity of the CWM, it is of utmost importance that both the owner and the user of the equipment study the content of this manual before operating the machine or any device controlled by equipment delivered by Cameron.

4.3.2.1 User Obligations

Observance of all descriptions, information and instructions set out in this manual is the full responsibility of the user. This is also true for any regulation or requirement issued by an authority or agency, which may overrule the content of this documentation. Any general legal or other mandatory regulation in force relating to accidental prevention or environment protection must be followed by the owner and by the user.

4.3.2.2 General Safety

Only authorized personnel shall operate the equipment delivered or controlled by a Cameron product. Prior to operating the equipment it shall be in a proper technical condition, in line with its intended use. Functional disorders must be taken care of immediately to avoid jeopardizing the safety of personnel and potential damage to equipment. It is the users responsibility to ensure that the operating area and operating path of the machine, equipment or other device delivered or controlled by a Cameron product is free from unauthorized personnel during start up and operation.





4.3.2.3 Safety in Maintenance

Prior to carrying out any maintenance or repair work, the maintenance personnel shall be completely familiar with the operation of the equipment, technical drawings and procedures. Secure extensively, as far as necessary, the area of the maintenance work. During replacement of heavier items, individual parts and/or heavy structural components must be carefully attached to the lifting appliances and safeguarded in order to avoid a possible source of danger. Use only approved lifting equipment with sufficient carrying capacity. Do not stay underneath or in the vicinity of suspended load. Only personnel authorized according to the regulations in force shall perform work on the electrical installation or the equipment. If specifications for inspection, maintenance or repair requires the equipment to be voltage free this can be achieved in the following ways:

• For circuits above 50 VAC/30 VDC, switch off and lock out the main circuit breaker on the supply side.

• For instrumentation circuits (below 50 VAC/30 VDC), isolate the control cubicle from the main supply.

• Open the fuses in the control cubicle, using the relevant (loop) drawings.

• Isolate the relevant wires/cores from the terminal block in the control cubicle.

• Follow any procedure to troubleshooting and repair the equipment in question.

• Before work proceeds verify that all circuits are voltage free.

4.3.2.4 Safety Precautions in Operation

During operation of the CWM all personnel shall be at a safe distance. There shall be no personnel within the working area of the machine during operation. The machine shall be shut off if personnel are moving in to the working area of the machine.





4.3.2.5 Operation of the CWM

This modern CWM is designed and built to be easy to operate and a highly reliable machinery. To be able to achieve this, it is important that the operator understand how to operate the system and how to act upon feedback from the machine.

The machine has sophisticated self-diagnostic functions built in to the control system to be able to give the operator an early warning in case there are faults in the system. Under normal operation, no alarms should be active for the CWM. If an alarm is present, this alarm should be cleared before operating the CWM.

4.3.2.6 Self-Protection

In some scenarios the CWM will give priority to self-protection. The control system will try to give the operator the optimal performance, but in case of failure or overload it will try to protect the machine from damages.

4.3.2.7 Emergency Stop

When an emergency stop is activated, the machine is switched off. The machine will not automatically start operation again when emergency stop is de-activated. For the machine to be operating again, the emergency stop has to be de-activated and machine to be switched on again.

WARNING:

The Emergency Stop function is a fully manual hardwired function. This function will override all built in safety functions in the control system and apply all brakes fully

and disconnect the drive motors from its functions.





There is a total of 6 Emergency stop buttons in the system:

• One Emergency Stop button in the X-Com.

• Four Emergency Stop buttons at the CWM, Two on each side close to the front and two on each side at the rear end of the machine.

• One Emergency Stop button at the Remote Control panel. Activating either one of these Emergency Stop buttons will instantly override all control system features and release all motors (electric motor will be free-wheeling). Brakes will instantly be applied as the fail-safe, powerless state of the brake valves ensures the brakes are engaged.

Emergency stop can be pressed at any time, speed or load.

CAUTION:

Emergency stop shall not be used unless there is really an emergency. Activating the emergency stop at high speed will strain the machine and give increased wear on

brakes and structure.





4.3.3 Operator Interface

4.3.3.1 Introduction

This modern CWM is designed and built to be easy to operate and a highly reliable machinery. To be able to achieve this, it is important that the operator understands how to operate the system and how to act upon feedback from the machine. The Catwalk Machine comprises of a hinged Ramp, with two integrated cylinders elevating the hinge point. A Pusher unit adjusts the position of the tubular within the Ramp.

4.3.3.2 Touchpad & Joystick Functions

All operational commands to the CWM are given from the touch pads and joysticks in the Assistant Driller operator chair. During operation some of the buttons will be inhibited. This is a security measure that will help prevent pushing the wrong buttons at the wrong time. The inhibited buttons will be grey and impossible to operate. The operator will still be able to do operational error that can cause fatal accidents with the equipment. At all times, the operator must be responsible and understand all commands that he sends to the control system.

To use the joystick, the activation-switch located in the front of the joystick must be pressed (this happens if the hand is closed around the joystick).

When the joystick activate button is pressed, a pop-up window will appear on the touchpad, showing which functions are assigned to the joystick, and which directions each function has on the joystick.

The CWM is controlled using the touchpad and joystick.





4.3.3.3 Touchpad Functions

Available touchpad functions for the CWM:

On Toggle button with Push & Confirm. This will open a pop-up window where you need to confirm that you want to activate the CWM. Control Assign Toggle button. Control assign. Assign control of the catwalk back to the Assistant driller. If catwalk has been operated using the remote panel, it is necessary to press Control Assign button to take control back to the touchpad. System prevents retaken control if machine is currently in use from remote control.

Confirm Push & Hold. This button is used for miscellaneous operations the operator needs to confirm. A message will describe what needs to be confirmed, and the button will flash. Fine Adjust Toggle button. In auto modes this function is available at certain positions, allowing the operator to adjust the programmed target position. In manual mode the function activates creep speed. Drill pilot Enable Toggle button. Enable control of the machine to drill pilot. If activated, drill pilot is allowed to operate the machine. This is currently not in use. But added for making catwalk ready for drill pilot operation.





Interlock Override Push & Hold. This button will deactivate certain interlocks and gives the possibility to operate the machine past the defined working stop limits. Also, in some cases inhibited buttons will be possible to activate if interlock override is activated. It is two levels of interlock overrides.

Level 1: Single press, buttons turns yellow. Level 2: Press and hold, buttons turns red. Overrides and allow operation towards ZMS and TI limits.

WARNING:

When running in interlock override use extreme caution to prevent injuring personnel or damaging equipment.

Manual Toggle button. Activates manual mode for the machine.

Trip In Toggle button. Activates semi-auto mode trip in. Trip Out Toggle button. Activates semi-auto mode trip out.

Crane Toggle button. Activates operation of manipulator arm and manipulator arm winch in/out. Walking Manual Toggle button. Activates walking manual mode. Operate walking translation- and elevation cylinders using joystick. Use HMI RigUp popup for selecting whether walking front, rear or both front and rear. Walking Auto Toggle button. Activates walking auto mode. Operate walking auto mode using joystick. Rig Up/Down Toggle button. Activates rig/up mode. Operate pinned-leg and frame translation cylinder using joystick.

Follow TD/DW Toggle button. Follow TD, run as slave of Top Drive/Drawwork when picking up/laydown of pipe using TD and in auto mode.





Tubular DS Toggle button. Operate kickers, ejectors and TFU functions according to pipe located on driller side. Tubular ODS Toggle button. Operate kickers, ejectors and TFU functions according to pipe located on off driller side. Limiters DS Toggle button. Engage limiter and pipe guard on driller side. Limiters ODS Toggle button. Engage limiter and pipe guard on off driller side. Pipe On Ramp Toggle button. Pipe located on ramp. Buttons is useful when activating auto mode, to make sure that catwalk enters correct step. E.g. if tubular has been manually moved into ramp, and operator intents to operate machine in auto for delivering pipe to Top Drive. Press Pipe On Ramp prior to activate auto, to make sure correct auto step is entered. Target WC Toggle button. Selects WC as target position. WC target must be selected when delivering/picking up single pipes using top drive.

Target MH Toggle button. Selects MH as target position. MH target must be selected when delivering/picking up single pipes using pipe handling equipment e.g. Tubular delivery arm. Tail-In Up Toggle button. Moves tail-in arm up. Engaged. Tail-In Down Toggle button. Moves tail-in arm down. Disengaged.

Kicker Up Toggle button. Engage Pipe Kicker up. Kickers depends on Tubular side selected. If Tubular DS is active, then Kicker ODS is engaged to kick pipe out on DS side.

Ejector Up Toggle button. Engage Ejector up. Ejector depends on Tubular side selected. Ejector has two different modes; Ejector and Pipe stopper. If pipe on ramp, then ejector works on tubular side for ejecting pipe off ramp. If no pipe on ramp, then ejector works as pipe stopper and opposite ejector is activated to ensure pipe to roll into center of ramp/pusher (This applies not for casing).





Tubular Feeding Unit(TFU) Ejector Up Toggle button. Engage TFU Ejector up. Ejector is automatically retracted.

TFU Lower Pos Toggle button. Move Feeding Table to lower pos.

Upper Pos Toggle button. Move Feeding Table to upper pos. If auto trip out mode is active, then carriage is moved to top, then some down until it stops at tripping out proxes. This to make sure it is enough slope for pipes to roll off ramp onto the carriage.





4.3.3.4 Joystick Functions

Joystick – Manual Operation The following joystick functions are activated with the Touchpad:

• X-axis, left Pusher To Target(WC or MH)

• X-axis, right Pusher From Target(WC or MH)

• Y-axis, forward Ramp Lower

• Y-axis, backwards Ramp Elevate

• Top slider, up Tubular Feeding Unit Carriage(Pipe Table Up)

• Top slider, down Tubular Feeding Unit Carriage(Pipe Table Down)





Left Joystick – Crane Mode The following joystick functions are activated with the Touchpad. Note the pop-up will always be correct according to selected auto mode and selected target.

• X-axis, left Crane Jib Extend

• X-axis, right Crane Jib Retract

• Y-axis, forward Winch Out

• Y-axis, backwards Winch In

• Top slider, up Ramp Lower

• Top slider, down Ramp Elevate





4.3.3.5 Portable Operator Panel

In addition to from the operator chairs in the DCR, the Catwalk can be controlled by a portable operator panel. It is only possible to gain control from one location at a time, and control is gained in the first-come, -first serve basis. Procedure on how to operate Catwalk Machine from portable operator panel:

1. Ensure no other operator already has gained control of the machine (i.e from operator chair in

DCR).

2. Deactivate the “STOP”- button on the local panel.

3. Activate the “Remote On” button on the operator panel.

When the green “Ready to run” indication on the operator panel is lit, the Catwalk Machine is ready for operation from operator panel. In case control already is assigned from other location, the “Ready to Run” indicator will not lit up, and it is not possible to operate the Catwalk Machine from the portable operator panel.

All functions are working in the same matter as when operated from the operator chair.





4.3.3.6 Front Screens

The front screens in the operator chair give information about the operation. The CWM has a display showing information about the CWM and its auxiliary systems (Picture 8500). This screen is normally used for CWM setup and operation.

Standard Functions Click on any bar graph to change scale or any numeric value output to locally change units. For further information about front screen objects general functionality like scaling, reset, enter values, access control, and signal validation, please refer to the operator chair User Manual.

4.3.3.7 CWM Main Screen

The main screen contains all necessary information the operator needs for CWM operation. All relevant settings and additional status information is available through pop-ups. (This is a typical main screen picture. The final screen may differ from this).

Screen 4400

1. CWM current mode status info 2. Pipe type indicator/selector or manual input 3. Machine position monitoring 4. CWM pop-ups 5. Valve drive command 6. CWM status

1

2

3

4

5

6





4.3.3.7.1 CWM Sub Screens (pop-ups)

In this section the available pop-ups will be displayed and briefly described. A more detailed description on usage will be given throughout this user manual.

Settings The operator can access the Settings pop-up by pressing the button on the CWM main screen. In this pop-up, the operator can edit settings for Ramp targets and Pusher targets.

Screen 8502

Ramp Targets S – button Save current ramp cylinder position as new position. R – button Reset current ramp cylinder position to default position.





Loading Pos Ramp cylinder position when ramp located at feeding table position. Ready for receiving or kicking out pipes. This position is close to ramp cylinder max endstroke. Straight Pos Ramp cylinder position when ramp is straight allowing pusher to move between upper and lower ramp. Drill floor pos Ramp cylinder position when delivering/pickup pipe from drill floor.

Pusher Targets

Pusher pickup Pos Pusher position where it stops and waits for TDA or Topdrive to be in correct position for pickup. Default position is calculated using pipe data and located pusher in position where tooljoint is at the edge of upper ramp. Feeding Table Pos – Trip In Pusher position ready for receiving pipe from feeding table/casing table. Feeding Table Pos – Trip Out Pusher position ready for kicking out pipe/casing to feeding table. Crane Jib Targets

Target WC Crane jib cylinder position when picking up/delivering pipe to WC.

Target MH Crane jib cylinder position when picking up/delivering pipe to MH.

Misc Dist CW to WC

Calibrate the catwalk locating after rig move. This button is used for calculating the distance from well center to catwalk. This position must be acurate for allowing correct operation of the handover between catwalk and topdrive/tda, and for the ZMS system to work correct. Position the crane jib above the stickup in Well center. Verify that the hook is straight above the center of well center, and press S. The horizontal distance between the well center and rotation point of lower ramp is calculated and stored in plc.





Position Configuration The operator can access the Position Configuration pop-up by pressing the button on the CWM main screen. The pop-up displays position status information for all the CWM functions.

Screen 8503

Cylinders must be preset in minimun and maximum position. Preset min position Move cylinder to min(retracted) position using interlock override level 2 or using hyd handle. Make sure that cylinder is at min position, and press S for Min. Preset max position Move cylinder to max(extended) position using interlock override level 2 or using hyd handle. Make sure that cylinder is at max position, and press S for Max.





Pusher preset Move ramp straight and position the pusher at the rear endstop, make sure that the wire tenison cylinder is tight. Push pusher position preset, and the pusher position will be updated. It is important that ramp is straight and pusher at the rear enstop when executing pusher preset. Crane Winch preset Make sure that the crane jib is at retracted position(0 m). Winch in the hook until it is close to the jib(1-2cm from the jib). It may be needed to operate the winch in interlock override.

Emergency Operation The operator can access the Emergency Operation pop-up by pressing the button on the CWM main screen. The pop-up is used for selecting and activating the misc. functions for emergency operation.

Screen 8505

Overview The operator can access the Overview pop-up by pressing the button on the CWM main screen. The pop-up is used for overview of positions, drive output and velocity feedback for the CWM functions.





Screen 8506

Rig Up The operator can access the Rig Up pop-up by pressing the button on the CWM main screen (Picture 8500).





Screen 8507

4.3.3.8 Parameter Settings

The operator can perform the necessary setup of the machine before use. It is important that all necessary settings are correct at all times.

4.3.3.8.1 Pipe Parameters

The operation of the CWM requires that the pipe type to be used is selected by the operator. There are two options: - Use Pipe database:

Pipe data is read from current pipe selected on TDA. - Use Manual Input:

Possible to update pipe parameters manual.





The following pipe data is vital for the operation: - Pipe Length:

Pipe length is used for calculating misc auto positions for pusher. Running with too big deviation between pipe length and actual length can lead to inaccurate auto operation.

- Single Weight: Weigth is used for determining pusher in low or highspeed. Pusher low speed is enabled if single weight exceeds 1150 kg.

- Casing/Tubing: Casing will enable operating of casing feeder instead of receiving pipe from pipe feeding table.

NOTE:

Always make sure the selected pipe type is identical to the pipe type used for operation. Selecting wrong pipe type will drastically reduce the performance of the control system.





4.3.4 Start and Stop

4.3.4.1 Pre-start Preparations

Before starting the CWM the Operator must ensure that the system is ready for the intended operation. The check list must as a minimum include the following checks:

1. Check alarms. Check each active alarm and take the necessary precautions in order to

prepare the operation of the CWM. 2. Check ZMS and TI. Check/Verify Zone management system. All ZMS and TI should be up

and running (green lights). 3. In case of cold weather; check the “Start up in cold weather” instructions in this manual for

details. 4. Check that the emergency stop buttons are deactivated. If one or more emergency buttons

are activated an alarm will be present in the alarm screen, and it will not be possible to start the CWM.

4.3.4.2 Pre-start Settings

Before starting the CWM the Operator must ensure that the system is set up correctly for the intended operation.

4.3.4.3 Normal Start-up

1. Select CWM screen on the right touchpad. 2. Activate the “ON” button in the upper left corner, and press confirm on the pop-up. 3. The “ON” button should now be highlighted indicating that the machine is on. 4. Select desired mode. Details are given in the following chapters. 5. Select the correct pipe type.

When the machine is on;

• Hydraulic shut-off valve activated (open - hydraulic pressure activated).

• No controls will be active until a mode is selected.

• All sensors for the control system will always be active regardless of the mode of the CWM. But some alarms will not be activated until the system is running, or in certain modes only (to avoid false alarms).

4.3.4.4 Start-up in cold weather

When starting up with a cold machine in temperatures below 0 degC, operate the machine at 30% of normal speed the first 30 minutes.





4.3.4.5 Normal Shut-down

1. Stop all movements and wait until the machine has come to a complete stop. 2. Press the “ON” button in the upper left corner, and then confirm on the pop-up. 3. The button will flash while the system shuts down and is unlit when complete.

4.3.4.6 Emergency Stop

There is a total of 6 Emergency stop buttons in the system:

• One Emergency Stop button in the X-Com.

• Four Emergency Stop buttons at the CWM, Two on each side close to the front and two on each side at the rear end of the machine.

• One Emergency Stop button at the Remote Control panel. Activating either one of these Emergency stop buttons will instantly override all control system feature.

CAUTION:

Emergency stop function is a fully manual hardwired function. This function will override all built in safety function in the control system and apply the brakes fully and disconnect the drive motors.

4.3.4.7 Start-up After Emergency Stop

1. Identify the cause of the emergency stop. 2. Check and correct errors and other potential problems. 3. Visually inspect the machine for damages due to the emergency stop. 4. When the cause is identified and corrected, reset all emergency stop buttons. 5. Follow the normal start-up procedure.

NOTE:

If the emergency stop button is reset, the system will not be started automatically.





4.3.5 Functions

4.3.5.1.1 Trip In

Move pipe from horizontal to vertical (trip in). Move pipe from CWM to TDA/TD.

4.3.5.1.2 Trip Out

Move pipe from vertical to horizontal (trip out). Move pipe from TDA/TD to CWM.

4.3.5.1.3 Follow mode

Follow mode is a sub mode for trip in/out. Pusher is operated as slave of TDA/TD and position the pusher according to bottom of pipe. It is possible to adjust the pusher using the x-direction of the CWM joystick. This may be necessary if the actual pipe length deviates from pipe data. If not operated in follow mode, the pusher must be operated using CWM joystick.

4.3.5.1.4 Manual Mode

Standard manual operating of the machine:

• Push/pull pipe to/from WC.

• Ramp elevate/lower.

• Pipe receive/eject.

4.3.5.1.5 Crane Mode

The CWM may be used in crane mode for special lifting purpose. Crane mode is a sub mode of manual mode. In order to activate crane mode, the following criteria must be fulfilled:

1. Manual mode active.

4.3.5.1.6 Rig Up/Down

• Rig up/down using Remote Control panel.

• Translation cylinder moves according to position regulator.

4.3.5.1.7 Walking

• Walking using Remote Control panel.

4.3.5.1.8 Pulling Winch (optional)

• Winch in/out using remote control (also available from emergency mode in HMI).





4.3.5.1.9 Emergency Operation

The following functions can be operated from the emergency operation:

• Ramp Elevate/Lower

• Pusher Forward/Backward

• Crane Jib Extend/Retract

• Crane Winch In/Out

• Pulling Winch In/Out

4.3.5.1.10 Pipe Length Measuring (optional)

• Measuring pipe length when tripping in pipe.





4.3.6 Auto Modes

4.3.6.1 General

Auto operation is the normal operation mode for the CWM and should always be the preferred way of handling tubular. Operating in Auto mode ensures that the pipe handling operation is the fastest, safest and smoothest way. Operating in Auto mode also reduces possible operator errors to a minimum. The CWM machine is programmed to follow standard paths during Auto sequences. This will make the system function in a way that will familiarize the operator with the tubular handling.

The pipe handler has two different Automatic modes;

1. Trip In(HTV) Mode with subsequences: a. Pipe from CWM to TDA. b. Pipe from CWM to TD.

2. Trip Out(VTH) Mode with subsequences: a. Pipe from TDA to CWM. b. Pipe from CWM to TDA.

The auto modes cannot be selected until the specific conditions for entering auto mode have been fulfilled. The mode is available when the touchpad button is available (button not inhibited). Switching between modes and targets is possible. See the Auto sequences for more specific details.

Reversibility The sequence control is performed by the left hand joystick. The speed is controlled by the deflection of the joystick. At any point of the sequence the sequence can be reversed by giving command in the other direction by the joystick.

4.3.6.2 Modes

The activation of the auto sequence is done by the following steps: 1. Select Mode (Touchpad):

a. HTV (Trip In) b. VTH (Trip out)

2. Select Target (Touchpad): a. WC b. TDA

3. Possible to select “Follow TDA” or “Follow TD” (depends on target). 4. Use left joystick to adjust the direction and speed of the sequence. 5. If in follow mode, the CWM will be operated from the master js (either TD or TDA).

4.3.6.3 Sequence description

The following sequence will be operated in auto mode when tripping in singles from feeding table to drill floor.





4.3.6.3.1 Trip In

Step Description

1 1 Init

Deactivates Tail-In arm.

Moves crane jib, pusher and ramp to default position.

2 8 Elevate tubular feeding unit

Operate the tubular feeding unit either using the touchpad upper/lower position or the topswitch for

manually operate the feeding unit.

Confirm required for entering next step:

Confirm: Confirm pipe on feeding unit.





Step Description

3 10 Adjust pusher for pipe receive

Adjust the pusher using the joystick x-axis to ensure that pipe is laid onto pusher.

Position can be stored at CW Setting “Feeding Table Pos: Trip In”.


Confirm: Confirm for roll pipe to CW.





Step Description

4 12 Feed drill pipe to catwalk

TFU ejector engages for moving pipe above indexer. Pipe is rolled into catwalk.

Ejectors on opposite side works as Pipe Stopper ensuring that pipe is laid in the centre of ramp.


Confirm: Confirm for transfer pipe to pickup position.

5 15 Push pipe to pickup position

Ejectors/stoppers are disengaged, limiters engaged.

Pipe On Ramp is activated on touchpad.

Ramp is elevated to straight position then pusher moves pipe to upper ramp. When pusher is on

upper ramp, the ramp is tilted to drill floor position.

Next step: Move joystick to centre.





Step Description

6 17 Adjust pipe for pickup

Adjust pipe for pickup.

X-axis is operating pusher.

Y-axis is used for adjusting ramp if needed.


Confirm: Confirm for lift pipe.

7 19 Pickup pipe

Pusher guides bottom of pipe when pipe is lifted.

Crane jib extends and Tail-In arm engaged, ready for delivering bottom of pipe to target.

If Follow TD/DW is active then pusher is moved automatically based on pipe data.

If not, pusher needs to be operated using the x-axis.


Confirm: Confirm for extending jib to target.





Step Description

8 20 Deliver pipe to target

Extend jib with Tail-In Arm engaged for delivering pipe to target (WC or MH).


Confirm: Confirm for next pipe.





4.3.6.3.2 Trip out

Step Description

1 1 Init

Deactivates Tail-In arm.

Moves crane jib, pusher and ramp to default position.

Next step: Move joystick to center.





Step Description

2 30 Tail In Pipe

Engage Tail In for moving pipe to pusher.

Confirm for engaging tail in arm when jib in correct position.

Tail in pipe to pusher.

Confirm for next step:

Confirm: Confirm for pipe resting at pusher.

3 34 Laydown pipe

Pusher guides bottom of pipe.

If Follow TD/DW is active then pusher is moved automatically based on pipe data.

If not, pusher needs to be operated using the x-axis.

Next step:

Move joystick to center (if not in follow mode).

[Follow mode] Elevator latch opened.





Step Description

4 36 Pusher to pipe feeding position

Ramp is tilted to straight position, pusher moves to stored/default trip out position.

Ramp is lowered to pipe loading/unloading position.

Next step: Move joystick to center.





Step Description

5 38 Eject pipe to feeding unit

Ready for kick out pipe when TFU Carriage at Trip out prox.

Move TFU using touchpad to upper position.

Then confirm for kick out pipe.


Confirm: Confirm for no pipe on ramp.

6 40 Lower tubular feeding unit

Operate TFU if needed.


Confirm: Confirm for trip out next pipe.





4.3.7 CWM Sub Systems

4.3.7.1 Safety System

The CWM is equipped with an advanced safety system with the following main tasks:

• Inform the operator of potential risks through the alarm and message system.

• Prevent operator generated critical situations from occurring.

• In case of equipment failure, quickly bring the machine to a safe state.

• Prevent internal collision, between the arms etc.

• Anti-collision system to prevent from crashing with other machines.

• Pipe Interlock system to prevent from losing pipes unintended.

4.3.7.1.1 Function Inhibit

Even during normal operation, the complexity of this machine makes it necessary to inhibit certain functions based on the current status of the machine. This includes for example: The control system will inhibit such functions and indicate this to the operator visually on the touchpad, or by messages displayed on the front screens.

4.3.7.1.2 Pipe Interlocks

During tubular handling, there will be several stages where there are more than one machine interacting with the tubular at the same time. In these cases, it is important that the machines inform each other of the current status to avoid incidents. The CWM control system interfaces a Pipe Interlock system and informs this of the status of each relevant function. Based on this information, and similar status information from the other machines, the Pipe Interlock system will notify the CWM whenever functions cannot be operated.

4.3.7.1.3 Anti-Collision / Zone Management

One possible cause for damages to any machine on drill floor is collisions with other machines. To avoid this, the CWM control system interfaces the ACS / ZMS system. All relevant position data is reported along with stop lengths and other relevant information to the ACS/ZMS system. Based on geometrical calculations and similar information from other machines, the ACS/ZMS system will command the CWM control system to stop if necessary.





4.3.7.1.4 Safety Modes

Certain faults in the system may require reducing performance or even inhibiting certain modes of operation. There are three main safety modes for the CWM: Shutdown Errors in critical instruments, communication loss with active operator chair or panel, functions moving when not commanded, and other faults resulting in lack of control over the machine will cause an immediate shutdown of the system, resetting any active mode or sequence. Two different shutdown modes are used, related to either electrical or hydraulic safety actions: Mode Abort Errors in critical instruments, movement in wrong direction, or other faults that could cause a dangerous situation if the current operation is continued will cause any active mode (Manual or Auto) to be disabled. Auto Mode Stop There are several instruments that are critical to the automatic operation of the CWM, and a fault in any of these would cause the auto sequence to be aborted and/or inhibited. This also includes severe deviations in the automatic positioning and other faults that degrade the reliability of the automatic sequences.

4.3.7.2 Message System

A sophisticated message system is included in the control system to guide and help the operator during the operation. Typical messages include:

• Information on active interlock for all buttons, both on touchpad and front screen. If a button is inhibited, the operator will be presented with information on the active interlock by pressing the interlocked button. A message will be displayed on the front screen.

• If an interlock on a joystick function is active, for instance internal collision avoidance, the operator is informed of the reason for the stop by a message on the front screen as the function is tried operated.

• Information during the auto sequence, for instance how to proceed in the sequence, active interlocks or reasons for a stop situation.

4.3.7.3 Position Measurement System

The operator can access the “Position Configuration” pop-up by pressing the button on the Pipehandler main screen. All references in this section refer to this screen. The pop-up displays position status information for all the CWM functions.





4.3.7.3.1 Preset Mode

The CWM is equipped with absolute encoders that will “remember” its positions regardless of power loss. Presetting of such encoders is normally not necessary, but in some cases faulty readings or damaged sensors can occur. In such case a presetting of an encoder may be necessary.

DANGER:

Presetting any of the position sensors wrongly, may cause the safety system to fail in critical situations, which in turn may lead to severe damage on the equipment or personnel.

The misc. encoders section displays the status of miscellaneous encoders and allows the operator to preset these individually. The actual position is displayed, and the preset position is described for each of the axes. To perform a correct preset of an encoder, the operator must ensure that the actual condition is fulfilled. This is normally performed by moving the function to the mechanical end stop in the correct direction. This can be done by operating the function in manual mode and activating the interlock override simultaneously. The operator shall confirm that the function is in mechanical end stop before activating the “S” button for the encoder.

After a preset of an encoder, check for correct operation by operating in manual mode. Carefully operate the function towards the soft-stop limit (close to the mechanical end stop limit) in both directions. Check for correct ramping down prior to entering the end stop position.

4.3.7.3.2 General Procedure for Preset of Position Sensor

1. Open the “Position Config.” Pop-up available from the CWM main screen. 2. Enter the correct password (refer to On Track user manual). 3. Activate preset mode. 4. If necessary, activate interlock override. 5. Carefully move the function to the preset position. 6. Perform a position preset, by pressing the “S”-button next to the position, and then “Set” on

the pop-up. 7. Verify correct position.





4.3.7.4 Emergency Operation

In case of equipment failure or special situation the emergency operation mode can be used for operating the machine. Great caution must be exercised to avoid equipment destruction or personnel injury. The emergency operation is controlled from the “Emergency Operation” pop-up available from the CWM main screen.

Picture 8505

4.3.7.4.1 Activation

1. Ensure the CWM is shut off. 2. Open the “Emergency Operation” pop-up. 3. Enter the Emergency operation password. The password is: “2010”. 4. Select the function(s) to operate. 5. Press the activate button. 6. Activate the “ON” button on the touchpad. When the machine is active, the interlock override

button is constantly active. Also, a message is displayed to inform that emergency mode is activated.

7. Select manual mode. 8. Carefully operate the machine.





WARNING:

When the CWM is operated in emergency operation, the most critical safety actions for the selected functions are disabled. This includes internal anti-collision, interlocks and position interlocks. All

alarms will still be presented to the operator, but the normal action is not executed. This may lead to extremely dangerous situations. The operator must be very observant and ready to activate the

emergency stop in case of unexpected situations.

4.3.7.4.2 Deactivation

The following actions will deactivate emergency operation (any of them):

• The machine is shut off (“ON” Button not active).

• The activate button on the Emergency operation pop-up is deactivated.

• The machine has not been commanded for 5 minutes. Each time the emergency operations mode has been deactivated, the activation sequence must be followed for reactivation.

Date post:	13-Jan-2020
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