August, 2008 Rev 0 TDS-11HP Troubleshooting Guide 1.0 Hydraulic System Pressure Low 1.1 System pressure cannot be obtained through following hydraulic setup procedure. 2.0 Shot pin does not engage. 3.0 Clamp cylinder does not actuate. 4.0 Shot pin engages but clamp cylinder does not activate. Symptoms / Problems 5.0 Clamp cylinder does not release. 6.0 Stand jump does not function. 7.0 RLA does not rotate. 8.0 Link tilt does not move to drill/mouse hole position. 9.0 Link tilt drift back to well center from drill/mouse hole. 10.0 Drill pipe elevator does not reach mouse hole/derrickman position. 11 0 I B O P does not operate 11.0 I.B.O.P. does not operate. 12.0 Oil pump loss alarm is on. 13.0 Hydraulic elevators will not function. Setup / Adjustment Guides Hydraulic manifold solenoid identification. Hydraulic system pressure setup. Hydraulic system manifold identification. Shot pin circuit setup procedure. Gear oil pump / pressure switch set‐up. Counterbalance / Stand Jump Adjustment Counterbalance /StandJump Adjustment. Stand jump/Clamp circuit isolation procedure. Blower Pressure switch adjustment. Charlie Ewing Ted A. Jones
Transcript
August, 2008Rev 0
TDS-11HP Troubleshooting Guide
1.0 Hydraulic System Pressure Low1.1 System pressure cannot be obtained through following hydraulic setup procedure.2.0 Shot pin does not engage.3.0 Clamp cylinder does not actuate.4.0 Shot pin engages but clamp cylinder does not activate.
Symptoms / Problems
5.0 Clamp cylinder does not release.6.0 Stand jump does not function.7.0 RLA does not rotate.8.0 Link tilt does not move to drill/mouse hole position.9.0 Link tilt drift back to well center from drill/mouse hole.10.0 Drill pipe elevator does not reach mouse hole/derrickman position.11 0 I B O P does not operate11.0 I.B.O.P. does not operate.12.0 Oil pump loss alarm is on.13.0 Hydraulic elevators will not function.
Setup / Adjustment Guides
Hydraulic manifold solenoid identification.
Hydraulic system pressure setup.
Hydraulic system manifold identification.
Shot pin circuit setup procedure.
Gear oil pump / pressure switch set‐up.
Counterbalance / Stand Jump AdjustmentCounterbalance / Stand Jump Adjustment.
Stand jump/Clamp circuit isolation procedure.
Blower Pressure switch adjustment.
Charlie Ewing Ted A. Jones
When you override a directional valve, you bypass the safety interlock which can result in
PROBLEM POSSIBLE CAUSE REMEDY DETAILS
1.0Hydraulic System Pressure Low
Counterbalance mode valve left in shut down/rig up position.
Counterbalance mode valve swithced to RUN
uncontrolled movement of top drive components, possibly causing serious injury or death.
No hydraulic A/C motor rotation / rotation backwards
Confirm A/C motor is rotating clockwise by looking into fan end of motor.
Flexible coupling is damaged. Replace the flexible coupling.
Remove hydraulic aux. circuit isolation, follow hydraulic system setup procedure.
Install pressure gauge at
2.0Shot pin does not engage.
Solenoid valve SV5 is not operating
Manually verify function of SV5, Replace SV5 if necessary
port B5 on shot pin assy. Manually function SV5 until shop pin rests on face of gear. Pressure should be 400 psi.If pin fires manually, check for proper voltagecheck for proper voltage and signal at SV5
relief valve faulty or out of adjustment (400psi).
verify functionality of clamp engage pressure switch
pressure switch is normally set to close (electrically) at 1500 psi.
shot pin motor faulty, not rotating
Refer to Section ( 7.0 ) RLA will not rotaterotating not rotate
3.0Clamp cylinder does not actuate.
Shot pin not engagedrefer to section 2.0 "shot pin will not engage"
No pressure or reduced pressure Test pressures CP on clamp
If no pressure is indicated at test port CP on clamp maniforld replace Check
at the clamp cylinder. manifold.maniforld, replace Check Valve CV5 on clamp manifold and recheck.
To provide high pressure to the clamp circuit, pressure at C5 must be
Cylinder is damaged.Inspect cylinder and repair or replace.
pressure at C5 must be 2,000 psi and G5 must be less than 100 psi. If this condition is met, pressure at CP should increase from less than 100 psi to higher than 2,000 psi. If not, check the plumbing, rotating link adapter, and clamp cylinder.
While clamping, pressure at CR should be 2.7 times the pressure at CP. When the dies contact the pipe, pressure at CR should be less than 100 psi. If the pressure does not fade, check valve CNEC for contamination.
Clean or repair CNEC valve.
If no pressure is indicated
4.0Shot pin engages but clamp cylinder does not activate.
Check Valve CV5 is faulty or sticking
Check pressure at test port CP (system pressure). Replace valve CV5
If no pressure is indicated at test port CP on clamp maniforld, replace Check Valve CV5 on clamp manifold and recheck.
Cartridge and/or check valve on remove valves, clean, check for clamp manifold is faulty or stuck trash and replace.
clamp cylinder leaking by replace clamp assy.
test port CP on clamp assy. Will not read system pressure if cylinder is leaking by.
5 0Clamp cylinder does
Control valve SV5 is stuck replace SV55.0p y
not releaseControl valve SV5 is stuck replace SV5
Clamp cylinder cartridge valves faulty or stuck
remove valves, clean, check for trash and replace.
valves are labeled as CNEC and COFA on hydraulic schematichydraulic line at port B5 on main hydraulic manifold must be
Inline flow control at Port B5 on main manifold plugged or stuck.
Replace inline flow control, remove and clean otherwise
manifold must be removed to access flow control valve. Flow control valve IS the boss fitting.
Logic Cartridge LC5 faulty or stuck
Replace LC5 at main manifoldstuck
6.0Stand jump does not function.
Solenoid valve SV9 is not operating.
with guage connected at port CB, manually function solenoid and check for pressure to increase by 200 psi.Test electrical and hydraulic
i R l i
If stand jump functions manually, either solenoid is defective, or no signal to solenoid valve.refer to counterbalance /
d joperation. Replace or repair as applicable.
stand jump set up procedure.
Cartridge valve PCC is not properly set or operating.
adjust or replace PCCRefer to counterbalance / stand jump set up
properly set or operating.procedure.
Relief valve SJR is not properly set or operating.
adjust or replace SJR.Refer to counterbalance / stand jump set up procedure.
Counterbalance cylinder Test cylinder and repair or damaged. Seal leaks. replace seal.Precharge on the counterbalance accumulator is low.
Charge the counterbalance accumulator to 900 psi.
7.0 RLA does not rotate System pressure is low refer to section 1.0
Solenoid Valve SV2/SV3 is inoperative or has no electrical signal
Manually function SV2/SV3 and check for electrical signal.Replace if defective.
If RLA does not rotate when SV2 is functioned manually, hook hydraulic test guages to motor test ports on shot pin and check for 1600 psi. in both ddirections.‐IF no pressure at motor, check relief valves for obstruction, replace SV2.‐IF pressure is present, replace hydraulic motor (shot pin)
Shot pin hydraulic motor damaged
replace hydraulic motor or shot pin assy.
(shot pin)When you override a directional valve, you bypass the safety interlock and top drive components move, possibly causing serious
Shot pin is engaged / clamp not retracted
refer to section 5.0
h i l i f d i
injury or death.
Mechanical interference. Inspect and repair.
TDS control system interlock will not allow
link tilt engaged function link tilt floatRLA to rotate left or right with link tilt engaged. Function link tilt FLOAT to clear interlock.
When you override a
8.0Link tilt does not move to drill/mousehole position.
Solenoid valve SV7 or SV6 is not shifting.
manually verify function of solenoid valves, check for electrical signal
When you override a directional valve, you bypass the safety interlock and top drive components move,
Float solenoid SV8 stuck in open verify no electrical signal to SV8 when not assigned, or
position valve spool is free by manually functioning
cylinder/s bad, defective seals, leaking by
test, replace leaking seals or cylinders
Run load holding valve dj t t f ll
9.0Link tilt drift back to well center from drill/mousehole.
Load holding relief valves CB1, CB2 on link tilt manifold are out of adjustment, stuck open, or contaminated.
Adjust or replace the load holding relief valve.
adjustment fully clockwise, then fully counterclock wise. Pressure at link tilt manifold TP should read +1500 psi.
Ch k l i iPressure at B8 on main manifold does not decay to less than 100 psi.
Replace the pilot to open check valves CV1, CV2 on link tilt manifold.
Check valve positions can be swapped to confirm defective or stuck check valve.
Pilot to open check valve is stuck open or contaminated.
Replace the pilot to open check valve.
see above
Faulty link tilt cylinder seal. Replace the faulty cylinder.
10.0
Drill pipe elevator does not reach mouse hole/derrickman position.
Link clamp incorrectly adjusted.Adjust link clamp to 27.5 inches from inside top of bale eye to center of bale clamp.
11.0I.B.O.P. does not operate
Solenoid Valve SV4 faulty or no electrical signal
Replace faulty SV4 or repair electrical connection
12.0Oil pump loss alarm is on.
test for oil pressure at oil pressure switch test port. Pressure should read 11+ psi.
Oil level too low. Add oil.
Oil viscosity too lowchange oil to oil specified in lube management program
Excessive oil viscosity. Lower oil viscosity.
Oil pressure switch is out of adjustment.
Adjust pressure switch to trip at less than 10 psi.
Refer to gear oil pump set up procedure.adjustment. at less than 10 psi. up procedure.
Faulty motor. Intermittent operation.
Replace motor.
Oil pump hydraulic motor failure.
Replace motor.
Faulty fixed displacement pump.Check pressure at PF. Replace pump if pressure is low.
Refer to gear oil pump set up procedure.pump if pressure is low. up procedure.
Low hydraulic fluid in reservoir. Add hydraulic fluid.
Gear spray nozzle missing. Replace spray nozzle.
13.0Hydraulic elevators will not function
Quick disconnets plugged or dirty
check / clean hydraulic quick disconnects
Hydraulic solenoid faulty or no electrical signal
check for electrical signal (24v), replace solenoid as needed.
elevator manifold hydraulic sequencing valve out of adjustment, contaminated, bad
adjust valve, replace if defective
run valve fully clockwise, then counter‐clockwise 4 1/2 turns to set. ‐IF elevators do not function, replace defective sequencingdefective sequencing valve.
STAND JUMP SOLENOID
BRAKE SOLENOID
ROTATING LINK ADAPTER LFT/RGT
I.B.O.P. CLOSE SOLENOID
TORQUE WRENCH CLAMP SOLENOID
LINK TILT FLOAT SOLENOID
LINK TILT/DRILL MODE SOLENOID (BOTTOM OF MANIFOLD)
PORT (A5) HOSE (SHOT PIN RETRACT)
HYDRAULIC COUNTERBALANCE VALVE: SHUT DOWN/RUN/RIG UP (SWITCH SHOWN IN RUN POSITION)
System Pressure set up Procedure TDS‐11HP
by Helmerich & Payne
Locate relief valve RV‐1 and remove cap. Adjust RV‐1 counterclockwise to its p jminimum setting.
Locate unloading valve UV‐1 and remove cap. Adjust UV‐1 fully clockwise to g p j yits maximum setting.
Locate test port P
Install test gauge at test port P
With TDS hydraulic motor running, turn RV‐1 clockwise while observing the test gauge rise to 2200 psi. Secure jam nut and put protective cover back on.p(While adjusting the valve, verify a linear relationship between turning the adjustment screw and observing the pressure gauge.)
Adjust unloading valve UV‐1 counterclockwise until the pressure starts falling The pressure will start cycling at this point Observestarts falling. The pressure will start cycling at this point. Observe several unload cycles to determine unload pressure. Adjust the setting of UV‐1 as required to a 2000 psi unload pressure. Secure jam nut and install protective cover.
TDS‐11 Hydraulic system manifold identification.
Test port A‐4. measures the open pressure. Pressure should read 500 psi. (The pressure will read system pressure for approximately one minute after assigning IBOP “open” ) then itminute after assigning IBOP “open”.) then it should fall to 500 psi. This is the timing circuit that protects IBOP crank rollers from continued excessive force.
Test ports at clamp manifold. You can measure open and close pressure.
This is reducing valve AR‐5. With a gauge in test port C‐5 the pressure is adjusted with AR‐5 to 1000 psi. This keeps a constant pressure on the clamp close circuit A reduced pressure at AR‐5 will result in slow clampclamp close circuit. A reduced pressure at AR‐5 will result in slow clamp retraction times.
These are the CLAMP/GEAR OIL and IBOP pressure switches. There are test ports on each. Clamp switch set at 1500 psiGear oil set at 10 psiGear oil set at 10 psiIBOP set at 1500 psi
Test port “P”. Install 3000 psi gauge here to monitor system pressure. Proper pressure will be 2000 psi falling to @ 1700 psi then loading back to 2000 psi after @ 20 seconds. A rapid cycle time of 10 seconds or less is problematic and most of the time a result of low system accumulator pressure.
Typical gear oil pressure of 21 psi. Switch set to alarm at 10 psi.
Gear oil pump hydraulic motor.
Three position switch in “rig‐up”. This will extend the counterbalance cylinders.
Three position switch must be in “SHUTDOWN” AND the TDS hydraulic pump MUST be locked out before any hydraulic lines are removed. (this does not i l d li )include test gauge lines.)
This is PCC, a pressure reducing/relieving valve for the counterbalance circuit.With a gauge connected at test port CB the proper setting will be 1450 psi.
Test port “CB”
This is RV‐2. It is the relief valve for the hydraulic motor turning the gear oil pump. With the pressure line to the gear oil pump plugged and a gauge connected to test port “PF” the proper setting is 400 psi.
Relief valve RV‐1 and test port “P”. Correct pressure 2000 psi falling to @ 1700 psi.
“P”
“RV‐1”
Relief valve “SJR”. With a gauge connected g gto test port “B‐9” AND stand jump assigned adjust to 200 psi.
“SJR”
Unloading valve “UV‐1”. See Setting up system pressure document.
Gauge connected at test port “P”. The gauge shows the pressure falling from 2000 psi.
Amp meter connected to hydraulic pump motor. This procedure is part of setting up the hydraulic pump compensator With “UV 1”part of setting up the hydraulic pump compensator. With UV‐1 fully clockwise you rotate “RV‐1” increasing pressure observed at test port “P” the amps shown should peak as the pressure passes through 800 psi.
Illustrates the above slide.
Under this cap is the compensating valve. It should be factory preset and no adjustment necessaryand no adjustment necessary.
Compensating valve
T t t L/T if ld Thi i f th “DRILL” itiTest port on L/T manifold. This one is for the “DRILL” position.
If you look closely you can see the flow control valve that hose “B‐5” connects to. This valve IS directional, the direction IS stamped on the valve This valve will causedirection IS stamped on the valve. This valve will cause the clamp not to release if plugged or malfunctioning.
Load holding valve for Link Tilt Drill. When link tilt drill is selected the links will travel to the drill position, once there the pressure will rise to system pressure. When the driller removes his finger from the screen the pressure will fall to the load holding valve set pointthe screen, the pressure will fall to the load holding valve set point. Adjust this valve counterclockwise to increase the pressure and clockwise to decrease. (opposite from the normal valve.)If you do not have sufficient pressure the links will “drift” back to well center when the driller removes his finger from the screen.
Load holding valve for Link Tilt “TILT”. Adjust the same as the “drill” valve.as the drill valve.
Link tilt “tilt” test port. Connect gauge here when setting “Tilt” pressure.p g g g p
Gauge connected to shot pin test port “B‐5”, relief valve to be adjusted to 400 psibe adjusted to 400 psi.
With gauge connected at test port on RLA motor manifold adjust relief valve opposite of the gauge. Correct pressure should be 1700 psi. NOTE: before this adjustment can be made the shot pin (and clamp) must be engaged to lock the gear.to lock the gear.
Repeat the procedure for opposite direction.
TDS‐11 Shot Pin and Clamp Setup Procedure.
The purpose of this procedure is to limit the amount of force the shot pin exerts on the ring gear. The adjustment at AR5 will speed up or slow down the retraction of the clamp once the j p p pcommand is given to release.
Be aware that the complete ROTATING LINK ADAPTOR ASSEMBLY AND BAILS /ELEVATORS WILL ROTATE WHEN THE DRILLER ASSIGNS “CLAMP ENGAGE”! BE ABSOLUTLY CERTAIN THAT ALL PERSONELL ARE CLEAR OF ANY PINCH POINTS DURING THIS PROCEDURE!
Assign three position valve to “run”. Turn on TDS hydraulics.
Locate test port B5 on shot pin body. Connect 3000 psi gauge.
Have driller assign torque wrench “ENGAGE”. Be certain that the shot pin stalls on the face of the ring gear.
Adjust relief valve to 400 psi.
Locate test port C5 and install 3000 psi gauge.
Locate Reducing valve AR‐5. With TDS hydraulics on and clamp released adjust reducing valve to 1000 psi.
Set‐up Procedure for Gear Oil Pump/Pressure Switch
Tools needed: Hydraulic pressure testing kit w/0‐60psi gauge, 0‐3000psi gauge, l i 5/32 ll h 9/16 bi i h 7/8 bi imulti‐meter, 5/32 allen wrench, 9/16 combination wrench, 7/8 combination
wrench, and a ‐8 (1/2) JIC cap and plug. 5/8 combination wrench, and a flathead/Philips head screwdriver.
Locate lube oil pressure switch
Locate RV2 pressure reducing valve and PF port on hydraulic manifold, and the PF test port on hydraulic manifold.
Remove the cover on the lube oil pressure switch and locate the blue and purple wires. Install the 0‐60psi gauge on the test port on the pressure switch.
: Engage TDS hydraulic motor and observe the pressure on the gauge. Once it achieves maximum pressure, th lti t t if ti it b t th bl d l i U th 9/16 h t b kuse the multi‐meter to verify continuity between the blue and purple wires. Use the 9/16 wrench to break
the jam nut on RV2. Use the 5/32 allen wrench to turn the pressure reducing valve (RV2 )counterclockwise until you observe 10psi on the gauge. Once you achieve 10psi, back the set screw off of the adjustable brass nut located in the pressure switch. Observe that the multi‐meter has lost continuity between the blue and purple wires. Use the 5/8 wrench to turn the brass nut until you achieve continuity. Reset the set screw and p p y yreinstall the cover on the pressure switch.
LO/TO TDS , Locate the PF port on the manifold and remove the line with a 7/8 wrench. Use the JIC fittings to cap and plug the line and port. Install the 0‐3000psi gauge on theUse the JIC fittings to cap and plug the line and port. Install the 0 3000psi gauge on the PF test port (located between solenoids next to the PF boss port). Re‐energize the hydraulics. Use the 5/32 allen wrench and turn RV2 clockwise until you achieve 400psi. Once you achieve 400psi, reset the jam nut on RV2 and turn off the hydraulics. LO/TO TDS d i t ll th h d li li t th PF t th if ldTDS and reinstall the hydraulic line to the PF port on the manifold.
Set‐up Procedure for Gear Oil Pump/Pressure Switch
• Tools needed: Hydraulic pressure testing kit w/0‐60psi gauge, 0‐3000psi gauge, multi‐meter, 5/32 allen wrench, 9/16 combination wrench, 7/8 combination wrench, and a ‐8 (1/2) JIC cap and plug. 5/8 combination wrench, and a flathead/Philips head screwdriver.
• Step 1: Locate lube oil pressure switch, RV2 pressure reducing valve, PF port on hydraulic manifold, and the PF test port on hydraulic manifold.
• Step 2: Remove the cover on the lube oil pressure switch and locate the blue and purple wires. Install the 0‐60psi gauge on the test port on the pressure switch.
• Step 3: Engage TDS hydraulic motor and observe the pressure on the gauge. Once it achieves maximum pressure, use the multi‐meter to verify continuity between the blue and purple wires. Use the 9/16 wrench to break the jam nut on RV2. Use the 5/32 allen wrench to turn the pressure reducing valve (RV2 )counterclockwise until you observe 10psi on the gauge. Once you achieve 10psi, back the set screw off of the adjustable brass nut located in the pressure switch. Observe that the multi‐meter has lost continuity between the blue and purple wires. Use the 5/8 wrench to turn the brass nut until you achieve continuity. Reset the set screw and reinstall the cover on the pressure switch.
• Step 4: Locate the PF port on the manifold and remove the line with a 7/8 wrench. Use the JIC fittings to cap and plug the line and port. Install the 0‐3000psi gauge on the PF test port (located between solenoids next to the PF boss port). Re‐energize the hydraulics. Use the 5/32 allen wrench and turn RV2 clockwise until you achieve 400psi. Once you achieve 400psi, reset the jam nut on RV2 and turn off the hydraulics. LO/TO TDS and reinstall the hydraulic line to the PF port on the manifold.
Locate Pressure reducing/relieving valve “PCC”, remove protective cap and loosen jam nut and . Turn TDS hydraulics on. Adjust PCC as required to 1450 psi. (On TDS 11 HP the setting is 1450 )setting is 1450.) On TDS 11 SA’s the pressure setting will be 1600 psi. (FLEX 2’s and retrofits.)
While observing the pressure have the driller assign “STAND JUMP”. The pressure should increase by 200 psi. If adjustment is necessary, locate relief l “SJR” d dj il i i b i dvalve “SJR” and adjust until correct pressure increase is obtained.
Stand jump/Clamp circuit isolation procedure
Lock out TDS hydraulic pump Assign three positionLock out TDS hydraulic pump. Assign three position switch to “Shut down”.
After all pressure has bled off, remove COUNTERBALANCE pressure line from drillers side cylinder. Plug and cap both ends
h h d l l k d d hWith TDS hydraulic pump locked out and three position switch in “shutdown”. After pressure has bled off, remove clamp supply and return lines and install caps and plugs.p p g
Adjustment Procedure for Blower Pressure
Switch - TDS11HP
1) Assign the Top Drive to “ON”. Blowers should come on. 2) Remove the cap on the Pressure Switch for the Blower.
3) Follow Directions on the inside of the cap.
4) Adjust Large Brass nut (using a 5/8” open end wrench) out until the alarm is no longer present. (This may take a couple of attempts to get desired setting.)
Note: Do not handle or touch the small plunger!
5) Once that the alarm is no longer present we need to disconnect the blower tube at the junction box and verify that the alarm is present.
Note: Blowers must be on during this test.
6) Install Tube after alarm verification test is complete.
7) Replace cap for the Pressure Switch and re-tie wire as necessary.
