Derrick, Crown & Accessories, National 516 Hojas

FINAL DOCUMENTATION PACKAGE
Derrick, Crown & Accessories

Serial Number: E-C18773-D70
January 2004 Customer References

Customer Rig Contract Number
PEMEX 4036 or 4035 4122335007
National Oilwell References

Job Number Sales Order Number
C18773 SP3062301
Operating and Maintenance Manual

Derrick, Rig and Accessories
January 2004
Customer References
Customer Rig Contract Number
PEMEX 4036 or 4035 4122335007
National Oilwell References

Job Number Sales Order Number
C18773 SP3062301
Final Documentation Package PEMEX Rig 4036 or Rig 4035 Derrick, Crown & Accessories
Project Number: C18773 Document Number: As Noted Chapter 1 Page 1 of 18
Table of Contents
Chapter - Section
OPERATING & MAINTENANCE MANUAL - Derrick Introduction Specifications Maintenance IDECO Drawworks Package Lubrication Parts Book
1.0 1.1 1.2
2.0 2.1 2.2
GE 752 DC Motor, Models: ARB1A and ARB1B General Maintenance Renewal Parts
3.0 3.1 3.2
BaylorTM Model 7838 Electromagnetic Brake Installation, Care & Operating - Universal Disc Brakes - Parts List and Drawings Installation & Maintenance - Hydraulic Power Unit - Purchased Parts Hook Block GA-500 Swivel P-500 Deadline Anchor Type EB Drill Line 1-3/8 x16,405
4.0 4.1
4.2
5.0 6.0 7.0 8.0
Final Documentation Package PEMEX Rig 4036 or Rig 4035 Derrick, Crown & Accessories
Project Number: C18773 Document Number: As Noted Chapter 1 Page 2 of 18
Table of Contents (continued)

MANUFACTURING RECORDS BOOK Derrick Company Certifications Certificates of Compliance General Arrangement Drawing Non-Destructive Test Reports Load Tests NDT Operator Qualifications Welder Qualifications Welding Procedures Material Traceability Material Test Reports Manufacturing Records IDECO Drawworks Certificate of Compliance Material Records Non-Destructive Examinations NDE Personnel Qualifications Inspection Reports Quality Assurance Plan Certified Welders List
Chapter - Section
9.0 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10
10.0 10.1 10.2 10.3 10.4 10.5 10.6 10.7
PEMEX RIG 4036 or RIG 4035
Chapter 1.0
Introduction
January 2004
Final Documentation Package Pemex Rig 4036 and 4035 Derrick, Crown & Accessories
Project Number: C18773 Document Number: As Noted Chapter 1 Section 1 Page 3 of 17
Introduction
The equipment in the scope of this manual is intended to withstand a broad range of conditions. The scope of this manual includes only equipment manufactured by National Oilwell and does not pertain to equipment supplied by Customer or others. We have supplied a section in this manual (Vendor Information) that does pertain to equipment that is supplied, but not manufactured, by National Oilwell. If there is any overlapping of information between this manual and a manual from a vendor, the vendors manual shall take precedence unless otherwise noted. The equipment design encompasses five objectives: safety, equipment durability, accessibility, usability, and cost effectiveness. The mechanical components in the scope of this manual have been engineered and selected for the most reliable yet cost-effective operation. Correct preventive maintenance should be considered an investment; it minimizes equipment wear, failures, and downtime. New parts may be installed at less expense when the equipment is in the shop for repairs or strip-down, than when the equipment requires emergency servicing.
Warranty
All National Oilwell equipment built in our plant is guaranteed to be free from defects in workmanship for a period of 12 months from the date of delivery to the original customer or as specified in the contract. In the event of any failure on which a warranty claim may be presented the owner must notify us and follow our instructions relative to the inspection or disposition of the defective part or parts and to the repairing and/or replacement thereof. The foregoing warranty is contingent on the proper application of equipment and products by the owner in accordance with the recommendations of the manufacturer National Oilwell, and shall not apply to any products which shall have been repaired or altered in any way so as in the judgment of National Oilwell to affect adversely their performance and reliability nor which have been subject to misuse, negligence or accident or equipment that has been repaired to the customer's specifications rather than to National Oilwells specifications. Our obligation under this warranty is limited to supplying parts and labour to correct defective workmanship to an amount not exceeding the charges for the original repair and shall not include any transportation charges, loss of revenue, or any direct or indirect consequential damages. Travel time and travel expenses will be charged to customer's account at cost. All warranty work will be done on a straight time basis and the customer will be charged for the difference between straight time and overtime. The warranty does not cover any hoisting, trucking or transportation charges. Products furnished by National Oilwell but not manufactured by National Oilwell will carry only the warranty of the manufacturer of such products. The entire liability and obligation of National Oilwell with respect to workmanship is defined by this warranty and is given in lieu of any and all other warranties, expressed or implied. No oral or written statements or representations with respect to the subject matter hereof shall be binding. Upon the expiration of this warranty, all liability on the part of National Oilwell in connection herewith shall terminate in any event.
Warranty Limitations
This manual is prepared as a guide for normal installation, care and operations of your unit. Because of the varying methods and requirements for these functions, it is not possible to detail all facets of these subjects and it is requested that when situations encountered are outside the scope of this publication, refer to the manufacturer's technical services department. The manufacturer will upon request and contract, provide trained personnel to assist you in the maintenance and servicing of this equipment. Improvements in design, engineering, materials, production methods, etc. may necessitate changes in this product over time. We reserve the right to make these design changes without incurring any obligation for equipment previously delivered.
Safety Summary
This manual uses the following standard safety terms and conventions that span all areas of industry: WARNING: is used when an operating procedure, practice, etc., which, if not correctly implemented, could result in personnel injury and/or equipment damage. is used when an operating procedure, practice, etc., which, if not correctly implemented, could result in equipment damage. provides information necessary to properly complete a procedure or information that will make the procedure easier to understand.
CAUTION:
NOTE:
Only qualified personnel should be allowed to operate and maintain the equipment. Personnel should not operate the unit unless they are thoroughly familiar with all unit operating controls, functions, and have read the equipment manual. Personnel are protected from exposed mechanical dangers by guards fabricated from expanded metal. Keep hands, hair, clothing, jewelry, rags, tools, etc. away from all moving parts during operation. Do not attempt equipment operation with inadequate visibility unless suitable lighting provisions are available. Operating and maintenance personnel should wear protective clothing and equipment suitable for work being performed. Promote good safety measures at all times around the equipment throughout all operating phases. It is the equipment owner's/operator's responsibility to establish good safety measures including personnel training, and enforce safety practices. Equipment used in lifting and moving the unit must be sufficiently rated to handle the weights involved. Before disconnecting any high pressure piping or hoses, ensure the unit has been bled to zero pressure. Observe similar procedures for electrical connections, ensuring electrical power is off and has been cut before attempting maintenance.
WARNING:
Do not breathe cleaning solvent vapors. The toxic effect of some solvents is cumulative. Continued inhalation can lead to permanent disability or death. When using flammable cleaning solvents, take all appropriate fire protection precautions to prevent injury to personnel and damage to equipment.
WARNING:
Do not direct compressed air against any part of the body. High pressure air can cause injuries. Do not rotate ball or roller bearings with compressed air. Do not direct compressed air against a fire. Tag controls and depressurize hydraulic system before disconnecting or removing any part of the hydraulic piping. Ensure all tanks, lines, and equipment are depressurized by slowly releasing pressure through approved means.
WARNING:
Use adequate hoisting equipment. Observe all safety precautions. Ensure that hydraulic systems are depressurized and controls are tagged DANGER DO NOT OPERATE EQUIPMENT BEING REPAIRED before attempting adjustment and repair procedures on the equipment.
WARNING:
Determine if equipment has preloaded components such as springs before disassembly. Remove preload prior to disassembly by approved format.
WARNING:
When working on a system, disconnect electrical power supply and tag controls to prevent accidental operation. Serious injury or death could result. Use mechanical shutoff when available.
WARNING:
DO NOT ADD ANY EQUIPMENT TO THE DRILLING MODULE THAT IS NOT DESIGNED TO BE PART OF THE DRILLING MODULE.
Section 1.1
Derrick Specifications
January 2004
Derrick SPECIFICATIONS
Serial Number:
Model:
E-C17896-D70
Clear Height: 147 (44.8 Meters) GNC: 1,392,000 lbs (631.4 Tonnes) Maximum Rated Static Hook Load with: 12 lines 1,044,000 lbs (473.5 Tonnes) HOOKLOAD 1,044,000 # 1,044,000 # 0 CAUTION: PIPE SETBACK 600,000 # 300,000 # 600,000 # MAXIMUM WIND 30 Knots 50 Knots 100 Knots
Acceleration or impact, as well as setback and wind load will reduce the maximum rated Static Hook Load Capacity. Model Number: Cluster Sheaves: Groove Diameter: Maximum Rated Static Hook Load: 5170B000 7 60 1-3/8 12 lines
Crown:
1,044,000 lbs. (473.5 t) To Traveling Block
CAUTION:
Acceleration or impact loads will reduce the maximum rated Static Hook Load.
Section 1.2
Derrick Maintenance
January 2004
MAINTENANCE
STRUCTURE AND EQUIPMENT
a. External inspection and routinely checked items. i. All pins and holes should be checked for wear, elongation and secure fit. If hole elongation occurs, it is die to an abnormal load. The origin of the abnormal load must be determined and this operation discontinued. The lug or logs require repair/replacement by approved method. If wear on pin or hole allows for excess movement then approved repair/replacement is required. Consideration should be given to loading movement and extremity of hazard. A pin to hole difference on 2 dia. and smaller pins is maximum 1/8 on diameter. A pin to hole difference on larder than 2 dia. is maximum 5/32 on diameter. If connection is considered unsecure, then approved repair/ replacement is required. Contact National Oilwell before making any repairs. Check all pin connections and ensure all pins are held in place by a bolt or safety pin on each end. Check all bolts for tightness. Pay particular attention to mast shoes, flanges, clamps, deadline anchor pigtail, traveling block, crown and other equipment. Inspect structural components for damage due to handling (load shifts, chain down). Inspect for bent or crimped members. Replace/repair according approved methods. After extreme load cases resulting from operation, check welds. Check for cracks or signs of deformity. Repair according to approved methods. During lubrication intervals check items being lubricated for damage, rubbing, wear and quality of fit. Replace as required. Examples: vi-a. Sheaves: Check for wobble, sheave groove bolt tightness, guards in place, wirelines. vi-b. Wireline: Check for line quality, pay close attention to area close to sockets and pins, sheave guards. vi-c. Rollers/wheels: Check bearings, bushings, rollers/wheels for wear, bearing wear surfaces for wear, grooving guards as applicable. vi-d. Shafts: Check for wear, eccentricity, end play movement, bearings or bushings. Just after regular use, check local areas by hand for excess heat. Repair or lubricate as required. vii. During rig up, periodically during operations, and while performing daily operations or specific operations, check areas for safety. Guards and handrails must be in place and secure. Safety harnesses must be in place, secure and of suitable quality. Damaged stairs must be repaired immediately. Hoses, cables, and wirelines must be kept coiled and properly stored when not in use. viii. Periodically check for cosmetic damage. Inspect handrails far straightness. Repair as required. ix. Periodically check painting for damage, chipping, peeling and cracking. Note areas with rust or corrosion and repair immediately. Use approved method of repair. Check for missing or damaged nameplates, tags, instruction plates or other equipment markings, and replace with
ii. iii. iv. v. vi.
exact duplicates. Check for proper markings on fluid type in piping. Look for rubbing against paint and repair. Review situation to reduce amount of rubbing.
Wireline / Slinglines
a. Check wirelines prior to use when they have been dormant for longer than one month. Inspect wirelines prior to and after extreme loading. For wirelines experiencing heavy usage, it is important to set up a review and lubrication program that meets the needs of the wireline. When inspecting wirelines, pay particular attention to areas near sockets or around sheaves or yokes. Frequency of any wireline inspection depends on line application, but should be done a minimum of once a month. b. Types of deterioration or damage to inspect for are: i. Corrosion In saline environments, corrosion is a major cause of concern. Every precaution should be taken to avoid corrosion. Corrosion reduces the metallic areas of a rope, thus weakening it. Also, it mars the surface of the wires by creating stress raisers, which hasten the development of broken wires. The most dangerous feature of a corroded rope is that it is almost impossible to ascertain the true condition of the rope. Areas adjacent to end connections should be examined closely for any evidence of rust. A significant amount of corrosion other than minor surface rust, should be cause for replacement. Proper lubrication of the wireline will combat corrosion. ii. Abrasion The ability of wire rope to withstand wear when operating over sheaves, roller, and drums or when rubbing over stationary objects is the measure of its resistance to abrasion. Larger diameter wires will withstand abrasion to a greater degree than small wires, therefore, the coarsest rope construction such as 6 x 7 will have a higher resistance to abrasive wear than a 6 x 16 classification. A line showing significant reduction in area or broken wires from abrasion should be replaced. iii. Elongation When a significant increase in length is evident in any section or rope, it should be replaced. Elongation is accompanied by a diameter reduction that can be measure with calipers and compared to original measurements taken when the rope was new. Diameter reductions of 1/16 or more in 1 1/8 ropes and 3/32 for 1 to 1 ropes are cause for replacement. iv. Broken Wires A line with any broken wires should be replaced. Breaks often occur in the valleys of the line and require close inspection to locate. v. Damage Avoid leaving the line or handling the line where damage such as kinking, crushing, heat damage resulting in distortion of the rope structure could occur. Any such damage should be cause for replacement. c. For further guidelines on wire ropes see API Recommended Practice on Application, Care and Use of Wire Rope for Oil Field Service, API RP 9B Latest Edition.
GENERAL NOTES
a. Most fixtures and accessories are already assembled to the structure, and all equipment is in place or accommodated prior to field installation. If, however, anything needs to be added or modified, then recommendations from the manufacturer are required. Do not drill or burn holes or weld unless approved methods are strictly adhered to and there is consultation with National Oilwell. b. Due to the nature of pin installation, whereby, they are scraped or scratched, there is a possibility for corrosion / rusting of the pin or connecting lugs. During pin installation, apply a light oil to the pin. This will maintain a more corrosion free environment and improve pin and connection life.
c. Disassemble only when and to the extent necessary to repair or replace defective components. This action reduces the possibility of contaminants entering the system. It reduces possible unnecessary damage to sensitive areas. It reduces possible incorrect re-assembly. This will minimize unnecessary downtime. Always disassemble by approved format and with proper disassembly methods. d. Replace all oil seals and gaskets when exposed during assembly. e. Protect uncoated clean parts, if not to be used immediately, with a preservation compound, to prevent rust and deterioration. Protect uncoated exposed areas or surfaces such as threads or machined surfaces to prevent rust or deterioration. When coating operating surfaces, use a coating compatible with the lubricant. f. Identify pipelines, connectors, and electrical wires as each is removed or disassembled to ensure proper reconnection when assembling. g. Review specific maintenance manuals for specific equipment.
WARNING: Do not breathe cleaning solvent vapors. The toxic effect of some solvents is cumulative. Continued inhalation can lead to permanent disability or death. When using flammable cleaning solvents, take all appropriate fire protection precautions to prevent injury to personnel and damage to equipment. Do not direct compressed air against any part of the body. High pressure air can cause injuries. Do not rotate ball or roller bearings with compressed air. Do not direct compressed air against a fire. Use adequate hoisting equipment. Observe all safety precautions. Ensure that hydraulic systems are depressurized and controls are tagged DANGER DO NOT OPERATE EQUIPMENT BEING REPAIRED before attempting adjustment and repair procedures on the equipment. Tag controls and depressurize hydraulic system before disconnecting or removing any part of the hydraulic piping. Disconnect hydraulic lines at quick couplers and cap ends immediately with caps provided to prevent foreign material from entering the system. Provide means to catch any hydraulic fluid that may escape during disconnection. Wipe up spills. Ensure all tanks, lines, and equipment are depressurized by slowly releasing pressure through approved means. Determine if equipment has preloaded components such as springs before disassembly. Remove preload prior to disassembly by approved format. Disconnect electrical power supply when working on a system and tag controls to prevent accidental operation. Use mechanical shut off when available.
LUBRICATION AND MAINTENANCE

a) b) The structure should be operated and maintained as required by API Standards and local regulations. Where the two overlap, the stricter rules should govern. Lubrication i. Sheaves require a #2 lithium base lubricant with extreme pressure resistance qualities at elevated temperatures. Greasing should be done at regular periods, which depend on the conditions. ii. All wirelines, must be kept coated with a good rope lubricant at all times. Operating and Maintenance i. Careful, periodic checking of the structure will assure safe, dependable and economical service of the rig. ii. Cap plates on all shafts and all wired bolts should be checked regularly to assure that the bolts are tight and the retaining wires in place. iii. Inspect the wirelines on a regular basis. Pay particular attention to areas near sockets or around sheaves. line with any broken wires should be replaced. line with significant net area reduction resulting from wear should be replaced. line with signs of corrosion other than minor surface rust should be replaced. kinking, crushing, or any damage resulting in distortion of the rope structure should constitute immediate replacement. iv. Any damage or distortion of the structural members should be repaired immediately. National Oilwell should be contracted prior to any repair, reinforcement, or other modification to ensure the structural acceptability, proper engineering design, fabrication and installation of the proposed modifications, and to ensure that adequate repair methods and procedures are followed so that the certification given by National Oilwell is not impaired.
c)
Tightening Torque Guide For Bolts

Tightening Torque Guide SAE Grade 5 - Fine Thread Clamp Load Plain 2,325 10 ftlbs 3,675 19 ftlbs 6,699 35 ftlbs 7,575 55 ftlbs 10,200 85 ftlbs 12,975 122 ftlbs 16,350 170 ftlbs 23,775 297 ftlbs 32,475 474 ftlbs 42,300 705 ftlbs 32,275 721 ftlbs 47,475 890 ftlbs 59,550 1,241 ftlbs 72,975 1,672 ftlbs 87,750 2,194 ftlbs
Size 1/4 - 28 (.250) 5/16 - 24 (.3125) 3/8 - 24 (.375) 7/16 - 20 (.4375) 1/2 - 20 (.500) 9/16 - 18 (.5625) 5/8 - 18 (.625) 3/4 - 16 (.750) 7/8 - 14 (.875) 1 - 12 (1.000) 1 - 14 (1.000) 1 1/8 - 12 (1.125) 1 1/4 - 12 (1.250) 1 3/8 - 12 (1.375) 1 1/2 - 12 (1.500)
Plated 87 inlbs 14 ftlbs 26 ftlbs 41 ftlbs 64 ftlbs 91 ftlbs 128 ftlbs 223 ftlbs 355 ftlbs 529 ftlbs 541 ftlbs 668 ftlbs 930 ftlbs 1,254 ftlbs 1,645 ftlbs
Size 1/4 - 20 (.250) 5/16 - 18 (.3125) 3/8 - 16 (.375) 7/16 - 14 (.4375) 1/2 - 13 (.500) 9/16 - 12 (.5625) 5/8 - 11 (.625) 3/4 - 10 (.750) 7/8 - 9 (.875) 1 - 8 (1.000) 1 1/8 - 7 (1.125) 1 1/4 - 7 (1.250) 1 3/8 - 6 (1.375) 1 1/2 - 6 (1.500)
Tightening Torque Guide SAE Grade 5 - Coarse Thread Clamp Load Plain 2,025 8 ftlbs 3,338 17 ftlbs 4,950 31 ftlbs 6,788 50 ftlbs 9,075 76 ftlbs 11,625 109 ftlbs 14,400 150 ftlbs 21,300 266 ftlbs 29,475 430 ftlbs 38,625 644 ftlbs 42,375 794 ftlbs 53,775 1,120 ftlbs 64,125 1,470 ftlbs 78,000 1,950 ftlbs
Plated 87 inlbs 13 ftlbs 23 ftlbs 37 ftlbs 57 ftlbs 82 ftlbs 112 ftlbs 200 ftlbs 322 ftlbs 483 ftlbs 596 ftlbs 840 ftlbs 1,102 ftlbs 1,462 ftlbs
Size 1/4 - 20 (.250) 5/16 - 18 (.3125) 3/8 - 16 (.375) 7/16 - 14 (.4375) 1/2 - 13 (.500) 9/16 - 12 (.5625) 5/8 - 11 (.625) 3/4 - 10 (.750) 7/8 - 9 (.875) 1 - 8 (1.000) 1 1/8 - 7 (1.125) 1 1/4 - 7 (1.250) 1 3/8 - 6 (1.375) 1 1/2 - 6 (1.500)
Tightening Torque Guide SAE Grade 8 - Coarse Thread Clamp Load Plain 2,850 12 ftlbs 4,725 25 ftlbs 6,975 44 ftlbs 9,600 70 ftlbs 12,750 106 ftlbs 16,350 153 ftlbs 20,325 212 ftlbs 30,075 376 ftlbs 41,550 606 ftlbs 54,525 909 ftlbs 68,700 1,288 ftlbs 87,225 1,817 ftlbs 103,950 2,382 ftlbs 126,450 3,161 ftlbs
Plated 9 ftlbs 18 ftlbs 33 ftlbs 52 ftlbs 80 ftlbs 115 ftlbs 159 ftlbs 282 ftlbs 454 ftlbs 682 ftlbs 966 ftlbs 1,363 ftlbs 1,787 ftlbs 2,371 ftlbs
Size 1/4 - 28 (.250) 5/16 - 24 (.3125) 3/8 - 24 (.375) 7/16 - 20 (.4375) 1/2 - 20 (.500) 9/16 - 18 (.5625) 5/8 - 18 (.625) 3/4 - 16 (.750) 7/8 - 14 (.875) 1 - 12 (1.000) 1 - 14 (1.000) 1 1/8 - 12 (1.125) 1 1/4 - 12 (1.250) 1 3/8 - 12 (1.375) 1 1/2 - 12 (1.500)
Tightening Torque Guide SAE Grade 8 - Fine Thread Clamp Load Plain 3,263 14 ftlbs 5,113 27 ftlbs 7,875 49 ftlbs 10,650 78 ftlbs 14,400 120 ftlbs 18,300 172 ftlbs 23,025 240 ftlbs 33,600 420 ftlbs 45,825 668 ftlbs 59,700 995 ftlbs 61,125 1,019 ftlbs 77,025 1,444 ftlbs 96,600 2,012 ftlbs 118,350 2,712 ftlbs 142,275 3,557 ftlbs
Plated 10 ftlbs 20 ftlbs 37 ftlbs 58 ftlbs 90 ftlbs 129 ftlbs 180 ftlbs 315 ftlbs 501 ftlbs 746 ftlbs 764 ftlbs 1,083 ftlbs 1,509 ftlbs 2,034 ftlbs 2,668 ftlbs
Socket Head Capscrew Tensile Requirements per ASTM A574-83 Screw Threads Inches Tensile Load Min. Tensile Rec. UNC Torque in Dia. Strength lbs. (in) UNC UNF UNC UNF psi/Min UNRC UNRF 0.060 80 324 180,000 2 0.073 64 72 473 500 180,000 4 4 0.086 56 64 666 709 180,000 6 7 0.099 48 56 877 941 180,000 10 11 0.112 40 48 1,090 1,190 180,000 15 16 0.125 40 44 1,430 1,490 180,000 20 21 0.138 32 40 1,640 1,830 180,000 28 30 0.184 32 36 2,520 2,650 180,000 49 50 0.190 24 32 3,150 3,600 180,000 64 76 20 28 5,730 6,500 180,000 150 170 5/16 18 24 9,440 10,400 180,000 305 325 3/8 16 24 13,900 15,800 180,000 545 570 7/16 14 20 19,100 21,400 180,000 840 900 13 20 25,500 28,800 180,000 1,300 1,370 5/8 11 18 38,400 43,500 170,000 1,850 1,970 10 16 56,800 63,400 170,000 2,630 2,660 7/8 9 14 78,500 86,500 170,000 4,400 4,800 1 8 12 103,000 113,000 170,000 7,000 7,600 1 7 12 129,000 146,000 170,000 10,400 11,000 1 7 12 165,000 182,000 170,000 14,900 15,600 1 3/8 6 12 196,000 224,000 170,000 21,000 22,600 1 6 12 239,000 269,000 170,000 27,800 29,300
Document No. Page
5910E241 16
Derrick Drawings
Drawing No. -5265B000 5265A010 5265A011 5265A012 5265A013 5265A014 5265L004 5265L005 5265L006 5279A008 5279A007 (L2) 5276A001 5274A000 5281A011 5170B000 5170A003 5850A002 5850A001 5281A010 5161A006 5161A007 5282A000 Drawing Title Nameplate Derrick General Arrangement O. Dwwks S. Derrick Assembly ODS Derrick Assembly Dwwks. S. Derrick Assembly Drillers Side Derrick Assembly Derrick Assembly (Bill of Materials) Derrick Lift Lug Layout Drill Line Reeving Diagram Platform Shoe Layout Ladder and Cage Assembly Landing Platform Assembly Ginpole Assembly Tong Counterweight Assembly V-Door Roller Assembly Crown General Assembly Crown Assembly 14 Snatch Block Assembly (12 Ton SWL) 14 Tugger Snatch Block Assembly (12 Ton SWL) Guide Roller Assembly Racking Board Assembly Collars and Fingers Locks Assembly Racking Board Platforms and Handrails Assembly
Chapter 2.0
IDECO Drawworks
January 2004
Section 2.1
Lubrication
January 2004
Section 2.2
Parts Book
January 2004
Chapter 3.0
GE 752 DC Motor
Models: ARB1A, and ARB1B
January 2004
Section 3.1
GE 752 DC Motor General Maintenance
January 2004
Section 3.2
GE 752 DC Motor Renewal Parts
January 2004
Chapter 4.0
Electromagnetic Brake Model 7838
January 2004
Section 4.1
Installation, Care and Operating Universal Disc Brakes
January 2004
PARTS LIST
E-2100DBH Drawworks Universal Disc Brake System
Code (X) CLIENT REVIEW STATUS
1 2 3 4
Accepted Accepted, incorporate comments at next scheduled revision Not accepted, revise and resubmit For information only
Date: Sign:
REV.
DATE
REV. DESCRIPTION
REV. BY
CHKD
APPR.
CUSTOMER NAME
PEMEX
CUSTOMER CONTRACT NUMBER: RIG NUMBER:
4122325007
NATIONAL OILWELL ORDER NO. ENGINEERING JOB NO. TOTAL NO. OF PAGES
01-802-890
This document contains proprietary and confidential information which belongs to National Oilwell , it is loaned for limited purposes only and remains the property of National Oilwell. Reproduction, in whole or in part, or use of this design or distribution of this information to others is not permitted without the express written consent of National Oilwell . This document is to be returned to National Oilwell upon request and in any event upon completion of the use for which it was loaned. ? Copyright be National Oilwell DOCUMENT NUMBER ADDRESS
37
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REV
EPL-1578
UNITED STATES STORES

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11-2000
Document number Revision Page
EPL-1578 0 Index Page (1 of 2)
E-2100DBH Universal Disc Brake System

Page 1 Drawing No. PL 704346 Rev. A Drawing Description Disc Brake Retrofit Kit with Manual Controls
Disc Brake Section: 2 PL 2112204 3 PL 2112227 4 PL 2112197 5 PL 2111820 6 PL 2110258 7 PL 2110668 8 PL 2110486 9 PL 2110634 10 PL 2110484 11 PL 2110001 12 PL 2110258 13 PL 2110486
C D C B C B K D B
Universal Disc Brake Retrofit Assembly Caliper Support Arm Assembly Service Caliper Assembly Main Service Cylinder Assembly Adjustable Plunger Assembly Service Caliper Wide Lever Assembly Brake Pad Plate Assembly Emergency Caliper Assembly Emergency Caliper Wide Lever Assembly Emergency Cylinder Assembly Adjustable Plunger Assembly Brake Pad Plate Assembly
Emergency Load Lowering Section: 14 PL 2111746 15 PL 7812716 A Manual Disc Brake Control Section: 16 PL 2112115 17 PL 2112042 18 PL 2112033 A Hydraulic Power Unit Section: 19 PL 2111960 20 PL 2111769 21 PL 2111770 22 PL 2111771 23 PL 2111772 24 PL 2111774 25 PL 2111775 26 PL 2111777 27 PL 2111778 28 PL 2111779
Emergency Load Lowering Assembly Load Lowering Manifold Assembly
Manual Disc Brake Control Assembly Brake Control Assembly Disc Brake Controller
E C B E A A B B A
Hydraulic Power Unit Assembly (2 Sheets) Reservoir Assembly (2 Sheets) Pump and Motor Assembly (2 Sheets) Accumulator Assembly (2 Sheets) Heat Exchanger Assembly (2 Sheets) Filter / Regulator Assembly (2 Sheets) High Pressure Filter Assembly (2 Sheets) Air Pump Assembly (2 Sheets) Header Assembly (2 Sheets) Needle Valve Assembly (2 Sheets)
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E-2100 Universal Disc Brake System
EPL-1578 0 Index Page (2 of 2)
Hydraulic Power Unit Section: (Continued) 29 PL 2111780 B 30 PL 2111781 A 31 PL 2111883 A 32 PL 2111885 A 33 PL 2111890 C Miscellaneous Information Section: 34 PL 2112007 35 PL 2112114 36 37 PL 2112212 PL 2112250
Pilot Valve Assembly (2 Sheets) Oil Transfer Tube Assembly Annunciator Assembly (5 Sheets) Pump Assembly (2 Sheets) Manifold Assembly (2 Sheets)
Hydraulic Power Unit Start-Up Kit Schematic Drawing for Manual Disc Brake Control with Load Lowering Hydraulic Piping Installation Panel Tags Assembly, Spanish
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PL 2112007 0 34
ITEM --1 2 3 4 5 6 7
REQD --1 2 2 2 2 4 2
BILL OF MATERIAL PART NO. DESCRIPTION 2112007 HYDRAULIC POWER UNIT START UP KIT (CONSISTS OF THE FOLLOWING) 7810638 ACCUMULATOR CHARGING KIT WITH GAUGE 7804881 ELEMENT, FILTER 7804880 ELEMENT, FILTER 7804882 ELEMENT, FILTER 7804879 ELEMENT, FILTER 7804858 ELEMENT, FILTER 7804370 ELEMENT, FILTER
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EXECUTIVE OFFICES
HOUSTON CORPORATE HEADQUARTERS 10000 Richmond Avenue Houston, TX 77042 P.O. Box 4888 Houston, TX 77210-4888 PHONE: 713/346-7500 HOUSTON PRODUCTS & TECHNOLOGY 5225 Hollister Street Houston, TX 77040 P.O. Box 4638 Houston, TX 77210-4638 PHONE: 713/935-8100
MANUFACTURING PLANTS
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UNITED STATES STORES

ANCHORAGE, AK PHONE: 907/522-3727 ANDREWS, TX PHONE: 915/523-2954 BAKER, MT PHONE: 406/778-3378 BAKERSFIELD, CA PHONE: 805/589-5750 BIG LAKE, TX PHONE: 915/884-2556 BIG PINEY , WY PHONE: 307/276-3916 BIG SPRING, TX PHONE: 915/267-2539 BILLINGS, MT PHONE: 406/252-7771 BRADFORD, PA PHONE: 814/368-4127 BROOKHAVEN, MS PHONE: 601/833-6511 BRYAN, TX PHONE: 409/778-1585 CAMERON, LA PHONE: 318/775-7078 CASPER, WY PHONE: 307/235-2751 CHARLESTON, WV PHONE: 304/342-5193 CHEYENNE WELLS, CO PHONE: 719/767-8801 CLAY CITY , IL PHONE: 618/676-1653 CORPUS CHRISTI, TX PHONE: 512/883-0871 CORTEZ , CO PHONE: 970/565-8428 CROSSVILLE, IL PHONE: 618/966-2165 DENVER CITY, TX PHONE: 806/592-2161 DICKINSON, ND PHONE: 701/227-0861 ELK CITY , OK PHONE: 405/225-7150 ELLINWOOD, KS PHONE: 316/564-2320 EVANSTON, WY PHONE: 307/789-2034 FT LUPTON, CO PHONE: 303/857-6242 FT. SMITH, AR PHONE: 501/646-1672 FREER, TX PHONE: 512/394-6115 GILLETTE, WY PHONE: 307/682-9337 GREAT BEND, KS PHONE: 316/793-8433 HARTSHORNE, OK PHONE: 918/297-2578 HARVEY , LA PHONE: 504/366-6426 HENDERSON, KY PHONE: 502/826-5774 HOBBS, NM PHONE: 505/393-3138 HOMINY , OK PHONE: 918/885-2108 HOUMA , LA PHONE: 504/872-6876 HOUSTON, TX PHONE: 713/675-6661 KALKASKA , MI PHONE: 616/258-8712 KENAI, AK PHONE: 907/283-6080 KENEDY , TX PHONE: 210/583-3355 KILGORE, TX PHONE: 903/984-3043 LAREDO, TX PHONE: 210/722-0581 LAUREL, MS PHONE: 601/425-8671 LIBERAL, KS PHONE: 316/642-2518 LINDSAY, OK PHONE: 405/756-3147 LONG BEACH, CA PHONE: 310/988-4900 MCALLEN, TX PHONE: 210/686-4329 MCCOOK, NB PHONE: 308/345-2210 MOBILE, AL PHONE: 334/479-0100 MOHALL, ND PHONE: 701/756-6834 MONAHANS , TX PHONE: 915/943-4351 MORGAN CITY , LA PHONE: 504/384-0810 MT. CARMEL, IL PHONE: 618/262-4148 MT. PLEASANT, MI PHONE: 517/773-9948 NESS CITY, KS PHONE: 913/798-3607 NEW IBERIA , LA PHONE: 318/364-7251 ODESSA, TX PHONE: 915/337-3541
11-2000
Section 4.2
Installation and Maintenance Hydraulic Power Unit
January 2004
INSTALLATION and MAINTENANCE MANUAL

UNIVERSAL DISC BRAKE HYDRAULIC POWER UNIT
EPL-1336
Issue date: July 2000 (Revised: April 2001) 1

Preface
National Oilwell is a worldwide leader in the design, manufacture and sale of comprehensive systems and components used in oil and gas drilling and production, as well as in providing supply chain integration services to the upstream oil and gas industry. This Installation and Maintenance Manual provides necessary information for installation and maintenance of the Universal Disc Brake Hydraulic Power Unit. In order to find particular information, just search for the applicable section as listed in the table of contents. However, changes in the equipment may occur. Therefore, we reserve the right to introduce amendments in the manual, as we deem necessary without notice or obligations. Before starting the installation and/or maintenance, the manual must be read and thoroughly understood in all respects. All involved personnel shall read and acknowledge the safety precautions that are stated in section 1.1. The content in this manual is subject to change without notice or obligation. Therefore, information contained herein should always be confirmed with National Oilwell or its representatives.

1. 1.1 1.2 2. 2.1 2.2 2.3 2.4 2.5 3. 3.1 3.2 4. 4.1 4.2 4.3 4.4 4.5 4.6 5. 5.1 5.2 5.3 6. 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 7. 7.1 7.2 7.3 7.4 7.5 7.6 Table of Contents GENERAL4 Safety precautions..4 Operating principle..6 TECHINCAL DATA 7 Operating conditions7 Cooling water7 Requirements for hydraulic fluid cleanliness8 Choice of hydraulic fluid..8 Power unit monitoring..9 HANDLING OF THE PACKED POWER UNIT.10 Storage of the packed power unit10 Lifting the packed power unit10 INSTALLATION.11 Installation directions.11 Lifting methods and weights.12 Positioning the power unit.13 Mounting of cabinet feet13 Electric connections...14 Pipe work.14 COMMISSIONING.15 Prior to commissioning..15 Filling up system with hydraulic fluid...16 Initial start-up procedure16 CORRECTIVE MAINTENANCE..18 Trouble shooting.18 Pump setting and adjustments.20 VPV Vane pump repair parts....21 Vane tip orientation23 Air back-up pump service and overhaul instructions24 HPU Detail...30 Recommended Spares and Service Parts.33 Recommended Service Intervals.....33 TECHNICAL DOCUMENTATION...34 Power requirements...34 Cooling Water.34 Air Supply.34 Pressure settings for operating National 1625 UDB Drawworks34 Hydraulic Schematic..35 Electrical Schematic...36

1. 1.1 GENERAL Safety precautions It is of extreme importance that the safety precautions are always followed. If you are unsure about anything, please contact your nearest National Oilwell representative for advice. Warning signs In this manual, you will find the following signs, which indicate a potential hazard, that can or will cause personal injury or substantial property damage. There are three levels of hazard classification:
General Limit access to the equipment only to authorized personnel. Only perform measures on the HPU when you are completely familiar with the function of the power unit (including the control system) as well as the complete system. Service and repair of the electrical, hydraulic, and the mechanical functions require professional service personnel who are aware of risks involved. Safety equipment necessary for the prevention of accidents during the mounting and maintenance must be used in accordance with the regulations prevailing in the local authority.
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Prior to troubleshooting Use the National Oilwell part number and other attached technical documentation to identify the features of your unique power unit. Read the attached technical documentation (this manual included) and make yourself familiar with the HPU and complete control system. Use safety equipment such as hard hat, protective goggles, safety shoes, and hearing protection. Always ensure that there is no accumulated energy in the system prior to maintenance. Ensure that all electric power is turned off and locked out. Ensure that there is no entrapped pressure in the hydraulic system. Ensure that no pressure will enter the system in the power unit via Emergency Calipers, stored in the accumulators. Ensure that all accumulators are discharged.
Electricity supply Safety equipment necessary for the prevention of accidents must be provided in accordance with the regulations prevailing local authority. All electrical supply levels shall be within limits that the equipment is constructed for, see technical documentation and maximum rating plates. Mounting Carefully follow the instructions and be aware of the large weights and forces involved during lifting. Incorrect mounting and setting of electrical, hydraulic and the mechanical components can cause personal injury or property damage. Before starting up Before starting up new, rebuilt or serviced equipment, all accessories and safety arrangement functions need to be checked and tested. Maintenance and service Follow the maintenance intervals for your specific HPU or the maximum intervals on the maintenance chart (section 5.2 Maintenance Chart) and keep a maintenance log. Regular and correct maintenance is necessary for the reliable and safe operation. Only use spare parts recommended and supplied by National Oilwell. Hydraulic fluid Be aware that most hydraulic fluids can cause personal injury and severe damage to the environment. Check the caution sign on the container or consult the supplier. Used hydraulic fluid can contain noxious contaminates. We recommend using the service of a professional oil company for supply and disposal of used fluids. Never dump hydraulic fluid where it can contaminate the environment. Hot surfaces Temperatures in the hydraulic system above 130 F will create hot surfaces
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Emergency situations Emergency shutdown: It has to be possible to turn off the electric power during an emergency situation. Only use a fire extinguisher that is approved for use on both oil products and electrical equipment. 1.2 Operating principle
Main components 1. Hydraulic pump 2. Drain valve 3. Sight glass 4. System pressure gauge 5. Air pump supply pressure gauge 6. DS & ODS service caliper pressure gauge 7. Port #11 pressure gauge 8. Air breather 9. Return filters 10. Electric motor 11. Suction filter 12. Oil cooler 13. Starter-annunciator panel 14. Level switches 15. Temperature switches 16. Air back-up pump 17. Air driven fill pump 18. Accumulators 19. High pressure filter 20. Air filter/regulator 21. Water modulating valve 22. System relief valve 23. Pressure reducing valve Function The function of the Universal Disc Brake Hydraulic Power Unit is to provide hydraulic pressure to operate the Disc Brake Service Calipers, and Emergency Calipers. The UDBHPU has four hydraulic pumps: 1. Main hydraulic pump 2. Air back-up pump 3. Cooling loop pump 4. Air driven fill pump

The UDBHPU has several control valves: 1. System relief valve 2. Pressure reducing valve 3. Emergency caliper release valve 4. Crown-O-matic interface valve 5. Water modulating valve 6. Cooling loop pressure control valve 7. Air driven pump speed control valve 8. Air back-up pump regulator valve 9. Air supply shut-off valve 10. Reservoir drain valve 11. Accumulator bleed valves 2. TECHNICAL DATA
2.1 Operating conditions The standard HPU is designed for the conditions listed below. If the requirements are outside of these conditions listed below, contact your National Oilwell representative with your specific requirements for special design considerations. Ambient temperature: Location: 2.2 Cooling water The cooling system is primarily designed to operate with clean water. When there are particles in the water, larger than 0.02 in. (0.5 mm), a water filter must be used. It is important to: Maintain the water filter (if any) in a correct way, this is to get the required flow of water through the water oil cooler. Ensure you have the required flow, pressure and temperature of the cooling water (see attached technical documentation). Check the temperature in the hydraulic system, according to the maintenance intervals on the chart. Clean the cooling system if the temperature in the hydraulic system is above the specified limits. Clean and empty the cooling system (waterside) before periods of inactivity (especially if the cooling water is not totally clean). IF THE COOLING CAPACITY IS TOO LOW, THE SERVICE LIFE OF COMPONENTS IN THE POWER UNIT, AND THE HYDRAULIC FLUID WILL BE REDUCED.

2.3 Requirements for the hydraulic fluid cleanliness The HPU is equipped with filters on the return, suction, fill, cooling loop, and discharge lines. In order to obtain rated service life it is important to follow recommendations concerning cleanliness levels and maintenance requirements. Cleanliness recommendations The system must be flushed before start-up (section 4.12 Flushing before start-up). When filling the reservoir with hydraulic fluid it is mandatory to use the fill system included with the HPU. The particle contamination level in the system should not exceed ISO/DIS 4406 16/13 (NAS 1638, class 7). The water content shall be <0.1% Always use filters elements that are supplied by National Oilwell. The hydraulic fluid should be analyzed according to the special maintenance chart (section 5.2 Maintenance Chart). You should be particularly careful when removing equipment for repairs or maintenance so that dirt cannot enter the system. Components should be cleaned and free of dirt prior to disassembly. DO NOT USE HYDRAULIC FLUID THAT HAS LEAKED OUT. 2.4 Choice of hydraulic fluid
The power unit is primarily designed to operate on conventional petroleum based hydraulic fluids. National Oilwell only approves specific hydraulic fluids to be used in the Universal Disc Brake System. Substituting any other types of hydraulic fluid will void all warranties, and can create a hazard to personnel and equipment. The following chart will help in the choice of hydraulic fluid for the HPU.
NATIONAL OILWELL RECOMMENDED HYDRAULIC FLUIDS CONDITIONS FLUID TYPE Type F Automatic Transmission Ambient temperatures above 40 F Warm Fluid, or AW 32 Hydraulic Oil Climates Ambient temperatures below 40 F Cold Climates MIL H5606 A or E
2.5
Power unit monitoring
If the monitoring function is not included in the control system supplied with the HPU, the following functions must be fulfilled in the system.
The monitoring of the HPU switches are grouped into two levels according to the above logic diagram.
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The warning or alarm indication is to inform about a problem in the HPU that needs to be addressed. The shut down indication is to inform about HPU shut down. When this happens the brakes on the drawworks will lock on, and not release, until the problem is resolved. The alarm horn can be silenced, but the strobe lamp and individual indicating lamps will remain illuminated until problem is corrected. 3. HANDLING OF THE PACKED HPU
3.1 Storage of the packed power unit At delivery the hydraulic components are protected internally by an oil film (containing rust preventing additives. This provides sufficient protection for indoor storage in air conditioned premises for up to 12 months. The HPU and included parts should be stored indoors, in dry, vibration free and dust free conditions. It should not be stored for more than three months in non-air conditioned premises. (That also includes parts belonging to the power unit that are delivered separately). Place power unit where it will not be exposed to direct sunlight or extreme cold to avoid condensation. IF STORAGE TIME EXCEEDS THE ABOVE-MENTIONED LIMITS, THEN THE POWER UNIT MUST BE OPERATED SO THAT THE HYDRAULIC SYSTEM IS LUBRICATED WITH NEEW FLUID. 3.2 Lifting the packed power unit
The packed power unit is labeled with a enter of gravity and weight. Normally the power unit package is designed for forklift truck handling. Center of gravity is high, see label on the power unit Avoid rapid acceleration, deceleration and turns while moving the equipment Position the forks according to the instructions below
Lifting with fork lift The absolute minimum fork length is 48 in. The minimum distance between the forks is 31.5 in. Position forks with regards to the center of gravity Parts that are delivered separately The package is always labeled with the weight. Packages on shipping skids are designed for forklift truck handling only. Some other packages may be lifted with a lifting crane, always check the label on the package Do not stand underneath hanging load.
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4. Use only lifting equipment adapted to the weight on the label of the package. INSTALLATION
4.1 Installation directions If the HPU is to work properly, it must be installed in accordance with these instructions. The conditions the power unit will operate in must be taken into consideration. Improper installation, not following the instructions in this manual and in the attached technical documentation, may affect the function and/or the service life of the power unit. It is important that the safety precautions mentioned in this manual are always followed. IN ORDER TO ACHIEVE AIR CIRCULATION REQUIREMENTS, YOU SHOULD NEVER PLACE THE POWER UNIT DIRECTLY AGAINST A WALL OR SIMILAR OBSTRUCTION. IF THIS IS THE CASE THEN CONTACT YOUR NATIONAL OILWELL REPRESETATIVE.
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Placing the power unit Take into consideration the following when placing the HPU Try to locate HPU as close to the Drawworks as possible To minimize piping runs To ensure proper ventilation for cooling purposes To ensure proper room to service unit Always locate HPU on the same level as the Drawworks.
4.2 Lifting methods and weight Lifting with ropes/or chains Ensure lifting ropes and chains are rated for the weight of HPU. Max weight is 2000 # Maximum lifting angle 90
Do not stand underneath a hanging load Use only lifting equipment adapted to the weight of the power unit Center of gravity is high, see label on cabinet Do not lift the power unit with hydraulic fluid in the tank.
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4.3 Positioning the power unit The following minimum space must be left around the HPU, to ensure proper ventilation and provide sufficient working space for easier maintenance. Heavier maintenance such as changing the pump/motor assembly will demand larger working space. It is important that all plumbing for water, air, and hydraulics are mounted properly to allow for sufficient working space for maintenance. 4.4 Mounting of the cabinet feet
The cabinet feet are tapped steel plates that are welded to the deck. They are delivered inside the HPU along with spare filter elements and accumulator charging kit. Attach mounting feet prior to setting HPU in place, with bolts that are provided. When HPU is located on the drawworks the mounting feet can be welded to the deck. Next lift HPU and set aside, while welder seal welds the mounting feet to the deck to prevent a space for moisture to collect.
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4.5 Electric connections Safety precautions All electric equipment is intended to be installed and used by personnel who are familiar with relevant safety requirements. Safety equipment necessary for the prevention of accidents at the mounting and operating site must be provided in accordance with regulations of the prevailing local authority. Grounding shall be carried out according to local regulations before electric equipment is connected to the main voltage. All electrical supply levels must be within the limits that the equipment is constructed for, see technical documentation and maximum rating plate. Junction box Connect the cables on the screw terminals inside the junction box. Make the connections according to the electrical drawing in the attached technical documentation. Electric motor Major voltage connection according to designation on rating plate. 4.6 Pipe work
When sizing hoses and hydraulic piping between the HPU, controls, and Disc Brake Calipers, a safety factor of at least 4 times the maximum system pressure should be used for tensile strength. Keep in mind that the equipment may be readjusted to higher pressure in duty. Pressure losses in the pipe system should generally be kept to a minimum. Contact a National Oilwell representative for more information. Hard plumbing Hard plumbing should be 304 stainless steel tubing ASTM A269, A213, or equivalent. 1/2 OD tubing should have a wall thickness of .035 or more. 3/8 OD tubing should have a wall thickness of .035 or more. 5/8 OD tubing should have a wall thickness of .049 or more. Pressure test A pressure test to 1 times the maximum working pressure should be performed on the main high pressure lines to check for possible leakage. Hoses To avoid damage caused by vibrations it is important that the HPU be isolated by hydraulic hoses. The hoses must be rated for the maximum hydraulic pressure of thee system. Be sure to allow for minimum permissible bend radius according to the data provided by the supplier of the hoses. Line sizes
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It is important that lines between the HPU, controls, and Disc Brake Calipers are as short as possible. This gives the following advantages: 1. Small compression volume in the hydraulic system. This is particularly important in hydraulic systems with large and rapid load variations, and high response is required. 2. Small power losses in the hydraulic system. 3. Lower installation costs in smaller plumbing sizes and shorter lengths can be used. Tubing clamps Tubes should be clamped with uniformly spaced clamps. The distance between clamps should not exceed 6ft (2m) for tubes with outside diameters between (15mm) and 1 (38mm). In addition, the tubes must be clamped immediately before and after a bend. The tubes must be clamped immediately before transition to hose as well. The tubing clamps must be of a type permitting a certain amount of axial and radial motion in the clamped joint and have good vibration-absorbing properties. Storage of included components The storage of included components must be in the same way as the power unit (section 3.1 storage of the packed power unit). Notice that the packing must not be removed during storage. JIC-fittings (SAE J514, ISO 8434) Tighten fittings by hand, then tighten to turn more using and appropriate wrench. Do not over tighten the fittings. Use correct tools, fittings can be damaged and difficult to remove. Be aware that all fittings may expand because of heat and vibrations. All fittings must be checked and retighten. Mounting of hoses Ensure that hoses are not stressed or twisted on installation, prevent premature failure. Bend radius should conform to manufacturer recommendations. 5. Commissioning 5.1 Prior to commissioning Read and understand this complete manual and other attached technical documentation. Visually check the whole system for signs of damage, incorrect circuitry, security of equipment, and the degree of filtration of the filters are according to the data in the technical documentation. Check the coupling between the electric motor and the pump is properly mounted. Check that the Precharge pressure in the accumulators is in accordance with the technical documentation. Cleanliness
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The hydraulic system must be thoroughly cleaned on the inside. If you are uncertain about the cleanliness of the system, it must be checked prior to filling with oil. Plumbing Are couplings properly tightened? Is the plumbing properly cleaned? Is the plumbing mounted free of stress? Are the lines in accordance with the installation drawing/piping plan? Electrical System Check that the electric motor and control system and other electrical components are connected to the correct voltages. Check the function of electrical components and monitoring system manually. Instruments that can not be actuated can be checked for correct wiring and possibly operated manually. Level switches and indication should be checked when filling the tank. 5.2 Filling up the HPU with hydraulic fluid Before filling Check that the correct type and quality of hydraulic fluid is used. Do not mix different types of hydraulic fluid. Check that the barrel with the hydraulic fluid and fill hoses are not contaminated with water or other substances. Fill case drain on hydraulic pump by removing case drain fitting. Use the fill wand provided with the HPU to fill the reservoir. Never pour hydraulic fluid from containers into reservoir. New fluid is normally not filtered and will introduce dirt into the system; the fluid must therefore always be filled through a filter. Never pour hydraulic fluid into the tank through the air breather filter. Fill the tank to the level indicated on the tag near the sight level glass. Check the function of the level switches during filling up of the tank. Check caution sign on the container and the warnings (section2.4 choice of hydraulic fluid). Avoid prolonged contact of hydraulic fluid with your skin. Clean hydraulic fluid spills from decks immediately to prevent personal injury. 5.3 Initial start-up procedure Important note! Make sure the system is ready to run, warn all personnel on the rig floor that a startup is in progress. Follow safety precautions in this manual. Never operate the power unit with defective instruments or control elements. During start-up period, the hydraulic system will be filtering to remove dirt particles, therefore keep an eye on the filter indicator during the entire start-up procedure. On cold start-up, the filters may indicate by-pass. After a few minutes of operating, check the indicator again, as the oil warms up the differential pressure across the filter
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will lower to normal levels. If the filter indicators continue to show a clogged condition after the hydraulic fluid warms up, then the elements must be inspected or changed. STEP 1 Immediately before starting Check fluid level in reservoir, and refill to levels indicated on the reservoir. Check if any components need filling with clean hydraulic fluid, such as the pump case. Check safety equipment. Check that all the prescribed steps (xxx Prior to commissioning) have been carried out. Check that cooling water is connected and turned on. For adjustments and settings on the control system see separate instruction in attached technical documentation. STEP 2 Start with unloaded pump at short intervals Starting the HPU shall be carried out with a completely unloaded pump in short intervals. When the hydraulic fluid is cold, first open bleed valves on the bottom of the accumulators. This will prevent the pump from building high pressure on start-up. Start pump by jogging electric motor on and off. Check rotation of motor with the arrows on the fan shroud. When rotation has been confirmed, let pump run to warm up the hydraulic fluid. When fluid temperature approaches between 80 and 90 F begin to close bleed valves on the bottom of accumulators. The system pressure should now be at specified level. STEP 3 Bleed system of air. With the HPU operating at the pressures detailed in the attached technical documentation. Air needs to be bleed from all Disc Brake Calipers. (SEE BLEEDING AND FLUSHING in the Universal Disc Brake System Manual) After the Disc Brake System has been bleed, recheck the hydraulic fluid level and refill as needed. STEP 4 Checking Check all fittings and hoses for leaks, retighten as needed. Check for unusual noises or vibrations. Check oil temperature. Check all filter indicators. STEP 5 Air back-up pump Turn on air to air back-up pump. Turn off electric motor and as pressure begins to fall, air back-up pump should begin to run at about 100 PSI below the electric pump compensator setting. If not adjust the air pressure regulator for the air back-up pump, until this pressure is attained. Turn electric pump back on and air back-up pump should stall out as pressure rises above its setting.
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6.0 6.1 CORRECTIVE MAINTENANCE TROUBLE SHOOTING
Excessive Pump Noise
Trouble Shooting for VPV Whisper Pumps 1 Coupling misalignment 1 Align the pump and motor to within .006 of an inch total indicator reading. The tighter the alignment, the quieter the pump will be. 2 The pumps have been sound 2 The continuous pressure is tuned at rated pressure. significantly below 200 PSI Consult factory or raise for 140 bar pumps minimum pressure 300 PSI 3 Fluid in reservoir is low and 3 Fill the reservoir so that the the pump and the pump is fluid level is well above the sucking air. end of the suction line during all of the working cycle 4 Restricted Inlet 4 If a suction strainer is used, check it for obstructions or dirt. Check also for shop rags left in reservoir. 5 Air leak in the suction line 5 Tighten all fittings. If it still leaks, smear grease over the joints to locate the leak. 6 Suction line has too many 6 The suction line should be as elbows, or is too long. short and straight as possible. 7 Air in fluid. 7 The return line should terminate below the fluid level to prevent splashing. 8 Suction is too small. 8 Suction line should always be equal in size to suction port. Never reduce it. 9 Vane does not move freely. 9 Contamination in fluid or a burr in vane slot can cause a vane to bind up. Proper filtration and or deburring of the vane slots are required. 10 Vane is install incorrectly. 10 In vane pumps VPV, the leading edge of the vanes must be oriented in the direction of rotation. 11 Vane is missing. 11 Make sure all vane slots have a vane in them.
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Pump will not prime. Trouble Shooting for VPV Whisper Pumps 12 Shaft rotation in the wrong 12 When installing a pump, direction. always jog electric motor to check the proper rotation. Rotation should always be clockwise (right hand) for VPV pumps. 13 Air leak in suction line. 13 Make sure fittings are tight. 14 Pump is air bound. 14 Use an air bleed valve to void the pump and suction line of air. 15 Fluid level in reservoir is too 15 Fill the reservoir so that fluid low. level is well above the end of the suction line. 16 Stroke limiter is turned in too 16 Flow should not be reduced far. more than 50% of maximum. 17 Suction port dust plug left in 17 Remove plug. place. 18 Contamination in the 18 Thoroughly clean the control compensator. orifices, and check filtration. 19 Pressure ring is not moving 19 Control piston should be properly. checked for freedom of movement. 20 Case drain line is installed 20 The case drain and pump inlet should be separated by too close to the pump inlet. a baffle in the reservoir. 21 Reservoir is undersized. The 21 Add a cooler. rule of thumb is a minimum of 2 to 3 times the output flow.
Pump is unstable
Pump is hot.
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6.2 Pump settings and adjustments Bosch VPV Vane Pump
There are only two adjustments on this pump. 1. Pressure compensator 2. Volume control
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6.3 VPV VANE PUMP REPAIR PARTS
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6.3 VPV VANE PUMP REPAIR PARTS
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6.4 VANE TIP ORIENTATION
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6.5 AIR BACK-UP PUMP SERVICE AND OVERHAUL INSTRUCTIONS
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25

26

27

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6.6 HPU DETAIL
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6.6 HPU DETAIL
31
6.6
HPU DETAIL
32
6.7
RECOMMENDED SPARES and SERVICE PARTS RECOMMENDED SPARES and SERVICE PARTS ITEM NO. DESCRIPTION NATIONAL PART NO. 1 TANK BREATHER FILTER 7805734 1A*(2) REPLACEMENT ELEMENT 7804882 2 SUCTION FILTER 7805833 2A*(2) REPLACEMENT ELEMENT 7804881 3 HIGH PRESSURE FILTER 7805831 3A*(2) REPLACEMENT ELEMENT 7804879 4 RETURN FILTER 7805832 4A*(4) REPLACEMENT ELEMENT 7804880 5 FILTER-REGULATOR 7805835 5A*(2) REPLACEMENT ELEMENT 7804370 5B*(2) REPAIR KIT 7810667 5C*(2) AUTO-DRAIN ELEMENT 7810668 6*(1) SYSTEM RELIEF VALVE CARTRIDGE 7500683 7*(1) PRESSURE REDUCING VALVE 7500693 8 FILL PUMP 7815438 9 MAIN PUMP 7815437 9A*(2) REPAIR KIT 7810663 9B*(2) SEAL KIT 7810664 10 AIR BACK-UP PUMP 7815201 10A*(2) OVERHAUL KIT 7810619 11 HYDRAULIC ACCUMULATOR 7800771 11A*(2) REPAIR KIT 7810666 11B* (2) AIR VALVE REPAIR KIT 7810638 12*(2) PRESSURE GAUGE 0-200 PSI 7806846 13*(2) PRESSURE GAUGE 0-2000 PSI 7806851 14*(2) PRESSURE GAUGE 0-3000 PSI 7806852 15*(1) NEEDLE VALVE 7500665 16*(1) WATER MODULATING VALVE 7500680 17*(1) EMERGENCY RELEASE/SET VALVE 7500694 18*(1) SHAFT COUPLING 7828306 * DENOTES RECOMMENDED SPARES 6.8 RECOMMENDED SERVICE INTERVALS RECOMMENDED SERVICE INTERVALS CHANGING AFTER THE FIRST 40 HRS OF OPERATION HYDRAULIC FILTER THEN EVERY 500 HRS. THEREAFTER ELEMENTS CHANGING AIR FILTER AFTER THE FIRST 40 HRS OF OPERATION THEN EVERY 250 HRS THEREAFTER LUBRICATE AIR BACK- ONCE A MONTH REMOVE AND GREASE VALVE SPOOL UP PUMP MAIN AIR
33

CHANGE EVERY SIX MONTHS CHANGE FLUID ONCE EVERY YEAR, CLEAN OUT RESERVOIR WHEN CHANGING FLUID 7. TECHNICAL DOCUMENTATION 7.1 Power requirements Power requirements for the UDBHPU as follows: 460 VAC 60 Hertz 3 phase @ 15 amperes. 7.2 Cooling Water Cooling water requirement: 5 to10 gallons per minute of fresh water @ 60 to 90F 7.3 Air Supply Air supply requirements: 75 to 80 CFM @ 100 PSI 7.4 Pressure settings for operating National 1625 UDB Drawworks The following pressure settings are for National Oilwell 1625 UDB Drawworks: 1. Main Pump Compensator: 2000 PSI 2. Service Caliper Pressure: 1200 PSI 3. Air Back-up Pump Output: 1900 PSI 4. System Relief Valve Setting: 2350 PSI 5. Accumulator Pre-charge: 1200 PSI VALVE BREATHER FILTER HYDRAULIC FLUID
34
7.5
Hydraulic Schematic
35
7.6
Electrical Schematic
36
Chapter 5.0
Hook BlockGA-500
January 2004
PARTS LIST
B660-GA-500 Hook Block
Assembly: 703992-AS
Document No.: EPL-1582 Date: November 2003
B660-GA-500 Hook Block Parts List
EPL-1582 00 1
INDEX
Page 1 2 3 4 5 6 7 8 Drawing No. PL 703992 PL 703992-1 PL 703782-3 PL 703782 PL 645595-1 PL 703782-1 PL 703782-2 PL 703992-3 Rev. A Description Hook Block Assembly Block Assembly Hook Complete Hook Assembly Lock Assembly Assembly Instructions for the Hook Assembly Instructions for the Block B660-GA-500 Hook Block Outline Drawing
www.natoil.com
Chapter 6.0
SwivelP-500
January 2004
Chapter 7.0
Deadline AnchorType EB
January 2004
PARTS LIST
Type EB Wire Line Anchor
Monogrammed to API-8A (Spanish) Assembly: 704017-AA3S
Document No.: EPL-1581 Date: November 2003
Chapter 8.0
Drill Line
January 2004

Derrick, Crown &amp; Accessories, National 516 Hojas

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Derrick, Crown & Accessories

January 2004 Customer References

PEMEX 4036 or 4035 4122335007

National Oilwell References

Operating and Maintenance Manual

PEMEX 4036 or 4035 4122335007

National Oilwell References

Project Number: C18773 Document Number: As Noted Chapter 1 Page 1 of 18

1.0 1.1 1.2

2.0 2.1 2.2

3.0 3.1 3.2

5.0 6.0 7.0 8.0

Project Number: C18773 Document Number: As Noted Chapter 1 Page 2 of 18

Table of Contents (continued)

10.0 10.1 10.2 10.3 10.4 10.5 10.6 10.7

PEMEX RIG 4036 or RIG 4035

Project Number: C18773 Document Number: As Noted Chapter 1 Section 1 Page 3 of 17

Project Number: C18773 Document Number: As Noted Chapter 1 Section 1 Page 4 of 17

Project Number: C18773 Document Number: As Noted Chapter 1 Section 1 Page 5 of 17

Project Number: C18773 Document Number: As Noted Chapter 1 Section 1 Page 6 of 17

Project Number: C18773 Document Number: As Noted Chapter 1 Section 1 Page 7 of 17

PEMEX RIG 4036 or RIG 4035

Project Number: C18773 Document Number: As Noted Chapter 1 Section 1 Page 8 of 17

1,044,000 lbs. (473.5 t) To Traveling Block

PEMEX RIG 4036 or RIG 4035

Project Number: C18773 Document Number: As Noted Chapter 1 Section 1 Page 9 of 17

ii. iii. iv. v. vi.

Project Number: C18773 Document Number: As Noted Chapter 1 Section 1 Page 10 of 17

Project Number: C18773 Document Number: As Noted Chapter 1 Section 1 Page 11 of 17

Project Number: C18773 Document Number: As Noted Chapter 1 Section 1 Page 12 of 17

Project Number: C18773 Document Number: As Noted Chapter 1 Section 1 Page 13 of 17

LUBRICATION AND MAINTENANCE

Project Number: C18773 Document Number: As Noted Chapter 1 Section 1 Page 14 of 17

Tightening Torque Guide For Bolts

Project Number: C18773 Document Number: As Noted Chapter 1 Section 1 Page 15 of 17

Project Number: C18773 Document Number: As Noted Chapter 1 Section 1 Page 16 of 17

Document No. Page

PEMEX RIG 4036 or RIG 4035

PEMEX RIG 4036 or RIG 4035

PEMEX RIG 4036 or RIG 4035

PEMEX RIG 4036 or RIG 4035

PEMEX RIG 4036 or RIG 4035

PEMEX RIG 4036 or RIG 4035

PEMEX RIG 4036 or RIG 4035

PEMEX RIG 4036 or RIG 4035

UNITED STATES STORES

NATIONAL-OILWELL DE VENEZUELA, C.A. HEADQUARTERS:

NATIONAL-OILWELL, INT'L UNITED STATES MAIN SALES OFFICE:

NATIONAL-OILWELL (U.K.) LTD. MACHINERY CENTRE: BADENTOY ROAD

NATIONAL-OILWELL PTE. LTD. SOUTHEAST ASIA SALES OFFICE:

NATIONAL-OILWELL (UAE) LTD. MIDDLE EAST SALES OFFICE:

Document number Revision Page

EPL-1578 0 Index Page (1 of 2)

E-2100DBH Universal Disc Brake System

Emergency Load Lowering Assembly Load Lowering Manifold Assembly

E-2100 Universal Disc Brake System

Document number Revision Page

EPL-1578 0 Index Page (2 of 2)

Document number Revision Page

UNITED STATES STORES

PEMEX RIG 4036 or RIG 4035

INSTALLATION and MAINTENANCE MANUAL

Derrick, Crown & Accessories, National 516 Hojas

Derrick, Crown & Accessories, National 516 Hojas