Operation manual

SSGD Drawworks

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

West Capella (former Mosvold Drillship No 2) S0100827 Main Drawworks
ADDITIONAL CODE SDRL CODE TOTAL PGS
5.3 68 This document contains proprietary and confidential National Oilwell Varco Norway AS
information which belongs to National Oilwell Varco; it is P.O. Box 8181
REMARKS loaned for limited purposes only and remains the property
of National Oilwell Varco. Reproduction, in whole or in 4069 Stavanger
MAIN TAG NUMBER DISCIPLINE part; or use of this design or distribution of this information Norway
to others is not permitted without the express written
consent of National Oilwell Varco. This document is to be
CLIENT PO NUMBER returned to National Oilwell Varco upon request and in Phone +47 51 81 81 81
any event upon completion of the use for which it was Fax +47 51 80 05 47
loaned.
© Copyright National Oilwell Varco - 2010

CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

S0100827-OPM-800 2
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REVISION HISTORY

2 04.02.2010 For Information LLJ VO SHH

1 08.12.2009 For Information VO ETM SHH
0 22.06.2006 For Information JSS OLFI LNE
Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

CHANGE DESCRIPTION

Revision Change description

2 new WOB setpoint button
1 Added Max Speed (chapter 3.1.2), Auto reaming (Chapter 3.4.7) and Trip Height
(Chapter 3.4.6). Added new buttons and keypad in chapter 3.2.2
Updated Settings screen and heights screen.
0 First Issue
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TABLE OF CONTENTS

1 INTRODUCTION ...............................................................................................................6
1.1 General ...................................................................................................................6
1.2 Abbreviations and definitions ..................................................................................6
1.3 Reference documents and drawings ....................................................................... 7
1.4 Service and support ................................................................................................7
2 SYSTEM OVERVIEW ........................................................................................................ 8
2.1 Drawworks mechanical parts...................................................................................8
2.1.1 Main frame and enclosures .......................................................................... 9
2.1.2 Drum ............................................................................................................ 9
2.1.3 Drive gear box ..............................................................................................9
2.1.4 Braking systems .........................................................................................10
2.1.5 Lubrication ................................................................................................. 11
2.2 Electric motors....................................................................................................... 11
2.3 Motor cooling blowers ...........................................................................................11
2.4 Drawworks control system .................................................................................... 12
2.4.1 Response time ...........................................................................................12
2.4.2 Miscellaneous field instruments ................................................................. 12
2.4.3 Drawworks interface mounting plate ..........................................................13
2.4.4 Hook load monitoring ................................................................................. 13
2.4.5 Emergency stop .........................................................................................14
2.4.6 Human-Machine Interface (HMI) ................................................................14
3 OPERATION INSTRUCTIONS ........................................................................................15
3.1 Preparation / configuration .................................................................................... 15
3.1.1 Block position .............................................................................................16
3.1.2 Maximum Speed Setting ............................................................................ 17
3.1.4 CMC Positioning limits ............................................................................... 18
3.1.5 Hookload selection ..................................................................................... 19
3.1.6 Encoder selection....................................................................................... 20
3.2 Human-Machine Interface (HMI) operator station ................................................. 22
3.2.1 Cyberbase displays .................................................................................... 22
3.2.2 Operator commands from keypads and joysticks ....................................... 29
3.3 Starting procedures ...............................................................................................32
3.4 Normal operation ................................................................................................... 32
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3.4.1 Drawworks slow speed .............................................................................. 32

3.4.2 Weight on bit reset ..................................................................................... 32
3.4.3 Crown saver override ................................................................................. 33
3.4.4 Floor saver override ................................................................................... 33
3.4.5 CMC Positioning System ........................................................................... 33
3.4.6 Trip Height Settings.................................................................................... 35
3.4.7 Auto Reaming ............................................................................................36
3.5 Stop procedures .................................................................................................... 37
3.5.1 Normal stop ................................................................................................37
3.5.2 Emergency stop .........................................................................................37
3.6 Emergency lowering ..............................................................................................37
3.7 Test and exception functions................................................................................. 38
3.7.1 Brake system safety and performance testing ........................................... 38
3.7.2 Brake burning procedure............................................................................ 41
3.7.3 Slip & cut .................................................................................................... 44
4 SAFETY AND SYSTEM FUNCTIONS ............................................................................ 45
4.1 General ................................................................................................................. 45
4.2 Emergency stop .................................................................................................... 45
4.3 Floor saver system ................................................................................................46
4.4 Crown saver system ..............................................................................................46
4.5 Slip alarms and Automatic Motor Start (AMS) ....................................................... 47
4.6 Creep alarm........................................................................................................... 48
4.7 Pinion slip detection ..............................................................................................48
4.8 Auto brake activation .............................................................................................48
4.9 Hookload monitoring .............................................................................................48
4.10 Block positioning ................................................................................................... 49
4.10.1 Block Position check ................................................................................ 49
4.10.2 Height not calibrated ................................................................................ 49
4.10.3 Low dead wrap check .............................................................................. 50
4.11 Dynamic acceleration / deceleration ramps ...........................................................50
4.12 High motor temperature ........................................................................................50
4.13 Brake capacity testing ...........................................................................................50
4.13.1 Brake burning ...........................................................................................51
4.14 Slip and cut mode.................................................................................................. 51
4.15 Interface to anti collision system............................................................................ 51
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4.16 Power management system .................................................................................. 52

4.16.1 Power consumption management ............................................................52
4.16.2 Power regeneration management ............................................................52
4.17 Interlocks with other machines .............................................................................. 52
4.17.1 Iron Roughneck (IR) interlocks ................................................................. 52
4.17.2 Top Drive (TD) clamp ............................................................................... 52
5 DISTURBANCE OF OPERATION, CORRECTIVE MEASURES .................................... 53
5.1 Message system ................................................................................................... 53
5.2 Alarms visualization ...............................................................................................54
5.3 Alarms and preferred actions ................................................................................ 55
5.3.1 Group 1 Diagnostic alarms ......................................................................... 56
5.3.2 Group 2 Communication alarms................................................................. 56
5.3.3 Group 3 Drive / motor alarms ..................................................................... 57
5.3.4 Group 4 Auxiliary equipment alarms ..........................................................58
5.3.5 Group 5 MRU Alarms (Not Applicable) ...................................................... 61
5.3.6 Group 6 Brake system alarms .................................................................... 61
5.3.7 Group 7 External signal fault alarms ..........................................................62
5.3.8 Group 8 Miscellaneous alarms ................................................................... 64
5.4 Alarm limits and important operational limits .........................................................67
6 HAZARDS AND PROTECTIVE MEASURES ................................................................. 68
6.1 Start after long term shutdown or major maintenance ........................................... 68
7 OPERATOR SKILLS AND TRAINING ............................................................................ 68
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1 INTRODUCTION

1.1 General

This operation manual describes the operations in conjunction with the day-to-day
running of the drawworks.

This document describes the various control and monitoring facilities. For Cyberbase
system overview and description of standard pop-ups etc, refer to document Cyberbase
Control System, operation manual /9/, ref chapter 1.3.

It is essential that the equipment operators have the required knowledge, education and
training before using the system.

Running the drawworks involves pinch point risk. Keep distance from working
area.

1.2 Abbreviations and definitions

AMS Automatic Motor Start

BOP Blow Out Preventer
CMC Crown Mounted Compensator
DCI Drilling Control Interface
DW Drawworks
FDS Functional Design Specification
HVAC Heat, Ventilation & Air Conditioning
IR Iron Roughneck
HMI Human-Machine Interface
MCC Motor Control Center
MP Mud Pump
P&ID Piping & Instrument Diagram
PLC Programmable Logic Controller
ROP Rate Of Penetration
RT Rotary Table
SSGD Single Speed Gear Driven (Drawworks)
STEP7 Siemens PLC Programming Software
TD Topdrive
VFD Variable Frequency Drive (=VSDS)
VSDS Variable Speed Drive System
WOB Weight on Bit

Operator The person assigned the responsibility of physically operating and

maintaining the equipment
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1.3 Reference documents and drawings

Please refer to documents and drawings part in final documentation dossier.

The following documents should be studied together in order to get a good

understanding of the functions, limitations and operation of the equipment;

Ref.no Document no. Description

/1/ 9130E104 User Manual, SSGD-1000-5750 Drawworks
/2/ S0100827-DAS-801 Datasheet SSGD-1000-5750-55-82-10.5
/3/ S0100827-SID-800-01/ System Interconnection Drawings, Drawworks
-02/-03 control system
/4/ 9130B049 SSGD-1000-5750 Drawworks General Assembly
/5/ 9130X101 SSGD-1000-5750 Lubrication Schematic
/6/ 9130X100 SSGD-1000-5750 Brake Hydraulic Schematic
/7/ S0100827-IDX-800 Instrument Index
/8/ S0100831-SID-300- System Topology Diagram
01/02/03
/9/ S0100831-OPM-001 Cyberbase Control System, operation manual
/10/ S0100832-TDO-300 Drilling Power Limiting System

1.4 Service and support

For assistance from National Oilwell Varco, please contact:

Company: National Oilwell Norway AS

Address: Lagerv. 8
P.B. 8181
4069 Stavanger
Contact: Service Department
E-mail: service.norway@nov.com
Telephone: +47 51818181
Telefax: +47 51800547
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2 SYSTEM OVERVIEW

The SSGD Drawworks consist of the following main elements:

- Drawworks mechanical parts with AC-motors, disc brakes and emergency

lowering system
- Cooling blowers for Drawworks motors
- Drawworks control system
- Interface to operator stations and other PLCs

The Drawworks is run by the VSDS system and is operated from the operator station in
the driller’s cabin. It communicates with these systems through communication network
links. Refer to the system topology drawing and the system interconnection drawings for
an overview of the networks.

Sketch of the drawworks

2.1 Drawworks mechanical parts

The drawworks mechanical part consists of mainframe, enclosures, drum, main drive
gearbox, electrical motors, disc brake system including Hydraulic Power Unit (HPU),
lube oil system and blower unit. See also reference /1/ in chapter 1.3.
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2.1.1 Main frame and enclosures

The main frame is a welded steel structure that has to be bolted to the substructure.

The drawworks gears, motors and utility equipment on each side of the drum are
covered by an enclosure to provide noise insulation and mechanical protection of the
equipment. Lighting fixture(s) is provided in the enclosure for maintenance purposes.

2.1.2 Drum

The drum is mounted directly to the main drive shaft. It is dynamically balanced. A two-
piece removable lebus grooving sleeve is bolted to the drum bottom and welded
together. For further information regarding drum and wire size refer to Product Data
Sheet.

2.1.3 Drive gear box

The main shaft is driven through a spur gear drive mounted on the end of the
drawworks. The gearbox is designed for three input shafts (electric motors) on one side
and two on the other (ref /4/). The gear ratio is 10.5:1. The electric motors are always
mechanically engaged, and cannot be disengaged from the shaft by accident.

The gearbox is designed to reduce the inertia effect caused by rotating parts in the
driveline.
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2.1.4 Braking systems

2.1.4.1 Main braking system

Normal braking when lowering is achieved by use of regenerative braking using the AC-
motors and the VSDS as generator, hence feeding the energy from the braking into the
resistor system.

2.1.4.2 Disc brake system

The disc brakes are designed as park brake and emergency stop brake. The drum has
two direct mounted discs. Each disc is equipped with multiple braking calipers. The
calipers are spring applied, and are deactivated by use of hydraulic pressure, thus
making the system fail safe. Covers that will reduce the contamination of the discs and
pads are installed. Disc / pad contamination will lower the braking capacity.

The braking capacity is at least 200% of maximum rated load when the brakes are
maintained according to the maintenance manual. Since the disc brakes are not
designed for dynamic braking (except for in emergency situations), the discs should cool
down to below 158 F (70 ºC) after an emergency stop before the operation continues.
The cooling time will depend on the speed before the emergency stop, the hook load
and the condition of the calipers. One single emergency stop should normally not result
in disc temperatures above 70ºC. The temperature should be measured before start
after an emergency stop using a hand instrument such as a laser temperature meter or
equivalent (not supplied by NOV).

The disc brake system consists of a brake system A and B. Each of these systems will
set half of the calipers. Each system has a capacity of 100% of the nominal braking
capacity. Separate return lines are provided for each system to ensure fail-safe
operation of the disc brakes.

Normal park brake activation from the operator station will set either brake system A or
brake system B. These are alternated each time the park brakes are set.
When the Drawworks is switched OFF, both system A and B will be set.

A Hydraulic Power Unit (HPU) is provided for supply of hydraulic pressure to the disc
brakes. The Hydraulic Power Unit consists of:
- 2 ea. Electric motor / pump assemblies
- 1 ea. Hand pump
- 1 ea. Hydraulic high pressure filter
- 2 ea. Accumulators with isolation valves
- 1 ea. Pressure safety valve
- 1 ea. Pressure reducing valve for reduction of supply pressure to caliper operating
pressure
- 1 ea. Pressure reducing valve for emergency lowering operation
- 1 ea. Stainless steel reservoir with low-level switch, level glass and temperature
transmitter
- 1 ea. Pressure transmitter for monitoring of supply pressure
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2.1.5 Lubrication

The spur gear drive has a lube oil / cooling system with two electrically driven lube oil
pumps for pressure spray lubrication and an internal oil sump, and a lube oil / fresh
water heat exchanger. The tank is equipped with a low-level switch for low-level alarm
to the operator, a dip stick and a temperature transmitter for high temperature alarm to
the operator.

The grease lubrication system is limited to the main bearings and the linkage system for
the brake calipers.

2.2 Electric motors

The main drive motors are Exe motors with forced air-cooling. The motors have installed
temperature sensors (PT100 elements) in the stator windings. Encoders are mounted at
the motor non-drive end for measuring of the motor speed. The speed feedback from
the encoder is giving input to the frequency converters for optimal regulation of the AC-
motor.

2.3 Motor cooling blowers

Two blower skid assemblies are provided for cooling of the drawworks motors and
ventilation of the enclosure. Each skid consist of two blowers, back draft dampers, high
efficiency weather louvers and an outlet plenum enclosure. The blowers are set up in a
duty – standby configuration where the active blower will be alternated every time the
drawworks is switched ON. A cool down timer keep the blower(s) running a predefined
time after the drawworks is turned off and none of the drives are running.
Dampers are provided inside the drawworks enclosure between the plenum chamber
and the AC-motors for isolation of the motors.
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2.4 Drawworks control system

The various control system functions will be described in detail in this operation manual.

2.4.1 Response time

The PLC response time is very short. The PLC processing time from receiving a signal
on the input card (from the operator or from sensors) to the appropriate action and
output signal is sent out is approx. 20-40 milliseconds. When using a National Oilwell
Cyberbase operator system and TCP/IP Ethernet and DP networks, the estimated
response time from the operator pushes the button or moves the joystick to the PLC has
processed the command and sent the signal to the receiver (AC-drives, MCC’s or
drawworks mechanical system) is typically less than 200 milliseconds.

There is however some control system sequences that will require longer activation
time. This is typically:

- Start-up of drawworks (pushing DW On button). This command will start a sequence

to start all the auxiliary motors, verify lube and hydraulic system pressures and
generally prepare the drawworks for operation. Depending on environment
temperature and time since the machine were last operated this sequence could
vary from 3-4 seconds to 1 minute.
- Brakes on / off command. This command will start a sequence with a hand shaking
process between the drawworks PLC and the AC-drive system and the caliper itself
will have some reaction time due to the hydraulic response time. This sequence will
take approximately 1-3 seconds.

2.4.2 Miscellaneous field instruments

The following field instruments are provided for control and safe operation of the
drawworks and are shortly described below:

Pressure switches:
The cooling pressure switch is mounted on the motor. It monitors the pressure
differential between the cooling flow inlet and the enclosure pressure. The switch gives
a low-pressure alarm as an early warning if the cooling flow is low.

Temperature transmitters:
The temperature transmitters are mounted inside the motor junction box. They monitor
the temperature on each of the three motor windings and the two bearings. In case of a
high-high alarm the applicable motor will be shut down. Temperature transmitters are
installed in both the lube oil and HPU oil tank for monitoring of the temperature.

Encoders:
Each motor is equipped with an encoder that is connected to the related drive to ensure
correct speed and torque regulation of the motor. In addition the speed and encoder
signal from the motors are fed to the drawworks PLC for block position measurement.
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Proximity switches:
Three proximity switches are mounted in the derrick. The switches are used to verify the
block position calculations and two switches are also part of the crown saver function;
one for block upper warning signal and one for block upper stop signal (brakes on).

Level switches:
A vibration fork type level switch is installed in both the lube oil and HPU oil tank for low-
level alarms to the operator.

Pressure differential switch (located on filter):

The filter pressure differential switch monitors the hydraulic filter and gives a filter-
clogged alarm to the operator.

2.4.3 Drawworks interface mounting plate

All valves and sensors for proper operation and monitoring of the drawworks hydraulic
disc brake system and the lube oil system are mounted on a mounting plate located
inside the drawworks enclosure. The following valves and sensors are provided (ref /3/
in chapter 1.3):

- 4 ea. Fail safe solenoid valves for operation of disc brakes on / off
- 1 ea. Pressure transmitter for monitoring of hydraulic supply pressure
- 4 ea. Pressure transmitters for monitoring of brake caliper operation
- 2 ea. Pressure transmitters for monitoring of lube oil pressure

2.4.4 Hook load monitoring

The hook load is calculated based on input from two load cells mounted on the TD or
from the dead line anchor (selectable by the operator) and the number of lines. The
drawworks uses the hook load for the floor saver and crown saver calculations and for
the WOB-function. The hook load value is also transferred to the operator display for
information to the operator. In case of a failure in the hook load measurement (based on
line monitoring), the PLC control system will increase the hook load to maximum to
ensure that the floor saver measurements are conservative. In addition the deceleration
towards crown saver is limited to a low value resulting in the speed being ramped down
early.
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2.4.5 Emergency stop

In addition to the common emergency stop system, an emergency stop mushroom

switch is provided for installation adjacent to the drawworks. By activating the
emergency stop, the disc brakes will immediately engage (hard wired), a shut down
signal will be given to the VSDS system to stop the drawworks motors and the auxiliary
equipment will be shut down as normal by the drawworks control system.

2.4.6 Human-Machine Interface (HMI)

The drawworks is operated from an operator station located in the driller’s cabin with all
the necessary switches and controls to operate the machine in a safe and controlled
manner.

Commands are selected and given from keypads / buttons / switches and joysticks on
left and right hand side of the operator station. Status signals are shown on the
monitor(s). Setup and configuration inputs are made from the screen(s). The operator
station will communicate with the drawworks control system through hardwired signals
and / or the UDP/IP Ethernet fibre optical net.
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3 OPERATION INSTRUCTIONS

3.1 Preparation / configuration

The drawworks control system has to be set up before the machine is ready to be used.
Most configuration data has been set during commissioning. Configuration data other
than those listed below has to be changed by an NOV service engineer.

Setup screen for the drawworks

This screen is a sub-page of the drawworks screen.

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3.1.1 Block position

Before the drawworks can be used the number of wire lines strung has to be set and the
block position need to be calibrated.
To change number of wire lines used the park brake must be on.

These settings have to be reconfigured if the wire has been replaced or a “Slip
and Cut”-operation has been executed. It is also necessary to do this if the PLC
memory has been reset. It is important to be accurate in order to ensure that the
positioning system works and that the floor- and crown-saver functions correctly.

3.1.1.1 Position calibration procedure

Proceed with the following procedure in order to calibrate block position calculation.
Block position calibration must be done with extended block.

1. Position the block where the wire on the drum transits from layer 1 to 2
(maximum 10 degrees offset).
2. Set the park brake on.
3. Press reset “Layer Shift 1 to 2” and confirm on the screen.
4. Release the park brake and go to the reference prox (speed is reduced and the
drawworks will stop automatically when the top drive reaches the reference prox)
5. Execute procedure for reset of zero elevator position. See procedure below.

It is important that the position calibration is accurate. Block position, speed and
safety-functions are based upon this.

Reset of layer shift 1 to 2 resets the encoder counter cards and defines the zero angle
on the drum for the control system position calculation. All position calculations are
based upon this angle. Position calibration has to be done if a “Height Not Calibrated”-
alarm has been given to the operator.

3.1.1.2 Zero elevator position

The zero elevator position is used for calculating the floor saver activation point.
Proceed with the following procedure in order to reset the zero elevator position:

1. Position the block at zero elevator position.

2. Set the park brake on.
3. Press reset “Zero Elevator Position”.
4. Verify on the operator screen that the elevator / hook position becomes zero.
5. Release the brakes and hoist the block up 3 meters (10 feet).
6. Lower the block and verify that it stops above the set height.

NOTE:
A safety margin of approx. 1 foot (30 cm) is added to the floor saver. This will ensure
that the block stops at a safe distance from the floor.
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3.1.2 Maximum Speed Setting

3.1.2.1 Max Speed Run in Hole

This parameter will rescale the Joystick setpoint so that maximum Joystick activation
will give the Block Speed set in this parameter (if not limited by something else).

Max Speed Run in Hole Limit is only active when lowering. The activation of the Max
Speed Run in Hole Limit is based on the hookload. When the weight is above a certain
limit, the speed is limited by this function. With an empty block, the speed is not limited
by this function.

3.1.2.2 Max Speed Run out of Hole

This parameter will rescale the Joystick setpoint so that maximum Joystick activation
will give the Block Speed set in this parameter (if not limited by something else). This
speed is weight dependent.

Max Speed Run out of Hole Limit is only active when hoisting. The activation of the Max
Speed Run out of Hole Limit is based on the hookload. When the weight is above a
certain limit, the speed is limited by this function. With empty block, the speed is not
limited by this function.

3.1.3 Max pull limit

Optional, not included in this delivery.

3.1.3.1 Max Overpull

The Max Overpull setting limits the maximum WOB upwards when tripping out of the
hole to protect the system / equipment if the pipe gets stuck. The overpull value is equal
to the negative WOB value. It is calculated based on the last “Zero WOB” command.
A low overpull setting will also limit the maximum hoisting speed.

When the overpull limit is reached the hoisting speed is set to zero.

The overpull setting is applicable for the ‘Constant ROP (with CMC locked)’ mode (refer
chapter 3.4.5) when going out of the hole.
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3.1.4 CMC Positioning limits

3.1.4.1 CMC Pos. Max WOB

The maximum WOB setting limits the maximum allowed WOB downwards. It is
calculated based on the last “Zero WOB” command.

This setting is applicable when using ‘CMC auto positioning’ mode or ‘Constant ROP
(with CMC locked)’ mode (refer chapter 3.4.5).

The “Max WOB” setpoint button can also be found in the SDI drilling page, see SDI
operation manual S0100833-OPM-100

3.1.4.2 CMC Pos. Max ROP

Optional, not included in this delivery.

3.1.4.3 CMC Pos. Lower stop height

The CMC Auto Positioning function will be turned off when the elevator reaches the
lower stop height. The block movement will stop and the speed is deactivated.

The lower stop height can not be lower than the minimum height set in the PLC.
(Approx. 0,5 meter above the elevator height reset).
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3.1.5 Hookload selection

This screen gives the operator possibility to select between two different hookload
measurements. It also gives status information for the hookload measurements.

The alternatives are:

• Traveling block
• Deadline anchor

3.1.5.1 Hookload from traveling block

For the traveling block measurement choose which load pin measurements that should
be included in the hookload calculation. Normally all load pins should be selected. Keep
in mind that there only exists two mechanical load pins. Each pin has two equal
measurement electronics (A and B). Measurement A and B for the two load pins should
under normal circumstances be about equal.

When using the traveling block hookload, the weight above the load pins will be added
to the calculated hookload shown to the operator and used by the system (eg. the
weight of the traveling block).

3.1.5.2 Hookload from deadline anchor

For the deadline measurement it is possible to set a filter value on the measured signal
ranging between 0 and 20 seconds. A higher filter time will make the signal more robust
against rapid fluctuations in the measured signal. The filter only affects the value
displayed on the operator station, not the weight used by the control system.
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Hookload selection screen

3.1.6 Encoder selection

This screen gives the operator the possibility to define which encoders that should be
used in the block positioning system. Normally all encoders should be selected.

It is possible to deselect one of the encoders. Note that running a motor with a faulted
encoder will not work. This is due to the speed feedback to the drive will be different on
this particular motor. It will then run or work against the other motors, ie. running faster
or slower than the ones that work. The motor with a faulted encoder should then be
electrically disabled to avoid stress on the system.

The encoders are set up in a voting system where the signals from all selected
encoders are averaged. An encoder deviating from the average is taken out of the
calculation and an alarm is given to the operator. If a fault is detected on one of the
encoders during operation, the faulty encoder signal is ramped out of the average
calculation by the control system. Relevant alarms are given to the operator. Ref. alarm
list in section 5.3.7.
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Encoder selection screen

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3.2 Human-Machine Interface (HMI) operator station

3.2.1 Cyberbase displays

Machine and operational status will be shown on the screens for the drawworks and the
instrument screen for drilling (Drilling -> Instrum.).

Machinery page for M1

the drawworks

This page shows the general status of the machine. It becomes visible by pressing the
DW button.
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3.2.1.1 Motor information popup

The drawworks machine screen as shown in chapter 3.2.1 gives access to information
about the motors. Each of the motors are animated with a motor symbol and a
belonging information button. By pressing any of the motor information buttons a new
page will be shown.

Motor information symbol

Drive / motor information

The most common alarms are animated on this page.

Pressing the “R”-eset drive fault will reset fault on all of the drives.
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3.2.1.2 Braking caliper animation

Each of the calipers are animated on the machinery screen.

Yellow: Either on or off

Green: Caliper released (brake is off)
White: Caliper set (brake is on)
Red: Either brake off- or on-fault present

Braking caliper animation

The pressure on each of the caliper sets is also shown.

3.2.1.3 Drawworks navigation menu

The menu on the top of the drawworks screen gives the operator access to all main
screens for the drawworks. The setup screen has a menu on the right which gives
access to sub-pages for the drawworks.

Drawworks navigation menu

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The position screen is only used to visualize all the different height settings used by the
control system.

Position screen

The “Height to Top Drive reference” shows at all time the height from the drill floor or
rotary table to the reference point on the top drive set during commissioning, and which
normally is the lowest fixed point on the top drive.
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T1

T3

T2

T4

Test / exception screen

This page gives access to the following test / exception modes;

- Brake burning
- Brake test
- Slip & cut

These functions will be described in detail in chapter 3.7.

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Instrument screen

The instrument screen shows the following data concerning the drawworks:

WOB Actual WOB

CMC position CMC position and CMC position setpoint (when using ‘CMC auto
positioning’, ref. chapter 3.4.5)
Hook load Hook load
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Drilling screen

The drilling screen shows the following data concerning the drawworks:

ROP Average ROP

ROP setpoint When using ‘Constant ROP (with CMC locked)’ mode (ref. chapter
3.4.5)
WOB Actual WOB
Hook load Hook load
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3.2.2 Operator commands from keypads and joysticks

When the Cyberbase operator station is set to mode 2, the following keypads will be
available.

MW Drawworks MP Control

Esc MENU Esc MENU

RST TT
Pump
On
TD IBOP MP
Auto Drill. Close MP Sync
Ream. Stop /
On Resume

Lower Trip Upper MP 1 MP 1 MP 1

Trip H. Height Trip H. On +
-
Set On Set

MP 2 MP 2 MP 2
Right
Left

- On +

Zero Crown MP 3 MP 3 MP 3
WOB Saver - On +
O/R

DW Act. DW MP 4 MP 4 MP 4
On Test Park - On +

Confirm Confirm

Elevator / Dolly Drawworks

Dolly Ext. Lower

Reset
Slow Speed Lim.
Elev. Slips
Close Close

Dolly Retr. Hoist

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By pressing the TD Drill.-swap on the left keypad, the TD Drilling keypad will appear
with the buttons for the CMC positioning system. When CMC positioning system is
activated the right joystick will switch from being hoist / lower to CMC Position setpoint.

MW TD Drilling MW Mud Pumps Auto

Esc MENU Esc MENU

DW TT
Pump
On
TD IBOP MP
Conn. Close MP Sync
Stop /
Resume

Torque TD Torque MP 1 MP 1 MP 1
- Rev. + - On +

Motor MP 2 MP 2 MP 2
Right
Left

Torque - On +
Zero

CMC Zero CMC MP 3 MP 3 MP 3

Pos. WOB Pos. - On +
Auto ROP

TD TD DW MP 4 MP 4 MP 4
On Brake Park - On +
On

Confirm Confirm

Top Drive CMC Pos. System

Speed Inc Setp.Inc.

Link Tilt Link Tilt

Bwd Fwd Deactivate
Act Slips
Close

Speed Dec Setp.Dec. .

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MW MP/AR Control

Esc MENU
TT
Pump
On
IBOP MP
Close MP Sync
Stop /
Resume

MP 1 MP 1 MP 1
- On +

MP 2 MP 2 MP 2
- On +

MP 3 MP 3 MP 3
+
Right
- On

MP 4 MP 4 MP 4
- On +

Confirm

Auto Reaming
Setp. Inc

Deactivate
Slips
Clos

Setp. Dec

For information about navigating on the Cyberbase keypads refer to the Cyberbase
operation manual, reference /9/ in chapter 1.3.
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3.3 Starting procedures

1. Select the correct operator mode on the operator station.

2. Verify correct settings on the “Setup” screen.
3. Press “DW On” and confirm in order to turn the machine on. The auxiliary
equipment such as blowers, hydraulic pumps and lube oil pumps will start
automatically.
4. Ensure that all auxiliary equipment is running and that no low hydraulic pressure
or low lube oil pressure alarms are active.
5. When the “DW Park” button comes available, press it followed by confirm. Doing
this will torque up the motors followed by the release of the park brake. It is now
possible to hoist and lower the block.
6. Run past the reference proximity switch with the block to ensure that the
positioning system is healthy.
7. The drawworks is now ready for operation.

3.4 Normal operation

As soon as the starting procedure has been finished normal operation of the drawworks
is possible. The block is hoisted / lowered using the right hand joystick. The drawworks
control system ensures smooth acceleration and deceleration depending on the
hookload and available power and regenerative power to the drawworks.

3.4.1 Drawworks slow speed

The slow speed mode gives only a small percentage of the maximum speed signal to
the drawworks when using the maximum range of the joystick. Pushing the joystick over
to slow speed will also reset the floor saver, if activated.

NOTE:
When using slow speed mode, both hard and soft floor saver is deactivated. Be aware
that using this function means that there is no automatic braking when moving
downwards.

3.4.2 Weight on bit reset

In order to reset the weight on bit monitoring, hold the drill string right above the bottom
of the drilled hole. Then press “Zero WOB” followed by confirm. The weight on the bit is
then calculated by subtracting actual hook load from the stored weight value. If
changing between deadline anchor and traveling block hook load monitoring, the weight
on bit should be reset. Zero WOB command is not allowed when using ‘CMC auto
positioning’ or ‘Constant ROP (with CMC locked)’ (refer chapter 3.4.5), but must be
pressed before entering these modes.
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3.4.3 Crown saver override

Push and hold the “Crown Saver O/R”-button to activate the crown saver override
function. This makes it possible to run past the upper stop proximity switch in slow
speed. Release the button to deactivate the crown saver override function.

Note:
Be aware that using this function means that there is no automatic braking / stopping
when moving upwards.

3.4.4 Floor saver override

Push and hold the drawworks joystick to the left while hoisting and lowering. This will
give slow speed and also disable the floor saver. Set the joystick in mid position in the x-
direction to enable the floor saver function again.

Note:
Be aware that using this function means that there is no automatic braking / stopping
when moving downwards.

3.4.5 CMC Positioning System

The drawworks control system is equipped with a CMC auto positioning system to
ensure more accurate performance, reduce bit wear and reduce strain on the driller.
The CMC auto positioning system has two different ‘automatic drilling’ modes, either
‘CMC auto positioning’ or ‘Constant ROP (with CMC locked)’.

3.4.5.1 CMC Auto Positioning

When activating this function the operator can select a set-point for the CMC position.
The control system will monitor the compensator position and will compensate for the
movements by slacking out or pulling in wire. Use of the joystick will increase or
decrease the compensator position set-point.

A maximum and minimum compensator position limit will be set at a fixed value in the
PLC. Operator set-point adjustment will be restricted by these values.

Max WOB and Max Overpull limits have to be set. If any of the limits are exceeded the
CMC auto positioning mode will be turned off.

If the block is below a predefined height above drillfloor, above upper warning height or
communication error between Drawworks control and Compensator control system, the
CMC auto positioning mode will automatically be shut off.
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A “Zero WOB”-command has to be done before starting the operation. This command
stores the hook load measured from the hook load sensors as a reference value. The
control system can then during operation calculate the WOB as the difference between
this reference hook load and the actual hook load.

Negative WOB

Max Overpull

0 Zero WOB

Max WOB

Positive WOB

1. Set Max WOB and Max Overpull in the “Setup”-screen.

2. Zero the WOB.
3. Press the “CMC Pos. Auto”-button followed by confirm. The button then becomes
white and the right joystick will switch to increase / decrease of CMC position
setpoint.
4. Adjust the position setpoint by moving the joystick forward or backward.
5. Deactivate the CMC auto positioning mode by using the deactivate function on
the right joystick or repressing the “CMC Pos. Auto”- button followed by confirm.

Note 1:
The CMC auto positioning mode will be deactivated if the floor saver is activated.

Note 2:
If the operator is adjusting the CMC position setpoint when the lower or upper limit is
reached, the joystick function will change to normal lowering / hoisting. In this case the
joystick will have to be set to neutral before normal operation can commence. This is
only applicable if not the operator has selected slow speed by pulling the joystick to the
left before deactivation of the CMC Auto Positioning.
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3.4.5.2 Constant ROP with CMC locked

This function is typically used during reaming operations when a constant rate of
penetration is required.

When activating this function, the control system will set the speed reference to the
ROP set by the operator. The ROP function can be adjusted to both positive and
negative setpoint, where the negative ROP setpoint will have an effect upwards. Note
that the maximum WOB setting (downwards) and maximum overpull setting (upwards)
will be used as limits together with the ROP function. If the limits are exceeded the
control system will reduce ROP to avoid damage to the equipment.

1. Set Max WOB and Max Overpull in the “Setup”-screen.

2. Zero the WOB.
3. Press the “CMC Pos. ROP”-button followed by confirm. The button then becomes
white and the right joystick will switch to increase / decrease of ROP setpoint.
4. Adjust the ROP by moving the joystick forward to increase speed or backward to
decrease speed.
5. Deactivate the ROP function by using the deactivate function on the right joystick
or repressing the “CMC Pos. ROP”- button followed by confirm.

Note 1:
To avoid too high WOB a maximum WOB limit (downwards) and maximum overpull limit
(upwards) must be set before starting the operation. If the maximum limits are exceeded
an alarm will be issued.

Note 2:
The Constant ROP mode will be deactivated if the floor saver is activated.

Note 3:
If the operator is adjusting the ROP-setpoint when the lower or upper limit is reached,
the joystick function will change to normal lowering / hoisting. In this case the joystick
will have to be set to neutral before normal operation can commence. This is only
applicable if not the operator has selected slow speed by pulling the joystick to the left
before deactivation of the Constant ROP mode.

3.4.6 Trip Height Settings

Upper Trip Height Setting:

• Run the Block to the desired stop position.
• Push the “Upper Trip Height Set”-button followed by confirm.

Lower Trip Height Setting:

• Run the Block to the desired stop position.
• Push the “Lower Trip Height Set”-button followed by confirm.
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Trip Height Activation:

• Push the “Trip Height On”-button followed by confirm for activation of the Trip
Height Mode. The button will become white.
• The Block will now stop at the preset positions every time.
• Push the “Trip Height On”-button followed by confirm to deactivate the Trip
Height Mode.

Note:
Hoisting and lowering can commence after the Joystick is set in the neutral position.

3.4.7 Auto Reaming

When Auto Reaming function is active, the Drawworks will hoist and lower the block
continuously between upper and lower trip heights with an operator set constant speed.
The WOB is compared against Max WOB and Max Overpull when Auto Reaming is
active. If WOB exceeds Max WOB whilst lowering, the Drawworks will stop downwards
movement and start hoisting. In the same way the Drawworks will stop hoisting and start
lowering if Overpull (Negative WOB) exceeds the Max Overpull Limit.

Procedure for Activation of Auto Reaming:

1. Set upper and lower trip heights according to procedure in Section 3.4.6.
2. Activate trip height function from Cyberbase Keypad.
3. Hoist or lower the Drawworks to a position between upper and lower trip heights
(it is not possible to activate Auto Reaming outside tripping limits).
4. Push “Auto Ream On” button and confirm on Cyberbase Keypad. The actual
speed command will be logged by the Control System and will be used as the
speed setpoint in the Auto Reaming function.
5. The speed setpoint can be adjusted up and down from Cyberbase Joystick.
6. The Drawworks will continue to hoist and lower the Block until Auto Reaming is
deactivated.

Deactivation of Auto Reaming:

• Auto Reaming function is deactivated by pushing “Auto Ream On” and Confirm
on the Cyberbase Keypad.
• Auto Reaming function can also be deactivated by use of the Deactivate function
on the Cyberbase Joystick.
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3.5 Stop procedures

3.5.1 Normal stop

A normal stop procedure for the equipment is done from the operator station.

• Set the joystick in the center position and deactivate the CMC auto position system
if active. Wait till the block comes to a standstill.
• Press then the “DW Park”-button followed by confirm to set the brakes.
• When the brakes are set, the drawworks can be switched off by pushing the “DW
On”-button followed by confirm.

Note:
If the Cyberbase mode switch is switched out of mode 2, the block will decelerate and
brakes will be set at standstill.

3.5.2 Emergency stop

Activating the emergency stop buttons on the operator station or the local emergency
stop adjacent to the drawworks will set the brakes immediately. Pull out the activated
emergency stop button and start up the drawworks to continue operation.

Note:
When activating emergency stop the drives might trip. The drives must then be reset
from the motor information screens as described in chapter 3.2.1.1, or locally on the
drive itself.

3.6 Emergency lowering

Emergency lowering of the block in an emergency situation is possible. Look in

reference /1/ in chapter 1.3.
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3.7 Test and exception functions

In order to enter any of the modes the drawworks must be turned off and the “Test /
Exception”-key switch inside the PLC control cabinet has to be switched over from
normal.

Then choose one of the desired test / exception

modes (T1).

Green light shows that the

key switch in the PLC
control cabinet is
activated.

3.7.1 Brake system safety and performance testing

The test is initiated manually, but the sequence is program controlled. During the test,
the motors are gradually torqued up in steps against an activated caliper set (one
caliper or caliper pair at the time). If the brake slips, the torque is logged and presented
for the operator as the tested caliper torque. The program will also allow the brake to
slip one rotation on the drum, if it slips before 120% of the pass torque is reached.

If the tested caliper torque reaches the pass value, a passed indication is presented for
the operator. Any caliper set that doesn’t get the passed indication will decrease the
maximum allowable hookload rating for the machine according to how far from the pass
value it were tested. Only the caliper set with the lowest tested torque (divided by 2 if
two calipers) will be used in the maximum allowable hookload calculation. If the tested
hookload rating is lower than 75% of the nominal drawworks rating, an alarm will be
given to the operator and the maximum allowable hookload will be set to a low value.
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The actual braking force for each caliper is depending on several conditions when
mounted on the drawworks:

1. Air gap between brake pad and disc when fully released. Increased air gap reduces
the clamping force. Refer to reference /1/ in section 1.3 for correct air gap
adjustments.

2. Coefficient of friction. This factor is strongly depending on the cleanliness of the

brake disc and the brake pads. Contamination from soap, hydraulic oil and lubricant
(wire lube, grease etc.), antiseize compounds will strongly reduce this coefficient and
thereby reduce the braking force. Glazing of the brake pads, i.e. the brake pad
material is heated and a hardened film of brake pad material is deposited on the
pad, will also lower the coefficient of friction and reduce the braking capacity.

3. Brake burning. The pads delivered together with the drawworks are burned to
achieve a braking force equal to or better than the design criteria as described
below. Some pads might be better than other pads depending on the burning. When
purchasing new pads, these will have to be burned after they have been mounted on
the drawworks.

Brake capacity test procedure:

1. Secure the load in the slips or elsewhere so that only the weight of the top drive is in
the hook.

2. Hoist the traveling block so that the elevator position is between 32.8 ft (10 meter)
and 82 ft (25 meters) above the drill floor.

3. Park the drawworks and switch it off. Switch to the “Test / Exception” operator
screen.

4. Turn the mode selector switch in the drawworks PLC control cabinet to test position.
Select “Brake Test” on the “Test / Exception” screen and start the drawworks and
release the brakes as normal.

5. Activate the “Act. Test”-button followed by confirm on the Cyberbase keypad. (This
will disable the normal drawworks operation and start the automatic sequence).
Note: The test can be aborted by activating the right drawworks joystick to the left at
any time during the automatic sequence.

6. The control system will now check that the block is located at safe distance from
floor and crown. It will also check that there is no load in the hook except for the top
drive and that there is enough motors available to fulfill the test. The ‘Brake Test
Aborted‘ and ‘Block Too Low/High’, ‘Block Weight Too High’ or ‘Not Enough Motors
Available’ indicators on the screen (T3) will be activated if any of these parameters
are outside the preset limits.
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7a. Verify that the “Brake Test On” and “Brake Test Active” indicators are activated on
the operator station. This will start the automatic test sequence as follows:

7b. When all brakes are released and the test is started, the mean torque value
representing the force from the external load is recorded by the program and
presented as the “Torque At Current Hookload”. This test is the offset test and takes
approximately 8 seconds.

7c. The motors are torqued up in steps for each caliper set until the caliper slips or
reaches a value well above the pass value. Each step will be held for approx. 1
second giving a test time of approx. a minute for each caliper set. The motors are
only applying torque to simulate a downward force. The actual tested torque value
working on the caliper will be increased gradually and displayed for the operator as
the test progresses.

7d. If the brake calipers do not slip before the passed value is reached, the passed
indication will be activated and the actual brake capacity represented as maximum
allowable hookload will be shown on the screen.

7e. If the caliper set slips (drum turning more than 4 degrees) before the passed value is
reached, the tested torque will stop being updated but the actual torque will still
show on the screen until the test is fulfilled. The test will continue until the drum has
done one whole revolution but the highest tested torque before the brake slipped
more than 4 degrees will be used as the caliper tested torque when the test is
finished.

7f. The test continues with the remaining caliper sets until all calipers are tested.

7g. If parts of the test is not completed the “Brake Test Aborted” indicator will be
activated and there will not be presented a final weight capacity.

8. When done, the drawworks brakes will be set automatically. Also turn off the
drawworks.

9. Ensure that the “Brake Test Active” and “Test Mode On” indicators are deactivated.

10. Turn the test/exception mode selector switch to normal in the drawworks PLC
control cabinet.

NOTE!
If the calipers have a capacity less than the pass value, the brake capacity is lower than
the design criteria and maintenance should be done to increase the capacity. Any load
above the “Maximum Allowable Hookload” should not be lifted.
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3.7.2 Brake burning procedure

Refer also to the brake manufacturer’ maintenance manual as incorporated in document

ref. /1/ in chapter 1.3.

WARNING:
"When working in drum area with drill line attached to the drum, lock out the drawworks
AC-drives".

NOTES:
• Only one caliper or linked pair of calipers can be burnt in at the same time.
• If changing pad or caliper or disassembling the caliper, ensure that an air gap check
is done before performing the brake capacity test or continuing operation.

Brake burning procedure:

1. Hang off traveling block with the hang off line and remove the drill line from the
drum.

2. Park the drawworks and switch it off. Switch to the “Test / Exception” operator
screen.

3. Clean the brake discs with white spirit and thereafter with thinner or trichloretylene
prior to inserting any new pads. Install new pads according to the procedure in the
maintenance manual.

4a. Ensure that all manual / remote valves are in REMOTE position. Refer to the sign
located inside the drum area for selection of correct valves.

4b. Install / extend, unlatch and pin the handle on the “EMERGENCY LOWERING” valve
(Item H on the schematic).

4c. Close the “EMERGENCY DUMP” valve (Item N on the schematic).

4d. Put the two (2) MANUAL / REMOTE valves (Item F on the schematic) on the pair of
calipers to be burned (bedded) in the MANUAL position. Refer to the sign located
inside the drum area for selection of correct valves and further instructions.

5. Turn the mode selector switch in the drawworks PLC control cabinet to test position.
Select “Brake Burning” on the “Test / Exception” screen.

6. Start the drawworks and release the brakes as normal, ensure the hydraulic supply
pressure is approximately 3000 psi.

7. Select the caliper pair to be burned (T2). Ensure that this is consistent with the
manually operated valves on the drawworks.
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8. Activate the “Act Test”-button followed by confirm on the Cyberbase keypad (this will
disable normal drawworks operation, override brake alarms and disengage the
calipers not selected). Verify that the “Brake Burn Active” indicator is activated.

9. Pull down the “EMERGENCY LOWERING” valve (Item H on the schematic) to

release the caliper pair to be burned from the brake disc.

10. Activate the joystick to rotate the drum (the drawworks control system will limit the
speed and motor torque).

11. Slowly raise the handle of the “EMERGENCY LOWERING” valve (Item H on the
schematic) to reduce the pressure on the caliper pair. The pressure should be held
between 400 and 600 psi depending on the number of calipers on the set that is
being burned. If the rotation stops the pressure needs to be adjusted to stay within
the available motor torque.

12. Monitor the brake disc temperature with an infrared temperature sensor (or
equivalent. Burn the brake until the disc temperature reaches 212° F or 100°
Celsius.

13. Once the disc reaches 212° F or 100° Celsius pull down on the “EMERGENCY
LOWERING” valve (Item H on the schematic) to fully disengage the disc caliper from
the disc.

14. Select “Disc Cooling” to disengage all calipers by the control system.

15. Raise the handle on the “EMERGENCY LOWERING” valve (Item H on the
schematic) and ensure that the calipers remain disengaged from the disc.

16. Continue to rotate the drum and spray clean fresh water (no soaps, detergents,
softeners, salts, oils, etc) onto both sides of the heated disc to cool it down to
approximately 77° F or 25° Celsius.

17. Deselect “Disc Cooling” to engage the previously selected caliper and repeat steps 7
thru 17 until the caliper pair has been burned 4 times total.

18. After the caliper pair has been burnt and the disc has been cooled down, stop
rotating the drum. Select next caliper pair (REMEMBER the manual operation on the
drawworks hydraulics) and repeat the procedure.

19. Raise the handle on the “EMERGENCY LOWERING” valve (Item H on the
schematic) and allow the caliper pair to engage the brake disc.

20. Deselect the “Act. Test” button to disable the test mode.

21. Select the “No Test Mode”.

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22. Switch the MANUAL / REMOTE (Item F on the schematic) valve for the caliper pair
to the REMOTE position.

23. Perform an automatic brake capacity test according to the procedure. If the caliper
pair capacity is insufficient burn the caliper pair 2 more times and perform a new
brake capacity test.

24. If the caliper pair capacity is adequate remove / retract, latch and pin the handle on
the “EMERGENCY LOWERING” valve (Item H on the schematic).

25. Open the “EMERGENCY DUMP” valve (Item N on the schematic).

26. Release the joystick and apply the brake when the complete procedure is finished.
Verify that the brakes are set on the operator screen.

27. Switch the mode selector switch in the drawworks control cabinet to normal.

28. Ensure that the “Brake Burning”, “Brake Test On” and “Test Mode On” indicators are
off, that the “Act. Test” button is disengaged, that the brakes are set and no alarms
are active.

29. Reattach the drill line to the drum and disconnect the hang off line.

NOTE:
It is possible to burn in one caliper by itself. To do this it is necessary to disconnect one
end of the brake cylinder from the caliper arm by removing the pin shown below.

Removing this pin will

allow the other caliper in
the pair to be burnt in by
itself. Thus it is
possible if necessary to
burn in each caliper
individually.
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3.7.3 Slip & cut

In this mode the block-position update / calculation is stopped (to avoid triggering the
floor and crown saver), the speed / torque limits are forced to low values. Slip & cut
mode must be turned off before the load is picked up after slip & cut operation.

Do the following before entering slip & cut mode:

• Hang off the load and block.
• Set the brakes.
• Switch the drawworks off.

Do the following to set slip & cut mode when wire is disconnected from the drum:
• Switch on the “Test / Exception”-key switch located inside drawworks control
cabinet.
• Select “Slip & Cut” mode on drawworks test / exception screen.
• Start up the drawworks. (Note that the torque is reduced by the system such it is
important that the load is hanged off!)

The following will be executed while the system is in slip & cut mode:
• Pull limit function is limiting absolute pull to 50T.
• Torque reference (start up torque) is set to ½ of torque limit.
• Slow speed activated, normally 10% of full speed.
• Disabling of block position system.
• Trig of “Height Not Calibrated”-alarm. A new block position calibration is required.

Do the following to deactivate slip & cut mode when the operation is done and wire is
attached to the block before picking up the load.
• Set the brakes.
• Switch the drawworks off.
• Deselect “Slip & Cut” mode on drawworks test / exception screen.
• Switch the “Test & Exception”-key switch located inside drawworks control
cabinet to normal mode.

Normal operation can commence:

• Execute a calibration of block position.
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4 SAFETY AND SYSTEM FUNCTIONS

4.1 General

The drawworks control system is designed to provide enhanced safety and integrity for
the operation, machinery, and the personnel onboard the platform. This is achieved by
an active control philosophy with equipment self-checks and monitoring, and by use of
duplicated critical equipment such as duplicated brake discs, blowers, hydraulic pumps,
lube oil pumps and encoders and by interface to other machines / systems to avoid
collision or equipment damage.

The primary safety requirement for the drawworks is that ‘one single point of failure shall
not cause any hazardous condition leading to either personnel injury or any damage to
the equipment.

4.2 Emergency stop

The drawworks is connected to the common emergency stop buttons and also to a
separate drawworks emergency stop button.

A drawworks emergency stop button (with cover) is provided for installation adjacent to
the drawworks in addition to the emergency stop buttons on the operator chair. By
activating the emergency stop, the disc brakes will immediately engage (hard wired). A
shut down signal will be given to the VSDS to stop the drawworks motors and the
auxiliary equipment will be shut down as normal by the drawworks control system.
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4.3 Floor saver system

The floor saver system works together with the regeneration power limiting system and
will at any time calculate actual stop length based on actual speed, hookload and
available braking force.

The floor saver has three activation steps:

- Speed ramp down function ramps down the maximum lowering speed depending on
calculated stop length and remaining distance to stop point. This maximum lowering
speed will override operator speed as soon as maximum speed is less than operator
given speed. This function will during “normal” conditions stop the block without
activation of the floor saver levels described below.
- The "Soft" floor saver is activated when the available stopping distance including a
safety distance is less than the calculated stop length. The "Soft" floor saver sets the
operator speed reference to zero. The drawworks PLC logic will decelerate the
drawworks according to calculated max deceleration ramp.
- The "Hard" floor saver is activated when the available stopping distance is less than
half the calculated stop length. The "Hard" floor saver sets the disc brakes.

To reset the floor saver put the joystick in slow speed mode.

It is possible to lower the block below the floor saver activation point by activating the
joystick in slow speed mode.

The stop point for the floor saver is set by the operator (zero floor height). If anti collision
or zone management systems are installed, the drawworks PLC will use the stop point
from this system if it is higher than the stop point set by the operator.

NOTE:
In case of a failure in the selected hookload measurement, the PLC control system will
increase the hookload to maximum to ensure that the floor saver measurements are
conservative

4.4 Crown saver system

The crown saver is both software- and a hardware-based system.

The hardware based crown saver uses two proximity switches installed in the derrick;
the upper warning switch gives a message to the operator that he is operating near the
crown, while the upper stop switch will set the brakes immediately to avoid collision with
the crown.

The software based crown saver has two activation steps:

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- The crown saver system will at any time calculate ramp down speed depending on
remaining distance to stop point (close to upper stop proximity switch). This
calculation is based on actual speed, hookload, block extended/retracted position
and available braking force. This ramp down speed will override the operator speed
as soon as it is less than the operator given speed. This function will during “normal”
conditions stop the block beneath upper stop proximity switch without activation of
the hard crown saver levels described below.
- The hard crown saver is activated when the upper stop proximity switch or upper
stop height is activated. The "hard" crown saver sets the disc brakes.

To reset the crown saver push crown saver reset button on Cyberbase keypad.

It is possible to hoist the block above upper stop point using the crown saver override
button. Operator speed is then restricted.

NOTE:
In case of a failure in the selected hookload measurement, the PLC control system will
use a low deceleration angle upwards to ensure conservative crown saver operation.

4.5 Slip alarms and Automatic Motor Start (AMS)

When the park brake is set (with drawworks on) and a movement of the block is
detected, a slip alarm will be announced to the operator and the PLC system will
automatically activate the second brake system (The remaining calipers).

After a slip alarm is given and the remaining calipers are set, the operator can release
the brakes in a normal manner to secure the load/operation and park the drawworks.
Before continued operation the required maintenance/repairs based on the slip alarm
have to be performed. National Oilwell Varco should be notified if this alarm occurs.

When both brake system are set, further detection of block movement will activate a
second slip alarm. The PLC system will automatically activate the AMS system
(Automatic Motor Start) and the motors will add braking force to the system.

IMPORTANT:
This function will under no circumstances replace the need to keep / maintain the brake
system to its design brake capacity conditions, as the AMS will not be available in a
power failure scenario. National Oilwell Varco should be notified if this alarm occurs.

If the drawworks is OFF (i.e. the drawworks is parked and the load is secured), all brake
calipers are applied and the slip alarm detection will be deactivated to avoid unwanted
motor starts in case of maintenance on PLC and/or block position counter system.
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4.6 Creep alarm

If the load is held at standstill by the motors with zero joystick command and brakes
released, and a movement larger than 5 cm (2”) on the traveling block is detected by the
drawworks control system, the brakes will be applied, the motors turned off and a creep
alarm is given to the operator.

4.7 Pinion slip detection

A function in the drawworks control system monitors the torque of each of the motors. If
the torque between the motors deviates more than a preset limit, the brakes will be set.
Disconnect the drive of the faulted motor, and investigate the mechanical parts of the
drawworks before continuing.

4.8 Auto brake activation

The brakes are normally set by the operator.

The brakes will also be set automatically after 5 minutes without joystick activation in
normal tripping mode and a pre-warning message is given to the operator 30 seconds
before brake set activation.

4.9 Hookload monitoring

The traveling assembly load cell measurements (if installed) will be selected as default
by the drawworks PLC. The operator can select the deadline anchor load cell if
installed.

The hookload is calculated based on input from the selected hookload sensor and the
number of lines. The drawworks uses selected hookload for the floor saver and crown
saver calculations, for max speed calculations and slack wire calculations. Selected
hookload value is also transferred to the operator display for information to the operator.

Weight of the traveling block is added to the travel assembly load cells when this is
used as selected hookload. This is done to get correct hookload for ton/mile calculation
and to get correct load for drawworks speed acceleration calculation.

To avoid that the hookload is changing while hoisting / lowering the weight of the
service loop and weight of wire line is taken into the hookload calculation. This
correction is included to minimize change in weight on bit when hoisting or lowering.

A dead line anchor filter value input is included on the displays. This is a command
value to filter (stabilize) the displayed hookload value from the deadline anchor. The
filter only affects the value on the operator display, not the weight used by the control
program.
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4.10 Block positioning

The encoder signals from the motors are fed to the drawworks control cabinet for block
position measurement. In the drawworks control system the signals from the sensors
are set up in a voting system calculating the average of the signal values. Signal values
deviating from the average are taken out of the calculations. Sensors deselected by the
control system will not be taken into the calculations again until the brakes are set.

The block position is calculated based on the average value of the selected encoders
together with the number of wire lines.

All encoders will be selected as default by the drawworks PLC. The operator can select
which encoders the system should use. The operator selection will not take effect until
the brake is applied.

4.10.1 Block Position check

All of the three proximity switches installed in the derrick are used to verify that the block
position calculated using the motor encoders is correct. If the block is passing the
proximity switch location without a proximity switch signal being sent to the drawworks
control system or if a signal is received from the proximity switch at the wrong block
position, an alarm will be sent to the operator. The drawworks will in these cases
assume that there is something wrong with the block position and activate the height not
calibrated alarm and reduce the operator speed to slow speed.

If the block is above the upper warning proximity switch and the control system receives
a signal from the upper stop switch, the brakes will be set. If this signal occurs below the
upper warning switch an alarm is given to the operator, but the brakes will not be set.

The flag activating the proximity switches is located on the top drive / dolly. The flag
height will be different depending on the whether the block is extended or retracted. A
block extend / retract signal from the top drive is used to adjust for this height deviation
on the proximity switch flag.

4.10.2 Height not calibrated

The drawworks control system activates this function as soon as there is doubt if the
block position is correct. Slow speed is only permitted until a reset of the positioning
system is executed.

The following conditions activate the “Height Not Calibrated”:

§ Proximity deviation alarm
§ Entry of “slip and cut”-mode
§ First PLC scan after restart
§ Change of number of lines
§ Brake burning
§ Encoder signal not healthy
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4.10.3 Low dead wrap check

There is a check against too few dead wraps left on the drawworks drum based on the
motor encoders and block position system. The blocks will ramp down and stop above
this position. If the limit is reached, lowering will be stopped and an alarm is given to the
operator. Lowering can be continued in slow speed by first setting the joystick in middle
position.

4.11 Dynamic acceleration / deceleration ramps

The drawworks control system calculates and restricts the maximum acceleration and
deceleration ramps of the drawworks motors. This is done to avoid wire slack problems,
power usage and regeneration outside the system limitations and operations outside the
dynamic capabilities of the drive system.

The calculations will take into account factors such as speed, direction, hookload and
the power limit values. These values are used in the calculations to ensure dynamic
ramps in both hoisting and lowering operations and for optimum performance as well as
safe operation of the drawworks.

4.12 High motor temperature

Each of the motors is equipped with winding temperature sensors. An alarm to the
operator is given upon high motor temperature. Soft stop of the drawworks is initiated if
the high high temperature level is reached. A motor with high high temperature fault is
excluded from new start as long as the alarm is present. This allows further operation
with remaining motors without fault.

As long as the drawworks is on or the motors are running the start signal is kept to all
blower motors.

4.13 Brake capacity testing

The control system has a feature for easy brake capacity testing implemented. This
feature should be used when new brake pads are installed, prior to handling of high
loads and also at regular intervals during the operation (frequency to be evaluated
during operation, recommended is once a week). The testing can be done without
hanging off the block.

When the operator activates the test, the control system will run an automatic sequence
torquing up the motors against each pair of calipers and measuring the braking force
when the calipers slip
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The output from the tests is the actual brake capacity presented as equivalent hookload
value for each system. Each caliper set will also have the actual torque value and a
passed indication presented on the display.

4.13.1 Brake burning

New brake pads installed on the drawworks must be “burnt” to achieve proper brake
capacity. The calipers are burnt in by selecting the brake burning function on the
operator displays and then applying the brake pad slightly using the emergency
lowering valve while turning the drum from the operator chair. The control system will
then over-ride the block positioning system and reduce the maximum speed.
The wire must be removed from the drum during brake burning.

4.14 Slip and cut mode

In order to do a slip & cut operation the block must first be hung off. Then the machine
has to be shut down. The mode selector key switch inside the PLC control cabinet has
to be set to test mode with drawworks in off position, and then slip & cut mode must be
selected on the operator screen. When slip & cut mode is active the motor torque is set
to a low value and only slow speed will be available for the operator.
New block calibration is required after a slip and cut operation.

4.15 Interface to anti collision system

The anti collision system is located in the DCI-B PLC.

The drawworks control system is prepared for receiving a machine height (m) signal and
a stop signal from the anti collision control system.

When receiving a machine height from the anti collision system the drawworks control
system will assume that a machine has been moved into the area below the
block/elevator and will adjust the floor level to the new machine height level. All
calculations for the floor saver will then be adjusted according to the new floor level.

In case of a stop signal from the anti collision system, the operator speed will be set to
zero.

Note:
When moving the block in slow speed the floor level set by the anti collision system will
be ignored and the operator can run the block all the way to the drill floor.

When running below the floor level, or above the upper stop level, the slow speed will
be further reduced.
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4.16 Power management system

The drawworks control system utilizes external power available signals to avoid a black
out and other dangerous situations. If a communication fault is detected to the power
management system, minimum power available values will be set. Refer also /10/ in
chapter 1.3.

4.16.1 Power consumption management

The power available signal is used in the calculation of maximum speed and maximum
acceleration calculations when hoisting.

4.16.2 Power regeneration management

The power available for regeneration is used in the calculation of maximum lowering
speed and maximum deceleration calculations and the floor saver calculations.

4.17 Interlocks with other machines

4.17.1 Iron Roughneck (IR) interlocks

Optional, not included in this delivery.

4.17.2 Top Drive (TD) clamp

Optional, not included in this delivery.

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5 DISTURBANCE OF OPERATION, CORRECTIVE MEASURES

It is very important that errors and unexpected operations are documented in

writing and as detailed as possible. A copy of these reports should be sent or e-
mailed to National Oilwell Varco support team.

5.1 Message system

A separate screen is used for displaying operator messages generated by the
drawworks control system. The screen is divided into four levels which display different
types of information. A combination of the message in level 1 and level 4 is displayed in
the message banner on Cyberbase screen when a level 4 message is active.

Level 1: Machine Operator Status

Level 1 displays the actual operator status of the machine. Messages in level 1 are
always active. Typical operator messages in level 1 can be:
• DW not ready to be turned on.
• Startup of auxiliary equipment in progress: Waiting for brake supply pressure.
• Brakes released, Autodriller WOB mode.

Level 2: Event / Cause

Level 2 displays the actual event or cause of the operator interrupt displayed in level 4.
Level 2 messages is also active when there are abnormalities in the system that is not
leading to operator interruption. Level 2 messages are often directly related to alarms
displayed in the alarm banner. Typical level 2 messages can be:
• Floorsaver active.
• Cyberbase Mode 2 deactivated.
• Block position not calibrated.

Level 3: Correction Action

Level 3 displays the corrective action needed to remove the event causing the operator
interrupt. The corrective action is also displayed when there are abnormalities in the
system that is not leading to operator interruption. Corrective action is always displayed
when an level 3 message is active. Typical level 3 messages can be:
• Reset floorsaver.
• Motor(s)not running, check MCC.
• Use crown saver override button to continue.

Level 4: Operator Interrupt

Level 4 displays the operator interrupt activated by the control system based on
abnormalities in the system. The level 4 message is only activated when operator is
limited by the control system. E.g. Zero Speed Up / Down message is not displayed
before the joystick is activated by the operator, even if the restriction is active in front.
Typical level 4 messages can be:
• Commando is ignored.
• Brake set by system (soft).
• Crown saver based on position is disabled.
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Message display

5.2 Alarms visualization

Alarms are shown in an alarm banner on top of the right Cyberbase screen. The last
trigged alarm will be shown in this banner.

Typical alarm banner

An alarm list is also available for the operator. This list will show the last received alarm
on the top. Unacknowledged alarms will be red, acknowledged yellow and
unacknowledged alarms which are no longer active will have OK-status. Alarms with
OK-status will disappear from the list as soon as they are acknowledged.
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Typical alarm listing

5.3 Alarms and preferred actions

The attached table gives a short description of the drawworks alarms and how to act on
these. Refer to the product manuals for further description of maintenance and repair.
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5.3.1 Group 1 Diagnostic alarms

Table 5-1
Alarm Description Control system action Operator action
DW - [1] PLC Major Diagnostic Error Combined alarm for serious Alarm Only Troubleshoot PLC system
PLC diagnostic errors including IO's and DP-
network.

5.3.2 Group 2 Communication alarms

Table 5-2
Alarm Description Control system action Operator action
DW - [2] Communication Error DW Drive A Alarm for fault diagnostics Alarm Only.
DW - [2] Communication Error DW Drive B One Drive must be Available to operate
DW - [2] Communication Error DW Drive C Drawworks
DW - [2] Communication Error DW Drive D Loss of Drive will (Could) Limit Speed
DW - [2] Communication Error DW Drive E
DW - [2] Communication Error DW-A-PLC And ABB Communication with the
PLC A ABB Drive PLC has been
lost.
DW - [2] Anti Collision PLC (B103) to Main DW PLC Communication with the Drawworks only operates in slow Operate lockout / Anti
Communication Error Anti Collision system has speed. Collision Release switches
been lost. as required.
DW - [2] OSM Fault Node A202 Alarm for fault diagnostics Check OSM and fiber optic
cables.
DW - [2] OLM Fault DP Node A102-10 Alarm for fault diagnostics Alarm only Check OLM and fiber optic
DW - [2] OLM Fault DP Node A102-11 cables.
DW - [2] OLM Fault DP Node A102-12
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5.3.3 Group 3 Drive / motor alarms

Table 5-3
Alarm Description Control system action Operator action
DW - [3] DW Release Brake Permissive Fault Release brake Alarm only
permissive from drives
timed out.
DW - [3] Drive A Emergency Stop Emergency Stop on Alarm Only
DW - [3] Drive B Emergency Stop drive activated
DW - [3] Drive C Emergency Stop
DW - [3] Drive D Emergency Stop
DW - [3] Drive E Emergency Stop
DW - [3] Drive A is Tripped Drive Tripped Alarm Alarm only. If the drawworks Check drive local display for
DW - [3] Drive B is Tripped cannot hold the load, the brakes further information. Restart
DW - [3] Drive C is Tripped will be set. drawworks to start drive
DW - [3] Drive D is Tripped again.
DW - [3] Drive E is Tripped
DW - [3] Drive A Common Alarm Drive Common Alarm Alarm Only Check Drives
DW - [3] Drive B Common Alarm
DW - [3] Drive C Common Alarm
DW - [3] Drive D Common Alarm
DW - [3] Drive E Common Alarm
DW - [3] Drive A Has Detected Motor Temperature High Motor windings high Alarm Only Check Blowers
DW - [3] Drive B Has Detected Motor Temperature High temperature alarm
DW - [3] Drive C Has Detected Motor Temperature High
DW - [3] Drive D Has Detected Motor Temperature High
DW - [3] Drive E Has Detected Motor Temperature High
DW - [3] Drive A Has Detected Motor Temperature High High Motor windings high- Speed decelerated to zero. Brakes Verify alarm by manually
DW - [3] Drive B Has Detected Motor Temperature High High high temperature set at standstill. Drive is disabled. checking motor temperature.
DW - [3] Drive C Has Detected Motor Temperature High High alarm. Ex-certification Restart Drawworks without
DW - [3] Drive D Has Detected Motor Temperature High High will be exceeded. actual motor.
DW - [3] Drive E Has Detected Motor Temperature High High
DW - [3] ABB has detected Drive Pinion Slip Fault ABB Drive system has Alarm Only
detected pinion slip.
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5.3.4 Group 4 Auxiliary equipment alarms

Table 5-4
Alarm Description Control system action Operator action
DW - [4] Brake HPU A Not Available Alarm Only Check MCC status
DW - [4] Brake HPU B Not Available
DW - [4] Brake HPU A Start Error Alarm Only Check MCC status
DW - [4] Brake HPU B Start Error
DW - [4] Brake HPU A Tripped Alarm Only Check pump for overload.
DW - [4] Brake HPU B Tripped
DW - [4] Brake HPU Excessive Running Brake HPU running for Alarm Only Compare transmitter
extended time (more than pressure (on screen) with
3min) pressure on local gauges.
Shut down brake HPU to
avoid overheating.
DW - [4] Brake HPU Filter Clogged Brake HPU filter is clogged Alarm Only Change filter element. Take
oil sample to verify
cleanliness of hydraulic oil.
DW - [4] Brake HPU Tank Level Low Low oil level in HPU tank Alarm Only Check level by reservoir dip
stick
DW - [4] Brake HPU Tank Temperature High High temperature in HPU Alarm Only Check the relief valve and
tank also if there is any leakages
in the system.
DW - [4] Brake Supply Pressure High High brake supply pressure Alarm Only Check the MCC. Verify the
transmitter pressure against
local gauge. Check the relief
valve.
DW - [4] Brake Supply Pressure Low Low brake supply pressure Slow speed up/down by system. Brake Verify alarm against local
release prevented. gauge. Check pressure
transmitter, relief valve and
MCC for HPU motors.
DW - [4] Brake Supply Pressure Low Low Too low brake supply Deactivates auto driller. Verify alarm against local
pressure gauge. Check pressure
transmitter, relief valve and
MCC for HPU motors.
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Alarm Description Control system action Operator action

DW - [4] Cooling Blower 1A Not Available Alarm only Check MCC status
DW - [4] Cooling Blower 1B Not Available
DW - [4] Cooling Blower 2A Not Available
DW - [4] Cooling Blower 2B Not Available
DW - [4] Cooling Blower 1A Start Error
DW - [4] Cooling Blower 1B Start Error
DW - [4] Cooling Blower 2A Start Error
DW - [4] Cooling Blower 2B Start Error
DW - [4] Cooling Blower 1A Tripped Alarm Only Check pump for overload.
DW - [4] Cooling Blower 1B Tripped
DW - [4] Cooling Blower 2A Tripped
DW - [4] Cooling Blower 2B Tripped
DW - [4] DW Motor A Cooling Pressure Low Alarm Only Check motor cooling system
DW - [4] DW Motor B Cooling Pressure Low (dampers closed?).
DW - [4] DW Motor C Cooling Pressure Low Motor cooling low pressure.
DW - [4] DW Motor D Cooling Pressure Low
DW - [4] DW Motor E Cooling Pressure Low
DW - [4] DW Motor A Cooling Pressure Low Switch Alarm Only
Faulty
DW - [4] DW Motor B Cooling Pressure Low Switch
Faulty
Pressure switch indicates
DW - [4] DW Motor C Cooling Pressure Low Switch
high pressure when blower
Faulty
is not running.
DW - [4] DW Motor D Cooling Pressure Low Switch
Faulty
DW - [4] DW Motor E Cooling Pressure Low Switch
Faulty
DW - [4] Lube Oil Pump A Not Available Alarm Only Check MCC status
DW - [4] Lube Oil Pump B Not Available
DW - [4] Lube Oil Pump A Start Error
DW - [4] Lube Oil Pump B Start Error
DW - [4] Lube Oil Pump A Tripped Alarm Only Check pump for overload
DW - [4] Lube Oil Pump B Tripped
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Alarm Description Control system action Operator action

DW - [4] Lube Oil A Pressure Low Lube oil pressure low Brake release prevented. Verify alarm against local
gauge. Check system for
Slow speed up/down if low pressure on leaks (internal or external).
one pressure transmitter and ‘Run Full Check lube oil
Speed With One Lube Oil Pump’ not pumps/motors.
selected.
DW - [4] Lube Oil B Pressure Low
Slow speed up/down if low pressure on
both pressure transmitters and ‘Run Full
Speed With One Lube Oil Pump’
selected.

DW - [4] Lube Oil A Pressure Low Low Lube oil pressure low low Alarm only Verify alarm against local
gauge. Check system for
leaks (internal or external).
DW - [4] Lube Oil B Pressure Low Low
Check lube oil
pumps/motors.
DW - [4] Lube Oil A Pressure High Lube oil pressure high Alarm only Verify alarm against local
gauge. Check system for
DW - [4] Lube Oil B Pressure High
blocked nozzles.
DW - [4] Lube Oil Tank Level Low Lube oil tank level low Alarm Only Check lube oil level by
reservoir dip stick and refill if
necessary.
DW - [4] Lube Oil Temperature High Lube oil temperature high Alarm Only Check heat exchanger
function.
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5.3.5 Group 5 MRU Alarms (Not Applicable)

Table 5-5
Alarm Description Control system action Operator action

5.3.6 Group 6 Brake system alarms

Table 5-6
Alarm Description Control system action Operator action
DW - [6] Brake Caliper 1&2 On Fault Caliper set On-faults All brakes applied. Check caliper transmitters,
DW - [6] Brake Caliper 3&4 On Fault calipers, caliper valves and
DW - [6] Brake Caliper 5&6 On Fault solenoid valves for faults.
DW - [6] Brake Caliper 7&8 On Fault

DW - [6] Brake Caliper 1&2 Off Fault Caliper set Off-faults Slow speed if brake off fault on one Secure load. Release brake
DW - [6] Brake Caliper 3&4 Off Fault caliper set. pressure manually.
DW - [6] Brake Caliper 5&6 Off Fault Zero speed and brake on at standstill if Check caliper transmitters,
DW - [6] Brake Caliper 7&8 Off Fault brake off fault on two or more caliper calipers, caliper valves and
sets. solenoid valves for faults
DW - [6] Brake Slip 1 Activated Drum moving while brakes All calipers will be applied. Check discs for
set (slipping). Level 1 - all contamination; check brake
calipers will be applied pads, brake test, brake
DW - [6] Brake Slip 2 Activated (Automatic Motor Drum moving while brakes Automatic motor start initiated. burning.
Start) set (slipping). Level 2 -
automatic motor start
DW - [6] Brake Test Results Less Than 75% - Brake test result less than Alarm only. Check discs for
Continued Operation Not Recommended 75% of designed brake contamination, check
capacity. brakepads, braketest, brake
burning.

Continued operation not

recommended.
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5.3.7 Group 7 External signal fault alarms

Table 5-7
Alarm Description Control system action Operator action
DW - [7] Brake Calipers1&2 Pressure Transmitter Analog Input Signal Failure Zero speed and brake on at standstill if Troubleshoot wiring or
Fault (Over range, Under range or transmitter fault on two or more caliper sensor failure.
DW - [7] Brake Calipers 3&4 Pressure Transmitter Wire break) sets (Brake off fault).
Fault
DW - [7] Brake Calipers 5&6 Pressure Transmitter
Fault
DW - [7] Brake Calipers 7&8 Pressure Transmitter
Fault
DW - [7] Brake Caliper Set 1 Pressure Deviation Pressure on one caliper set Alarm only Verify pressure signal with
DW - [7] Brake Caliper Set 2 Pressure Deviation deviate more than a local gauge. Replace or re-
DW - [7] Brake Caliper Set 3 Pressure Deviation predefined limit from the calibrate faulty pressure
DW - [7] Brake Caliper Set 4 Pressure Deviation average value. transmitter.

DW - [7] Brake Supply Pressure Transmitter Fault Analog input signal failure Slow speed up/down by system. Troubleshoot wiring or
(Over range, Under range or Brake release prevented. sensor failure.
DW - [7] Brake HPU Oil Tank Temp. Transmitter Wire break) Alarm only
Fault
DW - [7] Lube Oil Pump A Pressure Transmitter Analog Input Signal Failure Brake release prevented. Troubleshoot wiring or
Fault (Over range, Under range or sensor failure.
Wire break Slow speed up/down if transmitter fault
on one pressure transmitter and ‘Run
Full Speed With One Lube Oil Pump’
not selected.
DW - [7] Lube Oil Pump B Pressure Transmitter
Fault Slow speed up/down if transmitter fault
on both pressure transmitters and ‘Run
Full Speed With One Lube Oil Pump’
selected.

DW - [7] Lube Oil Tank Temp. Transmitter Fault Analog input signal failure Alarm only Troubleshoot wiring or
(overrange, underrange or sensor failure.
wirebrake)

DW - [7] Encoder A Fault Encoder fault detected. Alarm only. Encoder taken out of Check encoder and encoder
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Alarm Description Control system action Operator action

DW - [7] Encoder B Fault average-calculation (by ramp). wiring.
DW - [7] Encoder C Fault
DW - [7] Encoder D Fault
DW - [7] Encoder E Fault
DW - [7] Encoder A Deviation Alarm Value from one encoder
DW - [7] Encoder B Deviation Alarm deviate more than a
DW - [7] Encoder C Deviation Alarm predefined limit from the
DW - [7] Encoder D Deviation Alarm average value.
DW - [7] Encoder E Deviation Alarm
DW - [7] Encoder Voting Not Possible Voting not possible (less than Alarm only. Check encoders. Select
three encoders used) different / all encoders.
DW - [7] Encoder Voting Fault Voting fault
DW - [7] Encoder Measurement Fault All selected encoders are Sets height not calibrated. Check encoders.
faulty. No healthy encoder Slow speed up/down by system. Select different / all
measurement. encoders.
Perform block position
calibration.
DW - [7] Hookload Deadline Transmitter Fault Analog input signal failure Alarm only. Troubleshoot wiring or
(overrange, underrange or sensor failure.
wirebrake)

DW - [7] Hookload Top Drive Cell A Transmitter Analog input signal failure Alarm only. Troubleshoot wiring or
Fault (overrange, underrange or sensor failure.
DW - [7] Hookload Top Drive Cell B Transmitter wirebrake)
Fault
DW - [7] Hookload From Traveling Block Hookload from traveling When block moving: Hookload value Select the deadline anchor
Measurement Fault block fault. locked to the value at last standstill. hookload measurement.
When at Standstill: Hookload set to
max.
DW - [7] Selected Hookload Measurement Not Selected hookload High hookload used in floor saver
Healthy measurement not healthy calculations. Low deceleration angle
used against upper stop.
DW - [7] Load Cell A Fault Load cell fault detected. Alarm only. Hookload value taken out of Check load cell. Select
DW - [7] Load Cell B Fault average-calculation. different / all load cells.
DW - [7] Load Cell Deviation Fault The value from the two load Alarm only. Determine which load cell is
cells deviate. faulty. Select different load
cell.
DW - [7] Position Check Prox. External Fault Fault detected on proximity Alarm only. Check proximity switch for
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Alarm Description Control system action Operator action

DW - [7] Upper Stop Prox. External Fault switch. faults.
DW - [7] Upper Warning Prox. External Fault

5.3.8 Group 8 Miscellaneous alarms

Table 5-8
Alarm Description Control system action Operator action
DW - [8] Emergency Stop Manual Emergency stop Brakes on immediately. Reset the emergency stop
activated. when it is safe to do so.
DW - [8] Block Upper Stop / Crown Saver Block has passed stop Brakes on immediately. Manual hoisting in slow
prox.switch. . (or the preset speed allowed if crown saver
stop height) override is activated.
DW - [8] Soft Floor Saver Active The floor saver is activated Speed reference is set to zero. Reset floor saver.
based on block position Drawworks will decelerate at a
against obstacles predefined deceleration ramp. Further
downward movement in slow speed is
allowed.
DW - [8] Hard Floor Saver Active The floor saver is activated Brakes on immediately. Reset floor saver and
because soft floor saver did release the brakes again.
not stop the load
DW - [8] Too Few Dead Wraps Left On The Drum. Too few dead wraps left on Zero speed activated. Auto driller Set joystick in middle
Lowering Stopped - Cont. In Slow drum detected by control deactivated. position. Continued lowering
system. available in slow speed
mode.

DW - [8] Upper Stop Prox. Position Error Deviation between Sets height not calibrated. Slow speed Troubleshoot proximity
DW - [8] Upper Warning Prox. Position Error calculated Block Position up/down by system. switch and/or block position
DW - [8] Position Check Prox. Position Error and prox activation. calc. Perform block position
calibration.
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Alarm Description Control system action Operator action

DW - [8] Height Not Calibrated Height not calibrated set by Slow Speed Only Troubleshoot height
control system based on measurement or derrick
following conditions: proximity switches. Perform
-Prox. position error block position calibration.
-Encoder measurement
fault
-Number of wire lines
changed
-Activation of brake burning
-Activation of slip and cut.
DW - [8] Creep Alarm Drum rotation detected Brakes applied. Troubleshoot drive-system.
while zero-speed command
is sent to ac-drives. The drawworks was not able
to keep the block at standstill
while no operator speed
command.
DW - [8] Drum Velocity/Acceleration Fault Block speed reference and Brakes on immediately. Troubleshoot drive-system.
block position is compared
and a deviation in
speed/acceleration outside
allowable limits is detected.
DW - [8] Max WOB Exceeded Max WOB limit (set by Auto driller and auto reaming is WOB exceeded more than
operator) has been deactivated if active. 5% over the set maximum
exceeded with auto driller limit. Increase the limit or set
or auto reaming function the maximum ROP lower.
active.
DW - [8] Overpull Limit Exceeded Overpull Limit Exceeded Zero hoisting speed. Lower the load or increase
(Always ON, except in BOP the available overpull limit.
Mode)
DW - [8] Start Up Torque Not Reached Start up torque not reached Brake off sequence aborted. Electrician to check drive
during load transfer performance.
sequence.
DW - [8] Power Regeneration Alarm Operator speed is limited Alarm Only Increase available
by available power regeneration power (from
regeneration power system).
DW - [8] Power Consumption Alarm Operator speed is limited Alarm Only Increase available hoisting
by available power power (from power system).
consumption
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Alarm Description Control system action Operator action

DW - [8] Cmc position Auto error (position error or Alarm only.
max Wob exceeded)
DW - [8] Comm error, DP node A102-10 Alarm only Check topology screen
DW - [8] Comm error, DP node A102-11
DW - [8] Comm error, DP node A102-12

VFD - Aft. Diode Supply Units has detected non Alarm Only
tripping fault
VFD - Aft. Diode Supply Units tripped on critical fault Alarm Only
VFD - Braking Chopper 1 tripped
VFD - Braking Chopper 2 tripped
Alarm Only
VFD - Braking Chopper 3 tripped
VFD - Braking Chopper 4 tripped
VFD - Braking resistors element 1 temp. high
VFD - Braking resistors element 2 temp. high
Alarm Only
VFD - Braking resistors element 3 temp. high
VFD - Braking resistors element 4 temp. high
VFD - Braking resistors element 1 temp. high high
VFD - Braking resistors element 2 temp. high high
Alarm Only
VFD - Braking resistors element 3 temp. high high
VFD - Braking resistors element 4 temp. high high
VFD - Aft. BRU tank cooling water temp. high high Alarm Only
VFD - Aft. BRU tank cooling water level low low Alarm Only
VFD - Liquid Cooling Unit 51 has detected non
tripping fault
Alarm Only
VFD - Liquid Cooling Unit 53 has detected non
tripping fault
VFD - Liquid Cooling Unit 51 has tripped on critical The drawworks control system will shut
fault down the motors related to cooling unit
51
VFD - Liquid Cooling Unit 53 has tripped on critical The drawworks control system will shut
fault down the motors related to cooling unit
53
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5.4 Alarm limits and important operational limits

Table 5-9
Alarm limit Description Limit Unit Limit Unit
DW Lube Oil A/B Pressure low-low alarm 3,0 Barg 45 Psi
DW Lube Oil A/B Pressure low alarm 3,45 Barg 50 Psi
DW Lube Oil A/B Pressure high alarm 15,0 Barg 220 Psi
DW Lube Oil A/B Pressure high-high alarm 18,0 Barg 261 Psi

DW Lube Oil Temp. high alarm 80 °C 176 °F

DW Brake Supply Pressure low-low alarm 165 Barg 2400 Psi

DW Brake Supply Pressure low alarm 179 Barg 2600 Psi
DW Brake Supply Pressure high alarm 220 Barg 3200 Psi
DW Brake Supply Pressure high-high alarm 225 Barg 3250 Psi

DW Brake HPU Oil Temp. high alarm 70 °C 158 °F

Table 5-10
Operational limit Description Limit Unit Limit Unit
DW Brake Supply Pressure low, start pump 1 196,5 Barg 2850 Psi
DW Brake Supply Pressure low, start pump 2 186,2 Barg 2700 Psi
DW Brake Supply Pressure high, stop pump 1 and 2 207 Barg 3000 Psi
DW Brake Supply Pressure OK 193 Barg 2800 Psi
(allowed to release calipers)
Brakes OFF indication pressure (speed allowed) 104 Barg 1500 Psi
Brakes ON indication pressure 4 Barg 60 Psi
Brakes start to engage (approximately) 45 Barg 650 Psi
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6 HAZARDS AND PROTECTIVE MEASURES

Note that the drawworks is a rotating machinery with a high pinch point risk. Keep
people away from the machinery while in operation and not locked out.

Only qualified people should make changes to the mechanical structure and control
system to avoid any unwanted situations.

6.1 Start after long term shutdown or major maintenance

If the drawworks control cabinets has been out of active service for a period of time or
major maintenance has been done on the drawworks electrical system, the following
start up procedure shall be used:

• Megger test power cables

• Energize fuse board in the drawworks control cabinet, from highest level and
downwards, ensure that corresponding equipment is energized.
• Function test emergency stop circuits for the drawworks.
• Complete block position calibration procedure according to chapter 3.1.1.

7 OPERATOR SKILLS AND TRAINING

The operator should be experienced and well acquainted with the type of work and
operating sequences that the equipment is performing. The operator must pay special
attention to general safety aspects and be well aware of the limitations and capabilities
of the equipment.

As a minimum requirement, the operator must carefully study the documentation listed
in the reference section, chapter 1.3. Together, these documents give an overall
understanding of functions, possibilities, limitations and safety hazards related to
operation of the equipment. Further information can be obtained from National Oilwell
Varco and special training sessions can be offered upon request.