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Septenrber 15,201A To l{hclm It lvlay Concem: From: Brarrdy N. Iones, Marrufacturing Errgineerhrg.

6650 Bingle Road '1 1092 Houston, Texas

and solenoid part Pleasereview frndings in the attached document regarding FPF-# 22631.4 rtunrber 2232cn-$. Executive Surnmarv: FPP.# 226314 Description Of Failure: .DURING PILOT LINE TESTING OF THEPODS, WE HADA STRONG PULSATION OFTHEPILOT L]NE TI-IE SOLENOID PRESSURE ON NINEFUNCTIONS. WE REPL.ACED ASSOC]ATED VALVES ANDTHE TESTING OFTIIEFAULTY RJLSATION WENTAWAY. UPON FURTHER BENCH SOLENOID VALVES A PULSING SOUND COULD FROM INSIDE THEVALVE. THERE 9 VALVES IN TOTAL DISTINCT BEHEARD 8 YELLOW BLUE MUX OFFTHE MUX SECTION. ANDONE OFFTHE SECTION" Actions Taken: 1. 2, 3. Blue andYellow Pod'sarrivedto BingleFacility. were unplugged All solenoids from thelr pie connectors. Id€ntlfi€d 23 sol€nold valvesfroma comparlson of original setoutsto th€ currentMUX. In an effortto determinewhichsolenoids wer€ pulsating on the rig we performed th€ following tests usingtest procedure X-065393-05: A. Electrical: Resistance Test B, Electrical: InsulationTest c. Electrical: voltege, & Dropout voltage) Function Test: (Pull-in D, Hydraulic Function Testwith singl€Activatedcoil,with Both Activated coils After performing tests A- D, the coilterminationpoints were inspected, Additional verification tests performed. Presented results to customer, Engineering recommendations to Rig.

4, 5. 6. 7.

Summary Tcst/Insocction Rcsults; tSee :tppendix for e sunmary chert of test/inspectionresrlts.* A. Electrical: Resistance Test B. Electrical: InsulationTest : 1 Failure C. Electrical: Function Voltage, Testi (Pull-in & DropOutVoltage):1 Failure D. Hydraulic Function Testwith Single ActivatedCoil,Both ActivatedCoils:11 Passed, 12 Failed Coil Termination Prints Inspcction: . 7 of the nineteen polarity, on coil B pins 3 and 4. solenoidshadwires crossed,reversed Specifically, the white rvire was solderedto 4 and the blmk wire soldettd to 3. . 6 ofthe sevensolenoidswith revers€d polarity failed the leak test. ' F.A"T. results show (no pressurcsignalt'whcn both coilr werc energizcd,however per{ormed ptpedy with a singleactivatcd coil ' Ottly lofthe nvo solenoids that failed the electrical testhad reversed polarity.

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WorldwideCourt
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Additional Notes: ' 4 of lhe twenty-three identlfl€dsolenoids were plugged Intothe ortginal# 11 pieconnector, which were id€ntifi€d usingsol€noid location and the pi€ chart.Thesee-connectors were snipped off and sent to Seacon for analysis, A leaktest was performed on thes€ prior, but not a coil termlnation inspection. Pieconnector # 11 was alsosentto seacon. Seacon is going to perform an analysis for reason of failure possibly due to the overuse of greaseon the wrongarea. Results from Seaconare pending. 'The remaining (19) solenoids pointsinsoected. weretested and their coiltermination . Furthertear down of the falledvalves polaritywas not requested. withoutthe reverse In an effort to prove the effect of a solenoid with rcverse potarit-v tretwercnthe two coils on its lunction the following &{tions were tflken: l. 2. 3. 4. Pulleda newsolenoidfromstock. Reversedthe polarity on coil B switching wires 3 iurd 4. Spccificrlly, the wtrite wirc was solderedto pin 4 and the black wire solderedto pin 3. Performed hydraillic fiuction test with Single Activaled coil. Both Coil A arrdCoil B firnctioned properly. Pefornted hydtaulic ftrnction testwith both coils activatedResult: Pressure droppedto 0 psig after 2 seconds ofholding pressure. Solenoidrvasin a "locked" position rvith 0 psig.

The above test proves revene polarity betweencoil A:urd coil B resultsintwo different magnetichelds rvlilchcancel eachother oul. In order to simulate field conditions anrl the alfects ol'a solenoidrvith reverse polaritl, we hoohed the $olenoidup to a Mark II Sf,M with the following results: Rewlts: Coil A Activated: Good Coil B Activated: Good Coil A and B Activated: The pulsaling sound rcported in the field vas heartl. Putl in and <lrop out voltrgc switching quicldp Conclusion: It is evident ttrat reversepolarity between Coil A and Coil B in a 223291)43solenoid valve will not allow tt to properly fimction withboth coils energized.Reversing the polarity crea-tes opposilg rnagneticfields rvith acancehng affect. It is vital to check function with both coils activated. This step is in the solenoid test focedure X-065393{5, ard was in the proceduredLring the assemblyand testing time of the solercids on the DrillMax 2 SparePods. In additio4 the power saving soffware installed on the SEM plays a vibl role iu producing the pulsation in a solenoidwith reverse polarity. It is possible this did not shorv up on out valve test stand at fir$ passbecausethosesolenoids are fad a consant 24V. Corrrctive Action: Solenoid valves,223290{3, ;ue sold individually as sparesand also as part of an upper level. Therefore, the most appropriate con€ctive action is to identi$ my solenoid fallures or reversed polarity vrfule the \alve is still in productiotl prior to shipping or POD F.A.T. After reviewing the assernblyand test procedure, X-065393-05for Cameronsolenoid ralves au ESR, engineering service request, rvill be sent to engineering requesting the changesbelow. l. Section 6.2: FunctionTest tvith Both Activated Coils, ard Sectim 6.3 Function Testwith One Activated Coit do not luve an amcl)ed appendix clu"rt t0 record rcsults otl A requestwill be nude to add in appendix for the testersto record and review their renrlts. Section 6.2; FunctionTest lvith BothActivated Coils shouldhaveinstructionsto watch for a drop in pressure to 0 PSI. If this happens,it is likety that the solenoidhas re"ersed polarity so the coil tcrmination poinb stronld bc chcckcd.

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of coil of tlr€ imDor&mce moreaware the valveroonrtochnicians requested will make Thechrnges
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tnterim Instmction$ to the Rig: Theseinstructions weresentto the rig for an interim testing sorution. September 10,2010 SubjeclFieldSolenoid ValveTest Refereuce: pie connector Cameron doc:SK-122178-62 chart This procedure is to verifv correctoperations of solenoid coilsfor eachfunction. Botlt coils uA",and"8" for eachfinction mustbe operated together to determine oorst operation. Steps: 1. 2. 3. I. 5. 6. Rcmovc powcrfrompods pong anddiscomect Openup bleeder hos€s from directpild funclions. Tum power backon to ALL SEMS (BlueA, BlueB, yellw A & yellow B) Perfonn firnction tests for bothpods usingsK- 122 I 7962pi€ connector chart. Allow function to stayir theenergized state for a mitirnumof30 seconds. Venteach function erfter the30second holdbefore going to nextfirnction. NOTE: Whilefiring eachPodfunction observe thata stead5r streamof hydraulic ffuid flows from port.Thereshould eachbleeder beNO oscillations or pulsirqof solenoids, Closebteeder ports,andreconnect directpilot hoses aftereachfirnctionhasbeen terifi.ed. 1. Switchto oppmitePOD, andperform the abovesteps, Jasorr VanLue Manager Field Service Camcron Dri.llingSystcms

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Appendix

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A. Summtry Chnrt of TestResults
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B.

Ilydrirulic F.A.T Results * iad valves denoted rvith a letter '6Sttinclicates a valve with n switched polarity.

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