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Document Title Rev

CONTROL SYSTEM SPECIFICATIONS MANUAL


Client Project

Ensign Energy EPC


Product

J1644
Model

Drawworks
Drawworks Serial Numbers
Document Number

DM1-1500A-3A Gearbox Serial Numbers Transmission Serial Numbers


Number of Pages

CSS-J1644-01

13

The information contained in this document is the intellectual property of Pacific Rim Engineered Products (1987) Ltd. and is commercially confidential. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose without the express written permission of Pacific Rim Engineered Products.

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TABLE OF CONTENTS
1 INTRODUCTION ..............................................................................................................................................1 1.1 1.2 1.3 1.4 1.5 1.6 2 CONTACT INFORMATION .............................................................................................................................2 REFERENCES ...............................................................................................................................................3 MANUAL PURPOSE ......................................................................................................................................3 GENERAL SAFETY .......................................................................................................................................3 WELDING PRECAUTIONS.............................................................................................................................4 DISCLAIMER .................................................................................................................................................4

EQUIPMENT SPECIFICATIONS...................................................................................................................5

LIST OF TABLES
Table 2-1 Table 2-2 Table 2-3 Table 2-4 Equipment Specifications..................................................................................................................5 Brake Circuit .......................................................................................................................................8 Lubrication/Shift Circuit .....................................................................................................................9 IO List with Ranges ..........................................................................................................................12

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INTRODUCTION
This document lists all functional, operational and control system specifications for the DM11500A-3A drawworks. This document supersedes all information contained within any previous control system specifications manuals issued for this product line. The values in this document are valid for drawworks configured as per the following documents: 1. Lubrication/shift Schematic: 2. Svendborg Hydraulic Power Unit Schematic: 3. Wiring Diagram: 8S-J1644-0Q2 1106-0006-603 8D-J1644-E30

The above documents are located in the PREP operation and maintenance manual.

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1.1 CONTACT INFORMATION


Parts and Service Inquiries: Email: PartsandService@prepglobal.com Technical and Field Service Inquiries: Email: TechnicalService@prepglobal.com General Inquiries: Main Telephone: +1-604-882-8755 Toll Free: +1-888-990-8900 (North America Only) Fax: +1-604-882-8757 Address: 9445 - 195th Street Surrey, British Columbia Canada V4N 4G3 Website: www.prepglobal.com

Hours of Operation: Monday to Friday: 08:00 to 16:30 (PST) Saturday and Sunday: Closed

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1.2 REFERENCES
Please refer to the following manuals for additional information:
Document Title Installation Manual Operation and Maintenance Manual Document Number
0000-0006 0000-0005

1.3 MANUAL PURPOSE


This manual provides information and specifications required for the safe operation and control of the drawworks. Refer to the operation and maintenance, and installation manuals for more information.

1.4 GENERAL SAFETY


Follow these additional safety principles when operating the drawworks:

Any personnel that install, operate, or service this equipment must have appropriate training and required certification. Comply with all approved safety procedures when installing, operating, or servicing this equipment. To prevent contact with moving parts, make sure that all guards are in place before operating this equipment. During operation, ensure that all personnel are a safe distance away from this equipment. Wear appropriate safety gear when installing, operating, or servicing this equipment. Before doing any work on this equipment, make sure that all parts of the equipment have come to a complete stop. Lock out and tag out all sources of electrical power, pneumatic pressure, hydraulic pressure, and any other energy sources that could cause any portion of the equipment to move. To prevent contact with moving parts, make sure that all guards are in place before operating this equipment. During operation ensure that all personnel are a safe distance away from the equipment.

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1.5 WELDING PRECAUTIONS


Follow these additional precautions when welding on or near the drawworks:

Contact PREP before performing any welding on the drawworks. Welding may void the warranty. Follow approved welding procedure and safety practices when carrying out any welding on the machinery. Ensure the ground cable is clamped directly to the component to be welded and as close to the weld as possible. Improper grounding can damage components that are averse to electrical currents such as bearings, valves, and electrical components. If possible, remove any current-averse components before welding.

1.6 DISCLAIMER
Pacific Rim Engineered Products, herein referred to as PREP, reserves the right to revise this document without prior notification. This document has been reviewed for errors and accuracy. Despite this, technical and typographical deviations can sometimes occur. This document is updated on a regular basis; changes will be published in future printings. Improvements and/or changes to the described products or manual can be implemented at any time without notice. In no event shall PREP be liable for any special, incidental, consequential or punitive damages. This includes, but is not limited to: damage to other property or person, inconvenience, loss of goodwill, lost profits or revenue, loss of use of this product or any associated equipment, cost of substitutive equipment, downtime costs or claims of any party such damages, resulting from any misspellings or inaccurate information in this guide. This document or parts hereof may in no event be copied, reproduced, changed or translated to other languages without explicit written permission from PREP.

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EQUIPMENT SPECIFICATIONS
The following tables include specification information for the drawworks (model DM1-1500A3A).
WARNING: THE CONTROL SYSTEM MUST ENSURE THE DRAWWORKS IS OPERATED WITHIN THE SAFE LIMIT OF THE SURROUNDING EQUIPMENT (MAST, CABLES, BLOCKS, ETC.) THE PERFORMANCE OF THE DRAWWORKS IS LIMITED BY THE SURROUNDING EQUIPMENT NOT BY ITS CAPABILITIES.

TABLE 2-1 EQUIPMENT SPECIFICATIONS Equipment Specifications General


Rated hook load Rated single line pull Minimum single line pull for proper spooling Rated number of lines Minimum number of lines Maximum number of lines Maximum block speed with 10 lines, layer 5 Total block travel with 10 lines Approximate total weight (dry) Length Width Height Hazardous Area Classification 800,000 lb (3,559 kN) 98,633 lb (439 kN) 10,700 lb (47.6 kN) 10 8 10 368 fpm (1.87 m/s) 133 ft (40.5 m) 55,000 lb (25,000 kg) 227.25 in. (5.77 m) 105 in. (2.67 m) 92 1 8 in. (2.34 m) None

Traction Motor
Number of motors Traction motor model Maximum drawworks duty power per motor Maximum continuous power per motor 1 NOV G77757-130E-F 2000 HP (1490 kW) 1500 HP (1118 kW)

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Maximum motor speed (no load) Maximum working motor speed

3000 rpm 2300 rpm

Transmission
Number of transmissions Number of transmission speeds Transmission reduction ratios 1 3 1:1.000, 1:1.872, 1:3.000

Gear box
Gear box reduction ratio Overall reduction ratios (transmission + gear box) Output rotation viewed from output shaft 1:6.506 1:6.506, 1:12.179, 1:19.517 CW + CCW

Drum
Drum base pitch diameter Drum length between wear plates Drum pitch Number of wraps per layer Maximum number of layers on drum Minimum number of wraps on drum Drum pitch diameter at layer 5 Cable storage capacity on drum Nominal cable diameter Cable grade Fleet angle Nominal fast-line exit angle Maximum drum RPM Drum RPM for 100 fpm pitch line velocity 30 in. (762 mm) 45.25 in. (1,149 mm) 1.414 in. (35.92 mm) 31.5 5 8 39.8 in. (1,011 mm) 1,376 ft (419 m) 1.375 in. (34.93 mm) EEIP WRC 0.25 - 1.25 8.3 (from vertical exit) 350 5.5 RPM

Brakes (supplied for reference, see Svendborg manual)


Number of brake discs Number of brake calipers Brake disc outer diameter 2 6 (3 per disc) 72 in. (1,829 mm)

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Nominal disc thickness Minimum dynamic torque required to hold maximum single line pull. This is a per channel value (3x caliper). (To be checked during brake check mode if minimum torque is not reached the brakes MUST be inspected and adjusted to meet this required braking torque.) Total brake pad air gap permissible (per side) Brake pad minimum thickness (material + backing plate) Nominal brake release hydraulic pressure Maximum allowable brake hydraulic pressure in brake caliper Brake oil type Brake oil capacity per HPU Brake fluid filter element System burnishing pressure Accumulator pre-charge Immersion heater thermostat setting

1.0 in. (25 mm)

132,655 ft-lb (179,856 Nm)

0.039 0.118 in. (1 3 mm) 0.866 inch (22 mm) 2750 psi (190 bar) 3300 psi (230 bar) ISO VG32 VI = 150 or greater see Svendborg manual 27.7 USG (105 L) 10 m 1450 psi (100 bar) 2250 psi (155 bar) 104F (40C)

Lubrication/shift hydraulic circuit


Approximate lubrication/shift oil capacity Lubrication oil type Lubrication oil filter element Immersion heater thermostat setting 70 USG (265 L) SAE50 transmission oil CAT TO-4 or equivalent. 10 m 110F (43C)

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Control settings Brake circuit1 (data supplied for reference, see Svendborg manual)
Location
Brake caliper (B1/B2) Brake HPU (B1/B2) Brake HPU (B1/B2) Brake HPU (B1/B2) Brake fluid supply (5e)

Limit type
Nominal pressure Low pressure alarm Low pressure shutdown Burnishing pressure High temperature alarm Low temperature alarm (With standard fluid. Alternate fluid is required for start-up below this temperature)2 Minimum operational temperature (With standard fluid. Alternate fluid is required for operation below this temperature)3 High differential pressure alarm Nominal pressure to be maintained by PLC control, See footnote 1 on page 8 Low pressure alarm High pressure alarm High pressure shutoff

Setting
2755 psi (190 bar) 2400 psi (165 bar) 2100 psi (145 bar) 1450 psi (100 bar) 149F (65C)

Brake fluid supply (5e)

-4F (-20C)

Brake fluid supply (5e)

14F (-10C) 72.5 psi (5 bar) 2,755 2,900 psi (190 200 bar) 2300 psi (165 bar) 3050 psi (210 bar) 3190 psi (220 bar) 3 in. below the black line at the top of the sight glass (ref. 6.9 mA)

Brake filter (42-40) Brake HPU (40) Brake HPU (40) Brake HPU (40) Brake HPU (42)

Oil supply (5a)

Low level alarm

Note: For brake circuit set points and controls see Svendborg manual. Actuation pressure (monitored with pressure sensor 40). Accumulator pressure is controlled by cycling valve 19. When the pressure falls below 2,755 psi (190 bar) valve 19 is energized to fill the accumulator. When pressure is above 2,900 psi (200 bar), valve 19 is de-energized and the pump flow returns to the tank. 2 For arctic ambient operating conditions (below 32F (0C)) the recommended alternate oil is premium anti-wear mineralbased hydraulic fluid VG32, VI = 300 or greater. For standard operating conditions (32 86F (0 30C) the drawworks is equipped with premium anti-wear mineral-based hydraulic fluid VG32, VI = 150 or greater. 3 See note 2 Commercial Confidential Pacific Rim Engineered Products (1987) Ltd. www.prepglobal.com 9445 195th Street, Surrey, BC, V4N 4G3, Canada | Tel: +1.604.882.8755

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Control settings Brake circuit1 (data supplied for reference, see Svendborg manual)
Location
Oil supply (5a)

Limit type
Low level shut down

Setting
6 in. below the black line at the top of the sight glass (ref. 5.8 mA)

TABLE 2-3 LUBRICATION/SHIFT CIRCUIT

Control settings Lubrication/shift circuit


Location
Lubrication oil supply (TT-01) Lubrication oil supply (TT-01) Lubrication oil level (LT01) Lubrication oil level (LT01) Lubrication oil cooling fan Lubrication oil cooling fan Lubrication oil supply (TT-01) Lubrication oil supply (TT-01)

Limit type
High temperature shutoff High temperature alarm Low level warning (visual measurement) Low level shut down (visual measurement) Fan on Fan off Minimum drawworks temperature (operation below this temperature will require different oils) Normal operational temperature Minimum pump start-up (motor supplied with SAE 50 transmission oil CAT TO-4 operation below this temperature will require different oils)

Setting
212F (100C) 194F (90C) 15.375 in. (391 mm) below split line (ref. 7.6 mA) 16.375 in. (416 mm) below split line (ref. 6.2 mA) 150F (66C) 140F (60C) 32F (0C) 113 185F (45 85C)

Lubrication oil sump (TT-02)

14F (-10C)

Pump discharge (PT-01) Nominal pressure Pump discharge (PT-01) Low pressure shutoff Pump discharge (PT-01) High pressure alarm Pump discharge (PT-01) High pressure shutoff

300 450 psi (20.7 31 bar) 120 psi (8.27 bar) 450 psi (31 bar) 550 psi (38 bar)

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Control settings Lubrication/shift circuit


Location
Lube/shift supply at gearbox (PT-02) Lube/shift supply at gearbox (PT-02) Lube/shift supply at gearbox (PT-02) Lube/shift supply at gearbox (PT-02) Lube/shift supply at gearbox (PT-02) Lubrication oil filter (PT-02 PT-01) Lubrication oil filter (PT-02 PT-01)

Limit type
Nominal pressure Low pressure alarm Low pressure shutoff High pressure alarm High pressure shutoff High differential pressure warning High differential pressure alarm

Setting
250 350 psi (17.2 24 bar) 225 psi (15.5 bar) 200 psi (13.8 bar) 350 psi (24.1 bar) 400 psi (27.6 bar) 45 psi ( 3 bar) @ 104F (40C) 50 psi ( 3.5 bar) @104F (40C)

Pressures below are with lube oil at normal operating temperatures High gear actuation (PT-06) High gear actuation (PT-06) High gear actuation (PT-06) High gear actuation (PT-06) Mid gear actuation (PT-05) Mid gear actuation (PT-05) Mid gear actuation (PT-05) Mid gear actuation (PT-05) Low gear actuation (PT-04) Low gear actuation (PT-04) Nominal pressure Low clutch pressure shut down High pressure alarm High pressure shutoff 280 320 psi (19.3 22.1 bar) 200 psi (13.8 bar) 350 psi (24.1 bar) 400 psi (27.6 bar) 280 320 psi (19.3 22.1 bar) 200 psi (13.8 bar) 350 psi (24.1 bar) 400 psi (27.6 bar) 280 320 psi (19.3 22.1 bar) 200 psi (13.8 bar)

Nominal pressure

Low pressure shut down High pressure alarm High pressure shutoff Nominal pressure Low pressure shut down

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Control settings Lubrication/shift circuit


Location
Low gear actuation (PT-04) Low gear actuation (PT-04) Clutch released (PT-04, -05, -06) Lube supply pressure (PT-07) Lube supply pressure (PT-07) Lube supply pressure (PT-07) Clutch pressure during shift (PT-04, 05, 06)4 Clutch pressure during shift(PT-04, 05, 06)5

Limit type
High pressure alarm

Setting
350 psi (24.1bar)

High pressure shutoff

400 psi (27.6 bar)

Maximum pressure

8 psi (0.55 bar)

Normal operation Low pressure alarm Low pressure shutdown Low warning Low shut down

30 60 psi (2 4.1bar) 25 psi (1.7 bar) 20 psi (1.38 bar) Under 175 psi (12 bar) for longer then 1 sec 150 psi (10.3 bar)

CAUTION: IF THE CLUTCH PRESSURE (PT-04, 05, 06) FALLS BELOW THE LOW PRESSURE SHUTDOWN LIMIT THE EMERGENCY BRAKES MUST BE ACTIVATED.

Note: The clutch pressure inside the clutch cavity (PT-04, -05, -06) as well as the supply pressure (PT-02) will dip for a short period of time following the command to a solenoid valve. If the pressure dips below the low shut down value stated in the table, or remains low for longer than the time specified for low warning, the emergency brakes should be activated. 5 See note 4 Commercial Confidential Pacific Rim Engineered Products (1987) Ltd. www.prepglobal.com 9445 195th Street, Surrey, BC, V4N 4G3, Canada | Tel: +1.604.882.8755

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TABLE 2-4 IO LIST WITH RANGES

IO List with Ranges


Tag-ID
19 20 20.1 20.2 22.1 23.1 23.2 30.1 31.1 40 42 5c 5e B1 B2

Name Description
Pump unloader valve Brake supply valve Brake caliper channel A isolation valve Brake caliper channel B isolation valve Brake burnish selector solenoid valve Brake dump solenoid valve Brake dump solenoid valve Handle position indicator Handle position indicator Accumulator pressure transducer Pump discharge pressure Level indicator Brake hydraulic temperature Brake channel A pressure transducer Brake channel B pressure transducer

Component
Solenoid valve (NO 2-position) Solenoid valve (NO 2-position) Solenoid valve (NO 2-position) Solenoid valve (NO 2-position) Solenoid valve (NO 2-position) Solenoid valve (NO 2-position) Solenoid valve (NO 2-position) Prox switch Prox switch Pressure transducer Pressure transducer Pressure Transducer (LEVEL) Temperature transducer Pressure transducer Pressure transducer

PLC Signal Type


DIGITAL OUTPUT DIGITAL OUTPUT DIGITAL OUTPUT DIGITAL OUTPUT DIGITAL OUTPUT DIGITAL OUTPUT DIGITAL OUTPUT DIGITAL INPUT DIGITAL INPUT 4-20 INPUT 2 wire 4-20 INPUT 2 wire 4-20 INPUT 2 wire 4-20 INPUT 2 wire 4-20 INPUT 2 wire 4-20 INPUT 2 wire

Range
24 VDC 24 VDC 24 VDC 24 VDC 24 VDC 24 VDC 24 VDC 5 to 24 VDC 5 to 24 VDC 0 to 3,626 psi (0 to 250 bar) 0 to 3,626 psi (0 to 250 bar) 0 to 1.45 psi (0 to 0.1 bar) assuming Tellus 32 0 to 47 in. (0 to 1,194 mm) 14 to 302 F (-10 to +150 C) 0 to 3,626 psi (0 to 250 bar) 0 to 3,626 psi (0 to 250 bar)

Schematic Ref: Svendborg 1106-0006-603 (located in the PREP operation and maintenance manual)

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IO List with Ranges


Tag-ID
LT-01 PT-01 PT-02 PT-04 PT-05 PT-06 PT-07 SOV-01 SOV-02 SOV-03 TT-01 TT-02

Name Description
Oil level Pump discharge pressure Shift supply pressure transducer Low gear clutch pressure Mid gear clutch pressure High gear clutch pressure Lube supply pressure Low gear solenoid valve Mid gear solenoid valve High gear solenoid valve Lube supply temperature Lube tank temperature

Component
Position sensor Pressure transducer Pressure transducer Pressure transducer Pressure transducer Pressure transducer Pressure transducer Solenoid valve Solenoid valve Solenoid valve Temperature transducer Temperature transducer

PLC Signal Type


4-20 INPUT 4 wire 4-20 INPUT 2 wire 4-20 INPUT 2 wire 4-20 INPUT 2 wire 4-20 INPUT 2 wire 4-20 INPUT 2 wire 4-20 INPUT 2 wire DIGITAL OUTPUT DIGITAL OUTPUT DIGITAL OUTPUT RTD INPUT 3 wire RTD INPUT 3 wire

Range
0 to 11 in. (0 to 280 mm) 0 to 1000 psi (0 to 69 bar) 0 to 1000 psi (0 to 69 bar) 0 to 1000 psi (0 to 69 bar) 0 to 1000 psi (0 to 69 bar) 0 to 1000 psi (0 to 69 bar) 0 to 160 psi (0 to 11 bar) 24 VDC 24 VDC 24 VDC PT100, class A, IEC 60751, Alpha = 0.00385 PT100, class A, IEC 60751, Alpha = 0.00385

Schematic Ref: PREP 8D-J1644-E30 (located in the PREP operation and maintenance manual)

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