T Complete User Manual Rev.1!1!100

User Manual
Portable Top Drive

HPT-500-2E-AC
RIG/PLANT REFERENCE REFERENCE DESCRIPTION

Atlas T3035 Top Drive HPT-05 500 AC SG TT
ADDITIONAL CODE SDRL CODE TOTAL PGS
8 2 This document contains proprietary and confidential National Oilwell Varco Norway AS
information which belongs to National Oilwell Varco; it is Postboks 401, Lundsiden
REMARKS loaned for limited purposes only and remains the property
of National Oilwell Varco. Reproduction, in whole or in N-4604 Kristiansand
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 38 19 20 00
any event upon completion of the use for which it was Fax +47 38 19 26 04
loaned.
© Copyright National Oilwell Varco - 2011
CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV
T3035-Z-MA-001 1
Document number T3035-Z-MA-001
Revision 1
Page 3
Table of Contents
1. INTRODUCTION
2. MAIN DATA
3. TECHNICAL DESCRIPTION
4. PREPARATION
5. OPERATING INSTRUCTIONS
6. MAINTENANCE
7. SAFETY AND SERVICE BULLETINS
8. SPARE PARTS LIST
9. DATA SHEETS
10. DRAWINGS AND PARTS LISTS

User Manual No.: T3035-Z-MA-001, Rev. 0
Equipment: Portable Top Drive
Page: 1 of 4
CHAPTER 1
INTRODUCTION
Chapter 1: Introduction
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TABLE OF CONTENTS
1 INTRODUCTION ............................................................................................................... 3
1.1 Portable Top Drive .................................................................................................. 3
1.2 Structure and Contents of Manual .......................................................................... 4
1.3 Contacts for Assistance .......................................................................................... 4
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1 INTRODUCTION
1.1 Portable Top Drive
This user manual describes the National Oilwell TM Portable Top Drive for the
rig/user stated at the document front page.
The objective of the top drive is rotating the drillstring, pipehandling, and passing
drilling mud into the drillstring. Reference is also made to volume 2 of this manual,
which describes the belonging Omron VFD unit.
Typical Top Drive in Test Stand

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1.2 Structure and Contents of Manual
The manual is based on Norwegian Standard NS 5820: Supplier's Documentation

of Equipment. It is composed of 10 main chapters that all belong to the same
document. The main chapters are listed after the document front sheet. Each
chapter consists of a front page, table of contents, and then the different sections
making up the chapter. Attachments are separated from the chapters by blue divider
sheets.
1.3 Contacts for Assistance
The below contact information applies for support from National Oilwell Norway AS.
Always refer to the National Oilwell Norway project number (T-number, see the first
part of the manual’s document number) when contacting National Oilwell Norway for
assistance or spare parts.
National Oilwell Norway AS

(Previously Hydralift ASA)
Servicebox 401
N-4604 Kristiansand S
NORWAY
Switchboard phone: +47 381 92000

Service phones: +47 381 92352 and +47 381 92353
Service fax: +47 381 92604
24 hours service phone: +47 381 92482
Spare parts phone: +47 381 92348
Spare parts fax: +47 381 92604
E-mail: customer.support.norway@natoil.com
Inquiries via e-mail will be handled continuously.
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CHAPTER 2
MAIN DATA
Chapter 2: Main Data
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TABLE OF CONTENTS
2 MAIN DATA ...................................................................................................................... 3

2.1 Safety Summary ..................................................................................................... 3
2.2 Main Data................................................................................................................ 3
2.2.1 Alarm and Setpoint Schedule ...................................................................... 4
2.2.2 Unit Conversions ......................................................................................... 5
2.2.3 Abbreviations............................................................................................... 5
2.3 External Connections.............................................................................................. 5
2.4 Restrictions in Use .................................................................................................. 6
2.5 Restrictions in Guarantee ....................................................................................... 6
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2 MAIN DATA
2.1 Safety Summary
The hazards and protective measures (cautions and warnings) applicable to this
equipment are summarised in sections 5.1 (Operating Instructions) and 6.1
(Maintenance).
2.2 Main Data
Equipment: National Oilwell TM Portable Top Drive

Equipment type: HPT-500-2E-AC
Client: Upetrom Group Management SRL

Rig: Atlas
Client main tag no.: None
Supplier’s project no.: T3035

Year of delivery: 2004
Third Party: None
Type of elevator links supplied: 350 tons, 108”
Recommended type of hydr. oil: Texaco Rando HDZ

Required viscosity of hydr. oil: ISO VG 46
Required cleanliness of hydr. oil: NAS 1638, Class 8
Hydr. oil quantity: 60 litres
Hydraulic supply pressure: 250 barg (max)
Gearbox oil type: Texaco Synlube CLP 150

Gearbox oil quantity: 180 litres
Further data: See the Product Data Sheet in chapter 9.
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2.2.1 Alarm and Setpoint Schedule
Description Setpoints Increasing Switch Comments

or Pos. No.
Decreasing
Alarm Setpoints
Temp. high in drilling motor 170 ºC Increasing TE001 + Alarm only (no shutdown).
windings (PTC thermistors) TE002 Restarting inhibited.
Gearbox oil temp. high 90 ºC Increasing TT011 Alarm only
Gearbox oil pressure low 0.5 barg Decreasing PS010 Alarm after 30 sec.
HPU temp. high 65 °C Increasing TT013 Alarm only
HPU level low Low level Decreasing LS012 Alarm only
HPU level low-low High level Decreasing LS012 Shutdown of onboard HPU
Other Setpoints
Grabber on 50 barg Decreasing PS008 Switch on light in control
button + provide PLC with
signals for various safety
interlocks.
Link tilt pressure 10 barg Increasing PS006 Inhibit pipehandler rotation

with links kicked out.
Lube oil filter bypass Δp = 2.5 N/A H23 Allows gear oil to pass
barg clogged filter.
Oil cooler bypass Δp = 2.2 N/A H22 Allows gear oil to pass
barg cooler when high visc.
LS pressure settings in Various Increasing H01 See hydraulic flow

main control valve block diagram.
Anti shock valves in main 230 barg Increasing H01 Prevents damaging &
control valve block bursting of hydr. cylinders.
Counter balance valves in Various Increasing H01 Provide intended functions

main control valve block working.
Main control valve safety 280 barg Increasing H01 Hydr. safety feature
valve
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2.2.2 Unit Conversions
barg = psig x 0.06895

psig = barg x 14.5038
MPa = barg x 0.1
barg = MPa x 10
bara = bar (absolute)

bard = bar (differential)
barg = bar (gravity)
2.2.3 Abbreviations
AC Alternating current
ACS Anti collision system
CPU Central processing unit (part of PLC)
DCR Drilling control room (= driller’s cabin)
2E Two electrical drilling motors
HPU Hydraulic power unit
IBOP Inline blow-out preventer
LCM Life cycle management
LED Light emitting diode
LER Local equipment room
N.C. Normally closed
N.O. Normally open
NS Norwegian Standard
PLC Programmable logic controller
PPM Parts per million
RPM Revolutions per minute
SD Shutdown
SP Setpoint
TP Terminal point (nozzle)
UPS Uninterrupted power supply
VFD Variable frequency drive (AC drive)
2.3 External Connections
The equipment is externally hooked up as follows:
Electrical connections: See the instrument block diagram.
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2.4 Restrictions in Use
Subject equipment must only be used for the prescribed purpose and within the
specified limitations. The operator must be qualified for the task.
Repairs and modifications must not be carried out without prior written approval
from National Oilwell Norway AS, except for the minor corrections that are
described in the maintenance chapter. If such work is carried out by others, National
Oilwell Norway AS procedures for this kind of work must be followed. Lead sealings
must not be broken without written approval from National Oilwell Norway AS. Only
approved materials and original spare parts must be used.
2.5 Restrictions in Guarantee
National Oilwell Norway AS refuse all responsibility caused by breach of the

restrictions described in section 2.4 (above). The guarantee for good performance is
strictly linked to the correct and careful application of the instructions in this user
manual. If, during the warranty period, these restrictions are breached, the
warranty/guarantee shall no longer be valid.
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CHAPTER 3
TECHNICAL DESCRIPTION
Chapter 3: Technical Description
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TABLE OF CONTENTS
3 TECHNICAL DESCRIPTION ............................................................................................ 3

3.1 General ................................................................................................................... 3
3.2 Overview of Main & Sub Assemblies ...................................................................... 4
3.3 Drive System (Motor and Gearbox) with Accessories............................................. 5
3.3.1 Gearbox....................................................................................................... 6
3.3.2 AC Drilling Motors........................................................................................ 7
3.3.3 Air Brakes.................................................................................................... 8
3.3.4 Motor Cooling System ................................................................................. 9
3.3.5 Suspension System ................................................................................... 10
3.3.6 Weight Compensating System .................................................................. 11
3.3.7 Water Course ............................................................................................ 12
3.3.8 Drill Stem Subs .......................................................................................... 13
3.3.9 Hydraulic Power Unit ................................................................................. 15
3.4 Pipehandler System .............................................................................................. 16
3.4.1 Rotating Head ........................................................................................... 17
3.4.2 Link Hanger ............................................................................................... 18
3.4.3 Link Tilt System ......................................................................................... 19
3.4.4 Torque Column .......................................................................................... 20
3.4.5 Back-up Grabber ....................................................................................... 21
3.4.6 IBOP Actuator ........................................................................................... 22
3.5 Control System ..................................................................................................... 23
3.5.1 Control Station, Incl. AC Drive and PLC .................................................... 23
3.5.2 Operator Control Panel.............................................................................. 25
3.5.3 Service Loop and Interconnection Cables ................................................. 26
3.5.4 Hydraulic Control Valve Unit ...................................................................... 27
3.6 Auxiliary Equipment .............................................................................................. 28
3.6.1 Torque Tube System ................................................................................. 28
3.6.2 Handling and Transport Frame .................................................................. 29
3.7 Supplied by Others ............................................................................................... 30
3.8 Sub-vendor Literature ........................................................................................... 31
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3 TECHNICAL DESCRIPTION
3.1 General
The National Oilwell HPT-500-2E-AC Portable Top Drive (hereafter mostly referred
to by the HPT abbreviation) is a dual motor AC top drive – with special advantages/
features for installation on land rigs and masts. The system includes an onboard
style hydraulic power unit, AC drive control unit and PLC (both installed in a control
house), internal cabling between cabinets and top drive (all with plugs & recept-
acles, and torque tube. The only utilities required are electric power and rig air.
The HPT package is optimized in respect of

minimize rig up / rig down time – as well as give
the drilling contractor the most efficient and
reliable tool available.
Key benefits of the HPT are:
• 16.2 ft stack-up height

• 900 HP
• 40000 ft-lbs drill torque
• 80000 ft breakout torque
• HYDRALLOCKTM Locking Device for
IBOPs
• Long-reach dual-link tilt system
• Onboard style HPU
• Grabber can handle ODs from 4” to 9½”
without replacing inserts.
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3.2 Overview of Main & Sub Assemblies
A standard HPT system consists of following main & sub assemblies:
Drive System (Motor and Gearbox with accessories), including:
• Gearbox
• AC Drilling Motors
• Air Brakes
• Motor Cooling System
• Suspension System
• Thread Compensating System
• Water Course
• Drill Stem Subs
• Onboard HPU
Pipehandler, including:
• Rotating Head
• Link Hanger
• Link Tilt System
• Torque Column
• Back-Up Grabber
• IBOP Actuator
Control System, including:
• Control Station incl. AC Drive and PLC

• Operator Control Panel
• Service Loop & Interconnection Cables
• Control Valve Unit
Auxiliary Equipment:
• Torque Tube System

• Handling Cradle
• Special Tools
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3.3 Drive System (Motor and Gearbox) with Accessories
The main part of the drive system is the gearbox and the drive/drilling motors, often
known as “the train”.
Upper Part of Top Drive
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3.3.1 Gearbox
The Gearbox is designed and manufactured with latest technology in helical cut
gearwheels, dual top & bottom lip seal systems. A housing made of high strength
cast steel supports both the thrust bearing as well as all gearwheels with bearings.
The bull gear is heat shrunken to the main shaft thrust shoulder. A set of springs
provides preloading of both main thrust bearing and axial upward thrust bearing -
ensures safe bearing and prevent shock load on the main thrust through top hole
drilling and jarring. The main shaft is radial supported by two separate radial
bearings. This precise guiding combined with dual lip seals provide optimal life time
for the wash pipe.
A screw pump is fixed to one of the high speed shaft NDE’s providing lubrication to
all gear wheels w/ bearings. A motor support frame is to the top of the gearbox. This
frame combines the function as motor support as well as transferring drilling loads
from motors into the gearbox and to the torque carriage.
Gearbox
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3.3.2 AC Drilling Motors
The AC Drilling Motors are fixed to the motor support bracket, and the rotation is
transferred into the gearbox via flexible couplings. A power box located at each
motor is used for termination of the jumper cables between the receptacles (service
loop connection) and the motor leads.
AC Drilling Motor
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3.3.3 Air Brakes
The Air Brakes (parking brakes) are fixed to the non-drive end of the drilling motors.
The brake drums have provision for transferring the drilling motor speed to a
tachometer. The 1024-pulse tachometer provides safe operation as well as precise
speed read out.
Air Brake Unit on Top of Drilling Motor
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3.3.4 Motor Cooling System
The Motor Cooling System is located above the air brakes. The blowers are made
of stainless steel and have curved forward blades in order to minimize noise,
combined with providing air flow and pressure as necessary for cooling the motors.
Each blower has washable inlet filters.
Oil coolers are mounted to both the drilling motor outlets – providing sufficient
cooling of the gearbox lubrication oil as well as the HPU return oil.
Air Cooling Blowers on Top of Drilling Motors
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3.3.5 Suspension System
The Suspension System (bail) is fixed to the gearbox via two bail pins. The upper
contact radius complies with API 8C.
Upper Part of Bail with Weight Compensator Cylinders
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3.3.6 Weight Compensating System
The Weight Compensating System is fixed to the bail via two brackets. Two
separate suspension systems consisting of hydraulic cylinders, shackles, chains
and links are fixed between the bail brackets and the ears on the drilling hook. (In
order to be installed together with several types of hooks – or sometimes directly to
a travelling block - the chains are delivered with a certain over-length allowing to be
cut to length as needed from rig to rig.
Weight Compensating System
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3.3.7 Water Course
The Water Course consists of the wash pipe and S-pipe system. A standard
National Oilwell wash pipe is used for transferring the drilling mud from the
stationary S-pipe to the rotating main shaft. S-pipe lower end terminates in a
hammer lug female sub.
Wash Pipe and Upper End of S-pipe
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3.3.8 Drill Stem Subs
A set of Drill Stem Subs is fixed to the lower end of the main shaft. The set consists
of two identical IBOPs, a saver sub, and a set of HYDRALLOCK locking rings. (The
drill stem sub technical specification is listed on the product data sheet). The
HYDRALLOCK rings consist of 3 sets of locking rings, where each set consists of
two rings with unequal number of locking teeth. As a system these rings provides a
simple, reliable and safe locking method of the drill stem subs through breakout
operations.
A split collar (thrust collar) is located at the lower end of the main shaft. In tripping
operations all loads run from the link hanger via the thrust collar up through the
main shaft – allowing full load rating of the top drive independently of lower sub
connection used.
Hydrallock Locking System Illustration
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Hydrallock Locking System Parts
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3.3.9 Hydraulic Power Unit
The Hydraulic Power Unit (onboard style) is located on the motor support frame –
between the two drilling motors. An 11 HP electric motor is used as drive for the
power regulated hydraulic pump. The benefit of the power regulated power unit is
allowing a small and compact onboard unit to be used, together with reducing the
noise – due to never producing higher pressure then required by the actual
consumer. The rigid tank is made of stainless steel and is equipped with return filter,
breather, level sensor, and temperature transmitter.
Onboard Hydraulic Power Unit
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3.4 Pipehandler System
The top drive is equipped with the most sophisticated pipehandler on the marked.
The link tilt facility has capacity of kicking out the elevator 6 ft (if 108” links are
installed). An ultra high capacity grabber is used for back-up when making up to the
drill string. All ranges from OD 4 ½” to 9” can be torqued-up by utilizing the same
pipehandler kit. The rotating head provides hydraulic flow to consumers while
allowing 360 degrees continuous rotation of the pipehandler. A high capacity locking
cylinder is designed to be engaged both when using the grabber and through drilling
operations
Lower Part of Top Drive
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3.4.1 Rotating Head
The Rotating Head provides hydraulic flow to consumers while allowing 360
degrees continuous rotation of the pipehandler. A locking cylinder fixed to the upper
flange of the rotating head is used for preventing rotation of the piehandler through
breakout operations.
The rotation is provided by a hydraulic cylinder fixed to a gear wheel driving the
slew ring bearing. The lower flange has four set of torque pins combined with four
spring packages. These pins are used for transferring pipehandler rotation loads
down to the elevator, while the springs ensure the link hanger to be clear of the
thrust collar while drilling.
Rotating Head before Installation
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3.4.2 Link Hanger
The Link Hanger is a cast steel body surrounding the main shaft. API designed &
rated ears allow installation of any standard 350 or 500 tons elevator links.
Link Hanger
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3.4.3 Link Tilt System
The Link Tilt System consists of a set of hydraulic cylinders and clamps for fixing to
the elevator links. (Standard clamps fit 350 tons links, while 500 tons clamps are
available as an option). By moving the position of the clamps the operator can
choose maximum forward and/or backward tilt for the elevator. Total fwd/bwd is
limited to approx. 90 degrees.
Link Tilt System

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3.4.4 Torque Column
The Torque Column is fixed to the lugs at the rear side of the link hanger. It acts as
a torque arrestor when breaking out connections using drilling motors and grabber.
Fixing holes for the grabber are located at 4 different locations along the column.
Both link tilt cylinders and IBOP actuator interface points are integrated parts of the
column.
Torque Column Sections
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3.4.5 Back-up Grabber
The Back-up Grabber is normally fixed to the lowest fixing point on the torque
column. The grabber body is floating on the column sleeve and kept in vertical
positions by two gas springs. A set of vertical keys allows both vertical travelling
combined with transferring torque from the column to the grabber body through
make up & break out sequences. The “horse shoes” like die retainers combined with
long reach clamp cylinders ensure “one kit fits all”. (The grabber grips from OD 4.0
in to 9.5 in without replacing die holders or dies.)
The lower end of the grabber has a rubber funnel providing precise stabbing of
grabber over the drill pipe though insertion of new stands. All hydraulic lines on the
grabber are hidden inside the body. The clean design minimizes any risk of
hydraulic leakages as well as getting objects stuck in the unit.
Backup Grabber
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3.4.6 IBOP Actuator
The IBOP Actuator consists of a pneumatic cylinder, a lever arm, and an actuating
sleeve. When the pneumatic cylinder retracts, it moves the lever arm up providing
lifting of the sleeve simultaneously as a key fixed to the remote operated IBOP
rotates 90 degrees and closes the IBOP valve.
IBOP Actuator
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3.5 Control System
The Control System includes all electric and hydraulic valves, actuators, sensors,
JBs, monitoring devices, panels, AC drive as needed to remote operate the top
drive in a safe and reliable manner.
3.5.1 Control Station, Incl. AC Drive and PLC
The Control Station, incl. AC Drive and PLC, is the main component of the contriol
system. All panels etc. are mounted inside a compact air temperature controlled
housing. The motor control unit (“Vector Flux” type VFD) and PLC cabinet are
completely wired up inside the housing, and all interface cabling is done via a plug
panel in one of the end walls. The other end wall has a 5 tons air condition unit and
a breaking resistor.
Control Station
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Cable Outlets from Control Station
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3.5.2 Operator Control Panel
The Operator Control Panel, made of stainless steel, includes all buttons, switches,
gauges, and potentiometers needed for remote control and read out of the top drive
functions. The operator control panel has a stud bolt at each end of the side walls,
allowing installation on a fork type bracket – which allows the panel to be adjusted
to preferable angle.
Operator Control Panel
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3.5.3 Service Loop and Interconnection Cables
The Service Loop and Interconnection Cables include all cabling normally required
between:
• Control Station and Operator Control Panel

• Control Panel and Split Point in Mast (# Both power and signal)
• Service Loops between Top Drive and Split Point in Mast (# Both power and
signal)
All cables & service loops are equipped with plugs or receptacles – all as required
for termination between the top drive components.
Service Loop Terminated on Top Drive

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3.5.4 Hydraulic Control Valve Unit
The Hydraulic Control Valve Unit is located at rear end, under the gearbox housing.
A support bracket includes the hydraulic and pneumatic control valve blocks,
instrument junction boxes, pressure switches, etc, - all as needed for remote
operate the top drive auxiliary remote operated functions and monitoring.
Hydraulic Control Valves at Rear of Gearbox
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3.6 Auxiliary Equipment
3.6.1 Torque Tube System
The torque tube system includes six sections of rectangular profiles, a universal
torque reaction spreader beam kit, and a top suspension beam. The torque tube
system is designed for quick rig-up & rig-down through rig move. The whole system
is designed to be “universal”, which means that the torque tube can be installed in
the major of the masts without need of any mast modification.
A special made “stabbing ramp” (or stab-in cradle) is used to simplify the operation
when putting the torque tube sections together. The cradle is designed to fit the
square opening in the rotary table, and due to the cradle being allowed to swing in
all directions the engagement between the section(s), hanging in the block and the
section parked in the cradle, becomes pretty simple.
Torque Tube
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3.6.2 Handling and Transport Frame
The top drive is supplied inside a Handling and Transport Frame. The frame is used
for lifting/handling the Top Drive while it is loaded/unloaded during rig moves, and
while the top drive is handled in and out of the V-door.
Top Drive in Transport Frame
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3.7 Supplied by Others
Following items are not included as standard, and must be organized and provide
by Client:
• Power incoming cables

• SCR modification (incl. circuit breaker)
• Mud stand pipe extension
• Mud hose length & coupling size/type to be checked
• Derrick cable kit supports (as needed for supporting & guiding of cable
bundles from derrick termination point to VFD-container.
• Air interface hose (in derrick)
• Support bracket for operator control panel
• Foundation/base “beams” for VFD-container
• Elevator links
• Gear oil for HPT gearbox (approx. 180 litres)
• Hydraulic oil for “onboard” HPU (approx. 60 litres)
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3.8 Sub-vendor Literature
The following sub-vendor literature is attached after this sheet:
Attachment: Bondura Bolts 6.6

Electronic file name: Bondura 6.6.doc
Description: Assembly and Maintenance Procedure for Bondura Bolts
6.6 and 6.0 – Offshore.
Total pages: 5
Attachment: Ingersoll-Rand Filter and Lubricator Modules

Electronic file name: HPS air filter and lubricator.pdf
Description: Literature for air filter and air lubricator.
Total pages: 4
Attachment: ITAG Kelly Valve Type TOPGUARD Manual

Electronic file name: ITAG Topguard kelly valves.pdf
Description: Operating and maintenance manual for IBOPs.
Total pages: 24
Attachment: Reliance Electric RPM AC Induction Motors

Electronic file name: Reliance drilling motors.pdf
Description: Installation, operation and maintenance of drilling motors
Total pages: 17
The following literature from the VFD sub-supplier is supplied in volume 2 of this
user manual (separate ring binder):
Attachment: Omron IDM Controls VFD (Top Drive House) Manual

Electronic file name: Multiple pdf files
Description: National Oilwell ref: VFD for HPT T3034.
Omron ref: Hydralift Top Drive House, 600 VAC,
810 Amp, PQ-12878-JG rev. B.
Total pages: 5 chapters i VFD manual
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BOLT NORGE AS Page 1 of 5
ASSEMBLY AND MAINTENANCE PROCEDURE FOR
BONDURA BOLTS 6.6 and 6.0 - OFFSHORE
Read the instructions carefully!
Bolt Norge AS does not guarantee the product if the assembly and maintenance procedures are not followed.
ASSEMBLY PROCEDURE.
1. Preparations.
1.1 Remove any burr. Clean the support.
1.2 Align the bolt hole. The middle section must line up with the support
on each side. See Fig. 1. Use a jack or hoists if necessary.
If the bolt is hammered into a hole where the bearing and the Fig.1
support does not line up, the bolt may be damaged.
2. Fitting the bolt

2.1 Unscrew the locking plates on the Bondura Bolt and remove the taper
sleeves.
2.2 Fit the bolt in the joint so that the bolt's tapered end is even with the Fig. 2a Correct centring of bolt
outside of the support. See Fig. 2a and 2b.
If the bolt is not centre-aligned, the taper sleeve may bottom out in
the support before the expansion is completed. The bolt will then
be partially loose, and may "cut" the taper screws and lock screws.
For 20-65 mm dia. Bondura:
NOTE! Remember that the locking tab on the bolt must fit
into the slot on the locking plate. See Fig. 3a.
Fig. 2b
3. Fitting taper sleeves Incorrect centring of the bolt results in poor
"wedging force"
3.1 Fit the taper sleeves and fasten the end plates with the plate screws.
When tightening the screws, alternate between the different sides to
ensure that the bolt does not shift. Tighten up with specified torque
(see table). Run the equipment for about one hour and retighten to the Locking tab
correct torque. Retightening after installation is necessary. See
"Maintenance».
In Table 1 you will find the required distance "x" from the taper flange
to the support before the expansion. It also specifies when the taper
sleeve must be replaced with an over-sized taper. In order to prevent
moisture from entering from the outside, you may use O-rings or
sealing compound on the taper sleeve, between the bolt and support.
Fig. 3a Locking of 20-65 mm dia bolt
4. Locking of Bondura Bolt
X O-ring/”marine seals”
The Bondura Bolt does not rotate or slide out because the taper
Locking plate
sleeves expand and result in a "wedging force" between the bolt
and support.
4.1 Use a spacer sleeve between the locking plate and the equipment to
ensure that the locking plate is not bent when tightening the lock
screw.See Fig. 3a and 3b.
4.2 The screws may be secured with "locktite".
Equipment classified as "suspended load" must always be secured T1
with a wire or cotter pin through the hole in the screw heads. Spacer sleeve
4.3 As an extra precaution, the locking plate must be fastened with a lock
Fig. 3b Locking of 70-320 mm dia bolt
screw to the equipment.
C:\Documents and Settings\PettersenK.NOV\Desktop\kladd\T3035\Bondura 6.6.doc 06.12.00 DF No. LD-12-B

INSTALLATION AND MAINTENANCE BONDURA ® 6.6 and 6.0 OFFSHORE ……..continued.
MAINTENANCE OF BONDURA ® 6.6 and 6.0 FOR USE OFFSHORE

Establish procedures for maintenance. This will extend the lifetime of the bolts. Lack of maintenance may result
in the bolts coming loose and sliding out of the bolt hole. If this happens, parts of the bolt or equipment may
fall down.
5. Bondura Bolt lubrication.

Follow the instructions from the vendors regarding type of
Bolt "X" before Min. «X».
grease and frequency. The bolt is lubricated most effectively diameter expansion Switch to
when it is "unloaded", as the weight of the equipment may dia over-sized taper
prevent lubrication of the bearing surfaces of the bolt.
20-40 5 1
45-65 8 4
6. Inspection/retightening.
79-95 9 5
Purpose:
It always takes some time before the bolt and the support is 100-180 9 5
"broken in". The resulting "play" must be absorbed by retightening 200-320 10 6
the screws that holds the taper sleeves in place. Table 1 shows the acceptable distance "x"
When they are retightened, the taper sleeves expand and also between the taper flange and support
absorb wear and ovality in the bolt supports. The taper sleeve
may absorb play of up to 2 mm in diameter. If the play is larger,
you must use an over-sized taper. See Fig. 4.
Check this box for used equipment. You have to take into
consideration the possibility of extra play. Retighten several ”x”=0
times during the first 100 hours, before switching to the
procedures in Item 6b
Maintenance of the Bondura Bolt consists of two

elements:
a) Inspection.
Establish inspection procedures, e.g. every time the bolts are
lubricated.
 That locking plates, taper sleeves and screws are in place.
 That the bolt cannot rotate (intact anti-rotation lock). Fig. 4. Too much play results in no
 That the wire safety is intact. "wedging force". Switch to over-sized
 Check that the bolt has not shifted to one side. taper. "X" is measured between the
 (if this is the case, see Item 1 under Troubleshooting) taper flange and support.
b) Retightening/inspection:
Establish retightening/inspection procedures as specified below.
Equipment Interval
Travelling block / clevis Annually
Bail / top drive link 3 times per year
Other top drive bolts 2 times per year
Dolly 2 times per year Play on
top
Drill string compensator Annually
Pipe handling machinery, cranes Annually
Drawworks Annually
 Check that the distance between the taper flange and support is not
less than the min. "x" stated in the table. The distance between the
taper flange and support must be the same (within approx. 2 mm)
Fig. 5. A heavy load on the bolt
on both sides of the bolt. Normally the play will be the same in
prevents complete tightening.
both supports. Unload the bolt before tightening.

INSTALLATION AND MAINTENANCE BONDURA ® 6.6 and 6.0 OFFSHORE ……..continued.
If you are in doubt as to whether the bolt is centre-aligned, it is possible to unscrew the plate and check the bolt.
If the distance is less than min. "x", the cause may be that:
a) The bolt has shifted to one side.
b) The play in the supports is too great for the taper sleeve (exceeds 2 mm). Switch to over-sized taper.
 Tighten the bolt screws to the specified torque in order to expand the taper sleeves. First "unload" the equipment.
The weight of the equipment may prevent effective tightening. See Fig. 5
7. Troubleshooting.
- If the bolt "rotates" or cuts the lock screws:
* Check that the bolt is properly centre-aligned. See Item 2, Fig. 2
* Tighten the bolt screws in order to expand the taper sleeves.
* Check that the distance between the taper flange and support side is not less than the min. "x" stated in Table 1. If
this is the case, the play in the support is too great for the taper sleeve (exceeds 2 mm). Switch to over-sized taper.
* If the bolt still rotates, it may be that the bearing surface on the bolt or bearing liner is "torn" and must be replaced.
- If there is axial movement in the bolt, and it no longer is centre-aligned in the supports:
* Check that the bolt screws are properly tightened and that the distance "x" between the taper flange and support is
not smaller than stated in Table 1. If necessary, switch to over-sized taper.
8. Disassembly of type 6.6 and 6.0 Bondura Bolts

The equipment must always be unloaded before starting the disassembly.
8.1 Unscrew the locking plate.
8.2 In most cases the tapers may be removed by using a pry bar/chisel between the support and the taper flange. We
recommend using penetrating oil first. In case of large bolt dimensions or problems, use a "taper puller" to pull off
the taper sleeves, see "Pullers».
8.3. In most instances, the bolts will come out easily. Another option is to pull out the bolts by screwing on the locking
plate and using a puller / jack on the locking plate. On larger bolt dimensions or in the event of problems, the bolt
can be pulled out using a hydraulic jack. "Pullers".
Bondura 6.6 dia. 20-65 mm

Item Position
Bolt 4 10 25 34 20 16 4 16 23 26
Taper K6 16
Locking plate 20
Locking side plate 34
Bolt screw 25
Bolt screw 26
Non-locking plate 23
Nipple 10 C1 C2
Lw
1
Bondura 6.6 dia. 70-320
26 20 16 4 16 23 26
Item Position.
Bolt 4
Taper K6 16
Locking plate 20
Bolt screw 26
Non-locking plate 23
Nipple 10 C1 C2
Lw
10
C:\Documents and Settings\PettersenK.NOV\Desktop\kladd\T3035\Bondura 6.6.doc 06.12.00 DF No. LD-12-

B
INSTALLATION AND MAINTENANCE BONDURA ® 6.6 ……..continued.
Dimensions and data for Bondura type

6.6 and 6.0 Non-locking plate
a
Taper sleeve
Locking plate
b
Plate screws
c
Lock screw
Sleeve
T1
Design 20-65 mm dia. Design 70-130 mm dia. Design 140-320 mm dia.

Plate screws:
dia. 200-320
All locking plates has a hole for through sleeve and lock screw. This is to prevent the locking
plate falling down if anything should happen to the plate screws.
BOLT DIA DIMENSION LOCK SCREW PLATE SCREWS

see dimensioned drawings M
mm a b c T1 Lock screw Torque Spanner gap Plate screw
max dimensions (Nm) NV dimensions
20 37 50 23 23 M10 x 30 40 17 2 x M10
25 - 30 37 50 28 23 M10 x 30 80 19 2 x M12
31.8 - 40 46 63 31 23 M10 x 30 190 24 2 x M16
44.4 - 65 71 113 55 28 M12 x 35 380 30 2 x M20
70 - 80 101 128 61 31 M16 x 40 100 22 6 x M14
85 - 95 101 128 66.5 31 M16 x 40 130 24 6 x M16
100 - 110 133 168 78 40 M20 x 50 190 24 8 x M16
114 - 127 133 168 85.5 43 M20 x 50 380 30 6 x M20
140 - 150 190 245 112 50 M30 x 70 500 36 6 x M24
160 - 180 190 245 120 50 M30 x 70 500 36 8 x M24
200 - 250 264 327 160 63 M36 x 90 500 36 10 x M24
260 - 300 338 416 190 63 M36 x 90 600 46 10 x M30
320 338 416 210 63 M36 x 90 600 46 10 x M30
BOLT
Bondura ® NORGE AS
- For safety's sake et datterselskap i Serigstad AS

INSTALLATION AND MAINTENANCE BONDURA ® 6.6 ……..continued.
STANDARD BONDURABOLT PROGRAM
Bondura ® 6.1 is used where there

is access only from one side,
or limited access on one side. The bolt is
installed from one side. The inner taper
sleeve is tightened via the centre shaft.
Both taper sleeves are tightened
(serviced) from one side.
Bondura ® 6.1 dia. 30-57 Bondura ® 6.1 dia. 60-180 mm
Bondura ® 6.2 is used in non-

fixed joints when one or both supports
are extra wide. This solution is also
used when the bolt cannot protrude
past the support on one side, but
where there is access to tighten the
bolt from both sides.
Bondura ® 6.2 dia. 30-65 Bondura ® 6.2 dia. 70-120 mm
Bondura ® 6.6 fits most bolt

locations in non-fixed joints. The bolt
requires access from both sides in
order to tighten the bolt screws.
Bondura ® 3.6.3.6 has expanding

taper sleeves on both outer and inner Bondura ® 6.6 dia. 20-65 Bondura ® 6.6 dia. 70-320 mm
support, ensuring a fixed connection
also in the middle segment. Examples
of applications for this bolt are in fixed
structural connections such as framed
structures and when joining sections.
It is also used in self-aligning plain
bearings where the bolt is "locked" to
the inner sleeve of the bearing. When
the inner taper sleeves expand during
installation, this ensures that the
bearing does not turn on the bolt Bondura ® 3.6.3.6 dia. 30-80 Bondura ® 3.6.3.6 dia. 90-320 mm
surface.
Bondura ® 3.1 and 3.3 are first

generation expanding bolts. They are
now replaced mainly by 6.1 and 6.6
with the exception of special bolt
positions
Bondura ® 3.3 dia. 30-200 mm Bondura ® 3.1 dia. 60-140 mm

F252XX-XXX RELEASED: 3-22-96
FILTER MODULE REVISED:
(REV. A)
9-24-99
TORQUE TO 18 - 22 IN. LBS. F20
F1
F1
F2
F7
F2
F3
TECHNICAL SPECIFICATIONS
MATERIALS OF CONSTRUCTION
F8
F4
Body: Zinc die-cast.
Bowls: Polycarbonate or zinc die-cast.
Bowl Guard: Zinc die-cast.
F4 Sight Glass: Grilamid.
Seals: Nitrile.
F5 Drain: Brass and Nitrile.
F9 Filter Element: Porous polypropylene.
OPERATION CONDITIONS
F10 F11 Q Temperature Range: Poly bowl - 0_ to 125_ F (-18_ to 52_C).
Metal bowl - 0_ to 175_ F (-18_ to 79_C).
Max. Inlet Air Pressure: Poly bowl - 150 p.s.i.g. (10.3 bar)
Metal bowl - 175 p.s.i.g. (12 bar)
Application: Industrial compressed air systems.
Sump Capacity (Filters): 2.87 oz. (85 cc).
Filter Area (Filters): 7.728 in.2 (4986.3 mm2).
Flow: Air flow is at 90 p.s.i.g. (6.2 bar) inlet and 5 p.s.i.g. (0.3
bar) pressure drop.
F14
Q F15 1/4” - 54 scfm
3/8” - 100 scfm
F6 F16
F13 1/2” - 122 scfm
F17
F12 Q F18
F19
Q LUBRICATE WITH KEY LUBE UPON ASSEMBLY.
ITEM DESCRIPTION (SIZE) [INCLUDES] QTY PART NO. ITEM DESCRIPTION (SIZE) [INCLUDES] QTY PART NO.
F1 Filter Base Ć Standard (1) N/A F12 Poly Bowl/Guard Asm. W/Flex Drain [F9ĆF12] (1) 104202I
Filter Base Ć Service Indicator (1) N/A F13 Metal Bowl W/Flex Drain [F9ĆF11,F13] (1) 104206I
F2 Element Holder (Torque to 20 Ć 40 in. lbs) (1) 100029 F14 Metal Bowl W/SĆGlass, FĆDrain [F9ĆF11,F14ĆF19] (1) 104204I
F3 Filter Element, Coalescing (.3 Micron) (1) 100032 jF15 O" Ring (1/16" x 2Ć1/4" o.d.) (1) Y325Ć34
F4 Baffle (hand tighten) (1) 100030 jF16 Sight Glass (1) 100011
F5 Auto Drain Kit [F6] (1) 104068 F17 Shroud (1) 100013
F6 Nut (1) N/A jF18 O" Ring (1/16" x 13/64" o.d.) (2) Y325Ć4
F7 Spinner (1) 100028 F19 Screw (Torque to 15 Ć 20 in. lbs) [F18] (2) 104252Ć1
F8 Filter Element (40 Micron) (1) 100031Ć1 F20 Repair Kit for Service Indicator, Mechanical (1) 104197
Filter Element (5 Micron) (1) 100031Ć3 Manual Drain Kit [F9,F10] (1) 104149
n F9 Drain Stem (1) 29730 n Repair Kit Parts (1) 104176
n F10 Drain Seal (1) 29731 j Sight Glass Kit Parts (1) 104182
n F11 O" Ring (3/32" x 2Ć1/4" o.d.) (1) Y325Ć137 I Filter base is date coded, prior to “892” consult factory.
INGERSOLL-RAND COMPANY
T ONE ARO CENTER D BRYAN, OHIO 43506-0151
& (419) 636-4242 D FAX (419) 633-1674 E1999 D PRINTED IN U.S.A.
OPERATING AND SAFETY PRECAUTIONS
• Use only genuine ARO replacement parts to assure com- Isolate the unit by closing the line valve or disconnect the sup-
patible pressure rating and performance. ply line or hose.
• Read carefully all warnings and safety precautions and
heed the following before operating, to avoid personal in- WARNING BOWL REMOVAL HAZARD. THE BOWL
jury and/or property damage. MUST BE SECURELY LOCKED INTO POSITION BEFORE
• Be certain anyone operating this equipment has been EXPOSING THE UNIT TO LINE PRESSURE. The bowls are
trained to use it safely. designed with a feature which inhibits removal while under
pressure. When reinstalling, push the bowl up into the body
WARNING COMPONENT RUPTURE. DO NOT EXCEED and rotate to the right 1/8 turn. Failure to lock the bowl could
MAXIMUM RATED OPERATING PRESSURE OF: Metal cause it to blow off, which could result in personal injury or
Bowl - 175 p.s.i. (12 bar), Polycarbonate Bowl - 150 p.s.i. (10 property damage.
bar). To avoid possible damage or personal injury, DO NOT
expose the unit to excessive pressure beyond the intended WARNING DO NOT USE DEGREASERS OR SOLVENTS
working range. TO CLEAN POLYCARBONATE BOWLS. Exposure internal-
ly or externally to incompatible chemicals or their vapors or
WARNING TEMPERATURE LIMITS. DO NOT EXCEED fumes could attack and weaken polycarbonate material,
MAXIMUM TEMPERATURE LIMITS OF: Metal Bowl - 175_ F causing failure.
(79_ C), Polycarbonate Bowl - 125_ F (52_ C). Excessive tem- DO NOT EXPOSE to acetone, trichloroethane, gasolene, al-
perature can affect non-metallic parts which may weaken cohols, keytones, esters, chlorinated hydrocarbons, toluene,
them and cause failure. etc.
Clean polycarbonate bowls with soap and water or kerosene
WARNING USE WITH INDUSTRIAL COMPRESSED AIR only. USE COMPATIBLE LUBRICATING OILS ONLY. Lubri-
SYSTEMS ONLY. DO NOT USE WITH BOTTLED GAS cating oils used in plastic bowls must be compatible with poly-
PRODUCTS OR FLUIDS. MISAPPLICATIONS CAN RE- carbonate plastic (some “fire resistant” oil additives are not
SULT IN COMPONENT FAILURE. compatible). Fumes of these substances in contact with poly-
carbonate bowls internally or externally can also damage the
bowl. Consult Aro catalog or the Aro Corporation, Bryan, Ohio
WARNING DISASSEMBLY HAZARD. DO NOT DISAS- 43506 for comprehensive listings of harmful chemicals and
SEMBLE THIS UNIT WHEN IT IS UNDER PRESSURE. compatible listings of harmful chemicals and compatible lubri-
SHUT OFF AND RELIEVE AIR SUPPLY BEFORE AT- cating oils. If questions arise, request form no. 4424.
TEMPTING SERVICE OR DISASSEMBLY PROCEDURES.
INSTALLATION OPERATION
• Install filters with the air flow as indicated by the arrow on the • Monitor the sediment accumulation.
top of the unit. • If the pressure drop across the filter becomes excessive,
• Install filters as close as possible to the air operated equip- empty the filter bowl, clean or replace the filter element to as-
ment for best performance. sure good performance.
• Filters must be installed with the bowls downward for proper • Clean the filter element periodically. Soak the filter bowl and
operation. clean with soap and water. Refer to warnings concerning poly-
• When using filters featuring the sight glass on the bowl, orient carbonate bowls.
the bowl so it is most visible for the operator.
• Locate the filter upstream from the regulator and lubricator.
MAINTENANCE
• Filters with manual drain must be drained as frequently as
necessary to keep the liquid level below the baffle, which
could cause liquid to be carried downstream.
PN 100400Ć005
2 OF 2 F252XXĆXXX
= L1
= Q L2 LUBRICATOR MODULEL262X1-XXX
RELEASED: 3-22-96
= L3
= Q L5 L4 =
MÓDULO LUBRICADOR REVISED:
(REV. D)
10-27-00
L6 =
MODULE LUBRIFICATEUR
= L7
TECHNICAL SPECIFICATIONS
L9 L8 MATERIALS OF CONSTRUCTION
L11
Body: Zinc dieĆcast.
L10 Bowls: Polycarbonate or zinc dieĆcast.
H L12 Bowl Guard: Zinc dieĆcast.
Sight Cap: Grilamid.
L13 Sight Glass: Grilamid.
L16 Seals: Nitrile.
L14 OPERATION CONDITIONS
L17 Temperature Range: Poly bowl Ć 0_ to 125_ F (Ć18_ to 52_C).
L15 Metal bowl Ć 0_ to 175_ F (Ć18_ to 79_C).
Max. Inlet Air Pressure: Poly bowl Ć 150 p.s.i.g. (10.3 bar).
Metal bowl Ć 175 p.s.i.g. (12 bar).
L18 L19 Q Application: Industrial compressed air systems.
Oil Capacity: 6 oz. (177 ml.).
Flow: Air flow is at 90 p.s.i.g. (6.2 bar) inlet and 10 p.s.i.g. (0.7 bar)
L28 L23 Q
L25
pressure drop.
L29
L27 1/4" Ć 75 scfm
L20 3/8" Ć 100 scfm
1/2" Ć 110 scfm
L21 Q LUBRICATE WITH KEY LUBE UPON ASSEMBLY.
LUBRIQUE CON LUBRICANTE KEY UNA VEZ QUE SE HALLA
L30 MONTADO.
L31 LUBRIFIER AU MOYEN DE KEYLUBE LORS DE
L’ASSEMBLAGE.
Q L33 H GREASE WITH LUBRICATING OIL UPON ASSEMBLY.
L32 ENGRASAR CON ACEITE LUBRICANTE AL MOMENTO DE
L24
L26 Q ENSAMBLARLO.
GRAISSE AVEC HUILE DE LUBRIFICATION DURANT
L’ASSEMBLAGE.
= INCLUDED IN 104226 REPAIR KIT.
SE INCLUYE EN EL JUEGO DE REPARACIÓN 104226.
L22 INCLUSE DANS LA TROUSSE DE RÉPARATION 104226.
I Lubricator base date coded, prior to “892” consult factory.
Q L23 La base del lubricador está cifrada con la fecha, consulte con la fábrica si es previo a “892”.
L24 Base lubrificatrice à code de datation, antérieur à “892”, communiquer avec le fabricant.
L25
Q L26 L27
ITEM DESCRIPTION (Size in Inches) QTY PART NO. ITEM DESCRIPTION (Size in Inches) QTY PART NO.
ELEMENTO Descripción (tamaño en pulgadas) Cant Numero de Pieza ELEMENTO Descripción (tamaño en pulgadas) Cant Numero de Pieza
ARTICLE Description (taille en pouces) Quan Numero de Pieces ARTICLE Description (taille en pouces) Quan Numero de Pieces
L1 Sight Cap (Outer) (Torque to 20 Ć 30 in. lbs) (1) 100046 nL19 O" Ring (3/32" x 2Ć1/4" o.d.) (1) Y325Ć137
nL2 O" Ring (1/16" x 1" o.d.) (1) Y325Ć20 L20 Poly Bowl / Guard Assembly [L19, L20] (1) 104203I
nL3 O" Ring (1/16" x 7/16" o.d.) (1) Y325Ć11 L21 Metal Bowl Not QuickĆFill [L19, L21] (1) 104207I
L4 Adjustment Screw [L5] (1) 104250 L22 Metal Bowl W / Sight Glass [L19, L22 Ć L27] (1) 104205I
nL5 O" Ring (1/16" x 7/32" o.d.) (1) Y325Ć5 jL23 O" Ring (1/16" x 2Ć1/4" o.d.) (1) Y325Ć34
L6 Sight Cap (Inner) (1) 100047 jL24 Sight Glass (1) 100011
nL7 O" Ring (1/16" x 5/8" o.d.) (1) Y325Ć14 L25 Shroud (1) 100013
L8 Plate [L9] (1) 104249 jL26 O" Ring (1/16" x 13/64" o.d.) (2) Y325Ć4
nL9 Compensating Valve (1) 100050 L27 Screw (Torque to 15 Ć 20 in. lbs) [L26] (2) 104252Ć1
nL10 O" Ring (1/16" x 3/4" o.d.) (1) Y325Ć16 L28 Adapter (1) 29619
L11 Fill Plug (Torque to 15 Ć 30 in. lbs) [L12] (1) 104251 L29 O" Ring (1/16" x 13/16" o.d.) (1) Y325Ć17
nL12 O" Ring (1/16" x 11/16" o.d.) (1) Y325Ć15 L30 Metal Bowl W / Sight Glass, QĆFill [L19, L23 Ć L33] (1) 104211I
L13 Lubricator Base (1) N/A L31 Nut (Torque to 30 Ć 40 in. lbs) (1) 29620
L14 Ball (.125" dia.) (1) Y16Ć204 L32 Fitting (QuickĆFill) (1) 29235
L15 Orifice (1) 100053 L33 O" Ring (1/16" x 7/16" o.d.) (1) Y325Ć11
L16 Ball (.125" dia.) (1) Y16Ć204 n Parts in Lubricator Repair Kit 104181
L17 Fitting (1) 100052 j Parts in Sight Glass Repair Kit 104182
L18 Tube (4.375" long) (1) 100063Ć1
INGERSOLL-RAND COMPANY
P.O. BOX 151 D ONE ARO CENTER D BRYAN, OHIO 43506Ć0151
& (419) 636-4242 D FAX (419) 633-1674 E2000 D PRINTED IN U.S.A.
OPERATING AND SAFETY PRECAUTIONS
• Use only genuine ARO replacement parts to assure compatĆ OFF AND RELIEVE AIR SUPPLY BEFORE ATTEMPTING SERĆ
ible pressure rating and performance. VICE OR DISASSEMBLY PROCEDURES. Isolate the unit by closĆ
• Read carefully all warnings and safety precautions and heed ing the line valve or disconnect the supply line or hose.
the following before operating, to avoid personal injury and/or
property damage. WARNING BOWL REMOVAL HAZARD. THE BOWL MUST
• Be certain anyone operating this equipment has been trained BE SECURELY LOCKED INTO POSITION BEFORE EXPOSING
to use it safely. THE UNIT TO LINE PRESSURE. The bowls are designed with a
feature which inhibits removal while under pressure. When reinstalĆ
WARNING COMPONENT RUPTURE. DO NOT EXCEED ling, push the bowl up into the body and rotate to the right 1/8 turn.
MAXIMUM RATED OPERATING PRESSURE OF: Metal Bowl Ć Failure to lock the bowl could cause it to blow off, which could result
175 p.s.i. (12 bar), Polycarbonate Bowl Ć 150 p.s.i. (10 bar). To in personal injury or property damage.
avoid possible damage or personal injury, DO NOT expose the unit
to excessive pressure beyond the intended working range. WARNING DO NOT USE DEGREASERS OR SOLVENTS TO
CLEAN POLYCARBONATE BOWLS. Exposure internally or exĆ
WARNING TEMPERATURE LIMITS. DO NOT EXCEED MAXĆ ternally to incompatible chemicals or their vapors or fumes could
IMUM TEMPERATURE LIMITS OF: Metal Bowl Ć 175_ F (79_ C), attack and weaken polycarbonate material, causing failure.
Polycarbonate Bowl Ć 125_ F (52_ C). Excessive temperature can DO NOT EXPOSE to acetone, trichloroethane, gasolene, alcohols,
affect nonĆmetallic parts which may weaken them and cause failĆ keytones, esters, chlorinated hydrocarbons, toluene, etc.
ure. Clean polycarbonate bowls with soap and water or kerosene only.
USE COMPATIBLE LUBRICATING OILS ONLY. Lubricating oils
WARNING USE WITH INDUSTRIAL COMPRESSED AIR used in plastic bowls must be compatible with polycarbonate plasĆ
SYSTEMS ONLY. DO NOT USE WITH BOTTLED GAS PRODĆ tic (some fire resistant" oil additives are not compatible). Fumes of
UCTS OR FLUIDS. MISAPPLICATIONS CAN RESULT IN COMĆ these substances in contact with polycarbonate bowls internally or
PONENT FAILURE. externally can also damage the bowl. Consult Aro catalog or the
Aro Corporation, Bryan, Ohio 43506 for comprehensive listings of
WARNING DISASSEMBLY HAZARD. DO NOT DISASĆ harmful chemicals and compatible listings of harmful chemicals
and compatible lubricating oils. If questions arise, request form no.
SEMBLE THIS UNIT WHEN IT IS UNDER PRESSURE. SHUT 4424.
INSTALLATION
• Install lubricators with the air flow as indicated by the arrow on the • Observe the markings (Ć, +) on the lubricator body which shows diĆ
top of the unit. rection. Turn the adjustment screw counterclockwise to increase
• Install lubricators as close as possible to the air operated equipĆ and clockwise to decrease.
ment for best performance.
• Lubricators must be installed with the bowls downward for proper LUBRICATOR ADJUSTMENT:
operation. NOTE: This is a siphon type lubricator design, adjustments need to
• When using lubricators featuring the sight glass on the bowl, orient be made with a constant rate of flow thru the lubricator in an operatĆ
the bowl so it is most visible for the operator. ing mode.
• Locate the lubricator downstream from the regulator and filter. • Use a small screwdriver to adjust the drip rate. The adjustment
screw is located in the sight feed cap on the top of the lubricator.
OPERATION • Determine the average rate of flow (SCFM) thru the lubricator, then
turn the adjustment screw to obtain one drop per minute for each 10
• Use a good grade of nonĆdetergent oil (ARO part # 29665) for use in SCFM. Example: If the average flow is 20 SCFM, set the drip rate at
2 drops per minute.
the air operated equipment. Refer to the air operated equipment
NOTE: The fill plug must be removed to allow removal of the lubriĆ
operator's manual.
NOTE: This lubricator uses a ball check valve located in the lubricaĆ cator bowl or filling of the unit.
tor body to restrict the operating pressure to the bowl and allow reĆ
• Remove the fill plug carefully.
moval of the fill plug. This will permit filling or lubricator bowl
• Fill to the top of the bowl. If the bowl is equipped with a side sight
removal while in the normal operating mode. glass, oil should always be visible in the glass.
PAGE 2 OF 4 L262X1ĆXXX
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Corporate Headquarters
Rockwell Automation, 777 East Wisconsin Avenue, Suite 1400, Milwaukee, WI, 53202-5302 USA, Tel: (1) 414.212.5200, Fax: (1) 414.212.5201
Headquarters for Dodge and Reliance Electric Products

Americas: Rockwell Automation, 6040 Ponders Court, Greenville, SC 29615-4617 USA, Tel: (1) 864.297.4800, Fax: (1) 864.281.2433
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Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444
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Copyright © 2002 Rockwell Automation. All rights reserved. Printed in USA.
RELIANCE ELECTRIC is a trademark of Rockwell Automation.
Page: 1 of 3
CHAPTER 4
PREPARATION
Chapter 4: Preparation
www.natoil.com
Page: 2 of 3
TABLE OF CONTENTS
4 PREPARATION ................................................................................................................ 3
4.1 Attached Project Documents................................................................................... 3
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Page: 3 of 3
4 PREPARATION
4.1 Attached Project Documents
Preparation covers all system activities between completed installation and routine
operation. These activities are also referred to as commissioning or start-up.
The following project documents are attached after this page:
Document title: Handling, Storage and Preservation Procedure

Supplier doc. no.: T3035-Z-KA-002
Supplier revision: 0
Document title: Installation Procedure

Document title: Alignment Procedure

Document title: Commissioning Procedure

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TECHNICAL DOCUMENT FRONT COVER
Rig / Plant Atlas

Reference T3035
Description
Sub description
Document title Handling, Storage and Preservation Procedure
Portable Top Drive
HPT-500-2E-AC
Code (X) REVIEW STATUS

1 Accepted
2 Accepted, incorporate comments at next scheduled revision Date: (dd.mm.yyyy)
2A Accepted, incorporate comments. Revise and resubmit
Sign:
3 Not accepted, revise and resubmit
4 For information only
0 30.06.2004 Issue for Implementation MAJ KST KST

Revision Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved
This document contains proprietary and confidential information which belongs to National Oilwell Norway AS, it is loaned for limited purposes only and remains the property of National
Oilwell Norway AS. Reproduction, in whole or in part, or use of this design or distribution of this information to others is not permitted without the express written consent of National
Oilwell Norway AS. This document is to be returned to National Oilwell Norway AS upon request and in any event upon completion of the use for which it was loaned.
© Copyright by National Oilwell Norway AS 2004
Client purchase order number Remarks
Area System Discipline Main tag number Total number of pages

13
Sub area Sub system Additional code SDRL codes Design contractor Archive binder
7.3 3035
Client document number Document number Revision
T3035-Z-KA-002 0
National Oilwell Norway AS

Servicebox 401
N-4604 Kristiansand
Norway
Phone +47 38 19 20 00
Telefax +47 38 19 23 11
www.natoil.com

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User Manual

Portable Top Drive

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

7. SAFETY AND SERVICE BULLETINS

8. SPARE PARTS LIST

10. DRAWINGS AND PARTS LISTS

1.1 Portable Top Drive

Typical Top Drive in Test Stand

1.2 Structure and Contents of Manual

The manual is based on Norwegian Standard NS 5820: Supplier's Documentation

1.3 Contacts for Assistance

National Oilwell Norway AS

Switchboard phone: +47 381 92000

Chapter 2: Main Data

2 MAIN DATA ...................................................................................................................... 3

Chapter 2: Main Data

2.1 Safety Summary

2.2 Main Data

Equipment: National Oilwell TM Portable Top Drive

Client: Upetrom Group Management SRL

Supplier’s project no.: T3035

Type of elevator links supplied: 350 tons, 108”

Recommended type of hydr. oil: Texaco Rando HDZ

Gearbox oil type: Texaco Synlube CLP 150

Further data: See the Product Data Sheet in chapter 9.

Chapter 2: Main Data

2.2.1 Alarm and Setpoint Schedule

Description Setpoints Increasing Switch Comments

Gearbox oil temp. high 90 ºC Increasing TT011 Alarm only

HPU temp. high 65 °C Increasing TT013 Alarm only

HPU level low Low level Decreasing LS012 Alarm only

Link tilt pressure 10 barg Increasing PS006 Inhibit pipehandler rotation

LS pressure settings in Various Increasing H01 See hydraulic flow

Counter balance valves in Various Increasing H01 Provide intended functions

Chapter 2: Main Data

2.2.2 Unit Conversions

barg = psig x 0.06895

bara = bar (absolute)

2.3 External Connections

The equipment is externally hooked up as follows:

Electrical connections: See the instrument block diagram.

Chapter 2: Main Data

2.4 Restrictions in Use

2.5 Restrictions in Guarantee

National Oilwell Norway AS refuse all responsibility caused by breach of the

Chapter 2: Main Data

Chapter 3: Technical Description

3 TECHNICAL DESCRIPTION ............................................................................................ 3

Chapter 3: Technical Description

The HPT package is optimized in respect of

Key benefits of the HPT are:

• 16.2 ft stack-up height

Chapter 3: Technical Description

3.2 Overview of Main & Sub Assemblies

A standard HPT system consists of following main & sub assemblies:

Drive System (Motor and Gearbox with accessories), including:

Control System, including:

• Control Station incl. AC Drive and PLC

• Torque Tube System

Chapter 3: Technical Description

3.3 Drive System (Motor and Gearbox) with Accessories

Upper Part of Top Drive

Chapter 3: Technical Description